MV Agusta 2008 F4 312RR 1078 Workshop 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
- 2 -
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 professional training of the technician.
With purpose of making the reading of this manual immediately comprehensible, the paragraphs 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 problems, MV Agusta S.p.A. reserves the right to make modifications to its products and technical 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
- 3 -
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
- 1 -
General description
A
SECTION A
Revision 0
- 2 -
General description
A
SUMMARY
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.
- 3 -
A
EXAMPLE
Steering pin tightening
Screw in the steering pin flange ring, without tightening.
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 significant 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 without prior notice and without incurring any obligation.
10°
- 4 -
General description
A
GLOSSARY AND SYMBOLS
During this kind of procedure inflammable vapours
might develop and metallic
parts might be expelled at
high velocity. Thus, it is necessary to:
-
work far from exposed
flames and sparks;
-
wear protective clothing;
-
wear protective eyeglasses.
ATTENTION
In case it should be necessary, due to wear, to substi-
tute a particular, relative to
a cylinder, we strongly suggest that you check and if
necessary, substitute the
same particular in all of the
cylinders for more satisfying
results.
In particular, we recommend that at the same time
you substitute:
-
pistons with relative elastic bands and piston pins;
-
valves with relative
springs, semi-cones,
disks and grazings;
-
Valve guides with relative
valves, springs, semicones 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 tolerances established. A tight
coupling, is in fact, cause
for seizure as soon as the
organs in motion begin to
heat, while a loose coupling 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 components, 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.
General description
- 5 -
A
Use the recommended oil.
Use the recommended grease.
Use the recommended brake fluid.
Use the recommended suspension fluid.
Use the recommended coolant.
Use the recommended thread-locking
fluid.
Use the recommended sealant.
Use the recommended adhesive.
Carry out accurate cleaning.
Use new components.
Substitute the component.
Do not leave litter about.
- 6 -
General description
A
RIGHT HAND AND LEFT HAND STANDARD
To clarify the right hand and left hand standard that is used in this manual, herewith below is a diagram of the
motorcycle and the engine against which are indicated the right and left sides.
Left side
Right side
Left side
Right side
Cylinder 1
Cylinder 2
Cylinder 3
Cylinder 4
General description
- 7 -
A
SAFETY
Carbon Monoxide
• Exhaust gases contain carbon monoxide (CO) that is poisonous. Carbon monoxide can cause the loss of consciousness and death.
• If it is necessary to switch on the engine, check that the environment is well ventilated. Never switch on the engine
in an enclosed environment.
• Switching on the engine can only be carried out in an enclosed environment when there are the appropriate devices
for the evacuation of exhaust gases.
Petrol
• Petrol is extremely inflammable and under certain conditions can be explosive.
• Keep sources of heat, sparks and flames away from the work area.
• Always work in a well-ventilated area.
• Never use petrol as a cleaning solvent. Generally, avoid handling it unless it is absolutely necessary.
• Do not use petrol for cleaning components by using compressed air.
• Keep petrol out of reach of children.
Engine oil
• Engine oil can cause skin illnesses if in constant and long contact with the skin.
• If the skin comes into contact with engine oil, wash the parts affected as soon as possible with soap and water.
• If engine oil comes into contact with the eyes, rinse abundantly with water and seek medical attention.
• If engine oil is swallowed, do not provocate vomiting to avoid the aspiration of the product into the lungs. Transport
the injured person immediately to hospital.
• Used oil contains dangerous substances and poisonous for the environment. To substitute oil, it is necessary to be
equipped to deal with the collection of used oil in respect of the norms in force.
• Do not dispose of used oil in the environment.
• Keep used oil out of the reach of children.
Engine coolant
• Under certain situations, the ethylene glycol contained in the engine coolant is inflammable and its flame is invisible.
Ethylene glycol would cause serious burns if ignited because it is invisible.
• Avoid bringing the engine coolant into contact with hot parts. Such parts could be sufficiently hot to ignite the coolant.
• The engine coolant (ethylene glycol) can cause irritation of the skin and is poisonous if swallowed.
• If the engine coolant comes into contact with the skin, immediately remove any contaminated clothing and wash with
soap and water. If it comes into contact with the eyes, abundantly rinse with clean water and immediately consult a
doctor. If swallowed, do not provocate vomiting to avoid the aspiration of the product into the lungs. Administer clean
water and transport the injured person immediately to hospital and show the product to the doctor.
