MV Agusta F4 750 User manual

L
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Cooling system
SECTION L
Revision 0

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L
Cooling system
SUMMARY
COMPLETE COOLING SYSTEM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3
COOLING SYSTEM LEAKAGE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 4
EXPANSION TANK CAP CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 4
ENGINE COOLANT EXTRACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 5
EXPANSION TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 5
RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 8
WATER/OIL HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 11
ELECTRIC FAN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 11
RADIATOR GROUP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 12
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 20
FAN THERMAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 21
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 22
EXPANSION TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 26
RADIATOR GROUP ASSEMBLY TO THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 29
FILLING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 33
SYSTEM FUNCTIONING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 34

L
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Cooling system
COMPLETE COOLING SYSTEM ASSEMBLY
Before proceeding with the disposal or overhaul of any component relative to the cooling system, carry out cer-
tain preliminary operations:
1)Let the engine cool down.
2)Remove the under-engine fairing, the left and right fairing side panels, the tail unit, the right and left side pan-
els, the fuel tank and the air compartment as described in chapter C “Bodywork”.

Cooling system
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Cooling system
COOLING SYSTEM LEAKAGE CHECK
Before removing the radiator and discharging the
engine coolant, check that the cooling system does not
have leakages.
Remove the expansion tank cap and connect the
tester (of the type shown in the diagram) to the filler
hole.
Do not open the radiator cap whilst the
engine is hot.
Apply a pressure of approximately 120 kPa (1.2
kg/cm2) and check that the system maintains the pres-
sure for at least 10 seconds.
If the pressure diminishes within ten seconds means
that there is a leak in the system.
If so, check the entire system and substitute the defec-
tive/damaged parts.
When removing the tester from the filler
hole, wrap a cloth around the filler hole to
avoid spurts of engine coolant.
Do not exceed the recommended pressure
to avoid damaging the radiator.
EXPANSION TANK CAP CHECK
Check the release pressure of the radiator cap by util-
ising the appropriate tester as follows:
Apply the cap to the tester as indicated and slowly cre-
ate a pressure by activating the tester.
Make sure that the increase in pressure is interrupted
at 110±15 kPa (1.1±0.15 kg/cm2) and check that with
the tester held steady, the pressure is maintained for at
least ten seconds. Substitute the cap if the pressure is
not maintained for ten seconds.
Radiator cap release pressure: 110±15 kPa (1.1±0.15
kg/cm2)

Cooling system
EXPANSION TANK REMOVAL
After having completely emptied the cooling system, it
is necessary to remove the ignition switch in the fol-
lowing way to remove the expansion tank:
Remove the ignition switch by unscrewing the two
screws (1).
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ENGINE COOLANT EXTRACTION
Open the cap of the expansion tank.
Empty the cooling system of the coolant as follows:
•Place under the engine a container to collect the dis-
charged coolant.
•Remove the discharge screw (1) situated on the
water pump (2)
•Make sure the coolant flows into the container. 1
2
Wait until all the engine coolant has dripped out of the
cooling system.
1

Cooling system
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Lift up the ignition switch (1) and then remove it by slid-
ing it backwards (2).
Disconnect the connector (1) of the ignition switch and
remove the relative rubber band (2).
Operate from the right side of the motorcycle.
1
Remove the connection tube shown in the figure.
Check the diameter of the tube that has just been
removed.
If the external diameter = Ø 10.5 mm and the internal
diameter = Ø 6.5 mm the tube can be reused for the
successive assembly.
If the dimensions of the tube are different from those
indicated it must be substituted for a new one.
If so, proceed with its complete removal.
2
1
2

Cooling system
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L
To extract the tube it is necessary to free it from its fix-
ings as indicated in the figure.
Disconnect the radiator charging tube.
Remove the band fasteners utilising the CLIC 205 pin-
cers.
Special tool: CLIC 205 pincers.

Cooling system
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Disconnect the overflow tube of the cooling system.
Special tool: CLIC 205 pincers.
Remove the expansion tank.
RADIATOR REMOVAL
Remove the band fastener of the thermostat connect-
ing tube of the radiator.
Special tool: CLIC 205 pincers.
Remove the band fastener of the radiator tube/metal
tube.
Special tool: CLIC 205 pincers.

Cooling system
Disconnect the tube coming from the heat exchanger.
Special tool: CLIC 205 pincer.
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Suck out the residue coolant from inside the lower radi-
ator.
Disconnect the connector of the water temperature
sensor (1).
1

Cooling system
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Disconnect the two connector of the electric fan (2) and
(3) situated on the right side of the motorcycle.
Remove the fixing screws of the radiator.
Extract the screw and the flanged aluminium bush.
The radiator is freed from its supports.
N.B. Carry out the said operations with
care. Pour the remaining coolant inside
the radiator into an appropriate container.
Do not dispose of engine coolant in the envi-
ronment. Collect in an appropriate container
and dispose of it according the norms in
force.
N.B.
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3