MV Agusta 2008 F4 312RR 1078 Instruction manual

©2008
The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A.
Part. N°8A00B2576 - Edition N°1
Printed – October 2008

MV AGUSTA F4 312RR 1078
Workshop engine manual

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Statement
This manual, to be used by the MV Agusta authorised workshops has been realised with the
purpose of assisting authorised personnel in maintenance and repairs operations of the
motorcycle. The knowledge of technical data herein noted, determines the complete profes-
sional training of the technician.
With purpose of making the reading of this manual immediately comprehensible, the para-
graphs have been aligned with detailed illustrations that highlight the argument dealt with.
Useful advice
To prevent any problems and to reach an excellent final result, MV Agusta recommends
keeping to the following guidelines:
- In the case of an eventual repair, evaluate the client’s impressions who states that there
is an abnormal functioning of the motorcycle and to formulate the right questions to
clarify the symptoms of the problem.
- Clearly diagnose the cause of the abnormality. The basic fundamental theories can be
absorbed by reading this manual that must necessarily be integrated to the personal
experience and the participation of training courses that are periodically organised by
MV Agusta.
- Rationally plan the repair to avoid slack periods, e.g. the collection of spare parts, the
preparation of tools and equipment, etc.
- To reach the part to be repaired limiting the work to the essential operations.
With regards to this, a valid help would be to consult this manual with regards to the
sequences of removal demonstrated in this manual.
Informative note
MV Agusta S.p.A. is committed to a policy of continuous improvement of their products. For
this reason, there could be slight differences between that which is written here and the
motorcycle on which repairs and/or maintenance are about to be carried out. MV Agusta
models are exported to many countries where different norms in relation to the highway
code and homologation procedures are valid. Hoping that you will comprehend these prob-
lems, MV Agusta S.p.A. reserves the right to make modifications to its products and tech-
nical documentation at any moment and without prior announcement.
Respect and defend the environment
Everything that we do has repercussions on the entire planet and its resources.
MV Agusta, wanting to protect the interest of the people, would like to make the client and
the technicians of the technical assistance centres aware and to adopt modalities of use of
the motorcycle and the disposure of its parts in full respect of the norms in force in terms of
environmental pollution, disposal and the recycling of waste.

Freni
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A
B
General Index
GENERAL DESCRIPTION ..........................................................................................
MAINTENANCE ............................................................................................................
CYLINDER KIT ..............................................................................................................
CRANKCASE ........................................................................................................
LUBRICATION................................................................................................................
ELECTRICAL COMPONENTS ......................................................................................
TIGHTENING TORQUES ..............................................................................................
SPECIAL TOOLS ..........................................................................................................
ANALYTICAL INDEX ....................................................................................................
C
D
E
F
G
H
I

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General description
A
SECTION A
Revision 0

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General description
ASUMMARY
HOW TO CONSULT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3
THE PURPOSE OF THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3
GLOSSARY AND SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 4
RIGHT HAND AND LEFT HAND STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 6
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 7
OBSERVATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 9
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 9
OPERATIVE TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 10

General description
HOW TO CONSULT THIS MANUAL
Order of the subjects
This manual is divided into chapters that deal with the
sub-groups of the motorcycle.
To quickly find the chapter required, the pages of each
chapter are marked with a reference mark aligned to
the relative item in the general index.
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A
EXAMPLE
Steering pin tightening
Screw in the steering pin flange ring, without tighten-
ing.
This operation must be done manually.
Check that the steering base is at the end of its travel,
to the right.
Using the special tool N. 800091645, tighten the ring
(1) by rotating it 10° calculated approximately as one
third of the movement between the two holes of the
ring (2) of the steering head (see the figure).
2
1
Display of the operations
The operations of disassembly, assembly, removal and control are presented with the help of illustrations (designs and
photographs).
The illustrations contain symbols that indicate the procedure, special tools and other information. See the symbols lists
for their significance.
The procedures are described step after step.
PURPOSE OF THE MANUAL
Principally, this manual has been written for MV Agusta dealers and qualified mechanics.
It is not possible to document all the knowledge necessary for a mechanic in a manual. Those who utilise it must have
a basic knowledge of mechanical concepts and the inherent procedures in the techniques of repairing motorcycles.
Without this knowledge, The maintenance and repair operations can render the motorcycle unsafe for use.
Updates
MV Agusta S.p.A. is committed to a policy of continuous updating of the models produced. The modifications and sig-
nificant changes to the specifications and the procedures will be communicated to the official dealers and will appear
in future editions of this manual.
All information, instructions and technical data included in this manual are based upon information on the product
updated at the moment of going to print. MV Agusta S.p.A. reserves the right to carry out changes at any moment with-
out prior notice and without incurring any obligation.
10°

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General description
AGLOSSARYAND SYMBOLS
During this kind of proce-
dure inflammable vapours
might develop and metallic
parts might be expelled at
high velocity. Thus, it is nec-
essary to:
- work far from exposed
flames and sparks;
- wear protective clothing;
- wear protective eye-
glasses.
ATTENTION
In case it should be neces-
sary, due to wear, to substi-
tute a particular, relative to
a cylinder, we strongly sug-
gest that you check and if
necessary, substitute the
same particular in all of the
cylinders for more satisfying
results.
In particular, we recom-
mend that at the same time
you substitute:
- pistons with relative elas-
tic bands and piston pins;
- valves with relative
springs, semi-cones,
disks and grazings;
- Valve guides with relative
valves, springs, semi-
cones and grazings;
- bed bearing;
- whatever else undergoes
uniform wear, aside from
the position of the relative
cylinder.
In order to allow the motor
to function under the best
conditions, it is necessary
that all of the couplings are
within the accepted toler-
ances established. A tight
coupling, is in fact, cause
for seizure as soon as the
organs in motion begin to
heat, while a loose cou-
pling is cause for vibrations
which accelerates wear on
the particulars in motion.
N.B. All of the countersigns indicting right,
left, superior, inferior, front and back,
refer to the motor-bike in the normal
direction of march.
WARNING
The motor supports numbering of the
cylinders and of the attached compo-
nents, increases moving from left
towards right in regards to the direction
of march.
N.B.
WARNING
This symbol indicates the "procedure to
be carried out with the motor removed
from the motor-bike".
This symbol indicates "the procedures
to be carried out with an empty cooling
circuit".
Tighten to the specified torque.
Tolerance or limit of use.
Utilise the tester.
Utilise a specific tool or equipment for
the correct carrying out of the operation
described.