• If exposed to high concentrations of vapour, transport the injured person to a non-poisonous atmosphere and if necessary call a doctor.
• Do not remove the radiator cap when the engine is still hot. Being under pressure, the engine coolant can be violently ejected and therefore provocate burns.
• The engine coolant contains dangerous and poisonous substances and is therefore dangerous for the environment.
To substitute used engine coolant, it is necessary to be equipped to deal with the collection of used oil/of used engine
coolant in respect of the norms in force.
• Do not dispose of engine coolant in the environment.
• Keep engine coolant out of reach of children.
ATTENTION
The information contained in this paragraph is fundamental so that the operations carried
out on the motorcycle can be conducted with minimum risk to the mechanic.
- 8 -
General description
Brake fluid
• Brake fluid is extremely corrosive.
• Avoid any contacts with the eyes, skin and the mucous membrane.
• If brake liquid comes into contact with the skin, remove all contaminated clothing and wash immediately with soap
and water.
• If brake fluid comes into contact with the eyes, abundantly rinse with water and call a doctor.
• If swallowed, do not provocate vomiting to avoid aspiration of the product into the lungs. Immediately call a doctor.
• Take the injured person immediately to hospital, if he has breathed brake fluid into the lungs.
• In the case of exposure to high concentrations of vapour, move the injured person to a non-poisonous atmosphere
and if necessary call a doctor.
• In the case of accidental contact, rinse abundantly with water and call a doctor.
• Keep brake fluid out of reach of children.
Thread-locking fluid
• As it is not classified as dangerous, the prolonged contact with the skin, particularly with regards to abrasions can
provocate sensitiveness and dermatitis. In the case of contact with the skin, rinse abundantly with running water.
• Move the injured person into the open air and call a doctor if the injured person feels ill after having breathed in the
product.
• In the case of contact with the eyes, rinse abundantly with water for at least 15 minutes.
• If the thread-locking fluid has been swallowed, drink an abundant quantity of water or milk. Do not provocate vomiting to avoid the aspiration of the product into the lungs. Immediately call a doctor.
• Keep out of reach of children.
Nitrogen - rear shock absorber
• The rear shock absorber contains nitrogen under pressure.
• Before disposing of used shock absorbers, discharge the nitrogen via the depressurising valve.
• Utilise only nitrogen to pressurise the shock absorber. The use of unstable gases can cause explosions that could
cause burns.
• Do not place the shock absorber near to flames or sources of heat as this could cause explosions with consequent
burns.
• Keep out of reach of children.
Battery
• The battery produces explosive gases. Keep it away from sparks, flames or cigarettes. During recharging, adequately ventilate the environment.
• The battery contains a solution of sulphuric acid (electrolyte).
• Sulphuric acid is corrosive and it destroys many materials and clothing. On contact with small quantities of water it
generates a violent reaction that manifests itself by creating large quantity of heat and spurts of hot acid. Sulphuric
acid attacks many metals thereby liberating hydrogen: an inflammable gas that forms an explosive mixture when
mixed with air.
• Contact with sulphuric acid can cause burns. In the case of contact, remove immediately all contaminated clothing
and wash the skin with abundant quantities of water. Take the injured person to hospital if necessary.
• In the case of contact with the eyes, rinse immediately with abundant water. Call a doctor and continue with the treatment until the doctor arrives.
• If the electrolyte is swallowed, rinse the mouth with water without swallowing. Take the injured person immediately
to hospital and explain to the doctor there what the injured person has swallowed.
• The battery contains dangerous substances that are poisonous for the environment. It is necessary to be equipped
to dispose of this product in respect of the norms in force.
• Do not dispose of used batteries in the environment.
• Keep out of reach of children.
Hot parts
• The engine and the exhaust system become very hot and maintain this temperature for some time after the engine
has been switched off. Wait for these parts to cool down before handling them or working on the motorcycle near to
them. Use protective gloves.
A
General description
- 9 -
A
SUMMARY OF EACH CHAPTER
GENERAL INDEX
INDEX
WARNING
The information contained in this
paragraph is important so that the
operations carried out on the motor-
cycle can be conducted without damaging the motorcycle.
• Thoroughly clean the motorcycle before disassembling it.
• During disassembly, clean all parts and place them in containers respecting exactly the order of disassembly.
• Always use the special utensils where necessary and
each time where prescribed.
• Always use adhesives, sealants and lubricants where prescribed. Respect the instructions about their technical
characteristics.
• Always substitute parts such as gaskets, O-rings, security
washers with new parts.
• Slackening or tightening nuts or screws, always start with
those of a greater dimension or from the centre. Always
respect the torque values indicated.
• Utilise only MV Agusta spare parts.
WARNING
- 10 -
General description
A
2) Engine registration number
1) Frame registration number
3) Homologation date
OPERATIVE TECHNICAL SPECIFICATIONS
MOTORCYCLE IDENTIFICATION
The registration number of the motorcycle is stamped on the right side of the steering head.
The engine registration number is stamped on the upper engine casing, near the forks.
ZCG F5 11 BB Y V 000000
Manufacturer identification
Vehicle model
Progressive frame number
Below is an example of the designation of the frame registration number:
- 1 -
B
Maintenance
SECTION B
Revision 0
- 2 -
Maintenance
B
SUMMARY
PLANNED MAINTENANCE SCHEDULE .................................................................................................. PAGE 3
ADJUSTMENT AND CALIBRATION OF THROTTLE BODY ...................................................................... PAG.11
- 3 -
B
Maintenance
PLANNED MAINTENANCE SCHEDULE
The following diagram shows the recommended planned maintenance intervals. Periodic maintenance is essential to keep the vehicle in perfect running order and to ensure optimum cost efficiency.
Use shorter maintenance intervals if the vehicle is used in particularly harsh conditions.
Let us help protect the environment
Everything we do affects the entire planet and its resources. To protect the common interest, MV Agusta
urges its customers and service operators to use the vehicles and dispose of their components in compliance with applicable regulations on environmental pollution control, waste disposal and recycling.
Scheduled maintenance tables
WARNING
fFrequency Km (mi)
Coupon
AB C DE F G
0 1000 6000 12000 18000 24000 30000 36000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-delivery
Description Procedure
Motor oil
Substitution
●●●●●●●
At least every year
Motor oil filter
●●●●●●●
Each time engine oil is renewed
Cooling liquid
Check / Top up
●●●●●●●●
Substitution Every two years
Cooling system Check for leaks ●●●●●●●●
Electric fans Check operation ●●●●●●●●
Valves Check / Regulation ●●●
Distribution chain
Check ●●
Substitution ●
Mobile distribution block
Check / Substitution ●●
Substitution
●
Every time timing chain is replaced
hain tightening block Check / Substitution ●●●
Spark plugs
Check / Substitution ●●●●
Substitution ●●●
Fuel filter Substitution ●●●
Throttle body Check / Regulation ●●●●●●●
Air filter Check / Substitution ●●●●●●
Brakes and clutch liquid
Level check ●●●●● ●●
Substitution
●
At least every two years
Brakes / Clutch Check operation ●●●●●●●●
Plant chexk ●●●●●●●●
Prake pads Check / Substitution
●●●●●●●
( front + rear )
Fuel lines
Check for defects and leaks
●●●●●●●
Substitution At least every 3 years
Throttle control Check operation ●●●●●●●●
Verify/adjust play
●●●●●●●●
Starter control Check operation ●●●●●●●●
Substitution
(Use only MV Agusta original
oil filter)
- 4 -
Maintenance
B
0 1000 6000 12000 18000 24000 30000 36000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-delivery-
Description Procedure
AB C DE F G
Check / Regulation
●●●●●●●●
Check / Regulation
●●●●●●●●
Drive chain Lubrification ●●●●
Substitution ●●●
Check
●●●●
Pinion / Stop washer
Substitution
●●●
Every time drive chain is replaced
Check
●●●●
Ring gear
Substitution
●●●
Every time drive chain is replaced
Sprocket elastic coupling
Check
●●●
Head tube ring nut
Check/ Regulation
●●●●
Steering bearings
Check/ Regulation
●●●●
Lubrification ●
Tyres
Check pressure ●●●●●●●●
Check wear ●●●●●●●
Wheel rim Visual check
●● ●●●●●
Every time tyres are replaced
Check
●●●●●
Front wheel bearings Every time tyres are replaced
Substitution ●
Magnesium parts
Visually check for
●●●●●●●
damage
● At least every 6 months
Side stand Check operation ●●●●●●●●
Side stand
Check operation ●●●●●●●●
switch
Rear wheel hub
Check / ●●
Substitution
/
●
Big fork bearings Check / lubrification ●
Big fork chain shoes Check / substitution ●●●●●●●
Frame plate chain shoes Check / substitution ●●●●●●●
Rear damper
Check/ Regulation
●●●●
Front fork oil Substitution ●
Battery connections Check and cleaning ●●●●●●●
Electric system Check operation ●●●●●●●●
Meter assy. combination Check operation ●●●●●●●●
Lights / visual signals Check operation ●●●●●●●●
Claxon Check operation ●●●●●●●●
Front head light
Check operation ●●●●●●●●
Regulation
Every time vehicle geometry is altered
Starter switch Check operation ●●●●●●●●
Locks Check operation ●●●●●●●●
Tightening of screws and nuts
Check
/ Tighten ●●●●●●●●
Hose clamps
Check
/ Tighten ●●●●●●●●
General lubrication ●●●●●●●●
General test ●●●●●●●●
Transmissions and flexible controls
needle bearing
lubrfication
needle bearing
lubrfication
Frequency Km (mi)
Coupon
*
: MV Agusta recommends purchasing the product from its authorized dealers. The engine oil AGIP Racing 4T
10W/60 has been specially designed for the F4 engine. Should this lubricant be unavailable, MV Agusta recommends using fully synthetic oils complying with or exceeding the following specifications:
– API SJ
– ACEA A3
– JASO MA
– SAE 20 W-50 o 10 W-60
The above specifications are to be found, alone or in combination with others,
on the lubricating oil container.
Motor oil
SAE 10 W-60
API SJ
ACEA A3
JASO MA
NOTE
- 5 -
B
Maintenance
Description Recommended product Specifications
Engine lubrication oil AGIP RACING 4T 10W/60 (*) API SJ SAE 10W/60
Ethylene glycol
Cooling liquid AGIP ECO - PERMANENT diluted with 50 per cent
distilled water
Clutch and brake fluid AGIP BRAKE FLUID DOT4 DOT4
Chain oil MOTUL CHAIN LUBE ROAD –
Table of lubricants and fluids
- 6 -
Maintenance
B
ITEM
VALVES
Ø Sealing external diameter
Exhaust..............................
Inlet....................................
Sealing face thickness......
Stem-guide clearance
Exhaust..............................
Inlet....................................
Ø Guide internal diameter.......
Valve stem
Exhaust..............................
Inlet....................................
Exhaust valve spring
Internal...............................
External..............................
Inlet valve spring
Internal...............................
External..............................
Valve-cam clearance
Exhaust..............................
Inlet....................................
STANDARD
24,6 mm
28,6 mm
1 mm
0,02 ÷ 0,04 mm.........................
0,01 ÷ 0.03 mm.........................
4,5 mm...........................
4,475 ± 0,005 mm.....................
4,485 ± 0,005 mm.....................
33,8 mm....................................
37,9 mm....................................
35,28 mm..................................
39,04 mm..................................
0,20 ÷ 0,29
0,15 ÷ 0,24
WEAR LIMIT
Coupling : 0,10 mm
0,08 mm
4,55 mm
4,445 mm
4,455 mm
33,3 mm
37,4 mm
34,78 mm
38,54 mm
+0,3
0
+0,3
0
+0,2
-0,3
+0
+0,012
- 7 -
B
ITEM
CYLINDER AND PISTON
Piston ovalization..................
Piston-cylinder play...............
Piston-pin play.......................
Pin-foot connecting rod play....
Segment thickness
1°...................................
2°...................................
Oil scraper......................
Maximum segment-cylinder play
1°...................................
2°...................................
Scraper..........................
FRIZIONE
Disk thickness.......................
Springs..................................
STANDARD
...................................................
0,038 ÷ 0,067 mm
0,004 ÷ 0,012 mm
0,015 ÷ 0,032 mm
0,8 mm...........................
0,8 mm...........................
1,5 mm...........................
0,2÷ 0,4 mm.............................
0,2 ÷ 0,4 mm.............................
0,2 ÷ 0,7 mm.............................
3 mm
41 mm
WEAR LIMIT
0,015 mm
0,10 mm
0,03 mm
0,06 mm
0,75 mm
0,75 mm
1,38 mm
0,6 mm
0,6 mm
1 mm
2,8 mm
39 mm
-0,01
-0,03
-0,03
-0,08
0
-0,02
Maintenance
- 8 -
Maintenance
B
ITEM
GEAR SHIFT
Gear fork-groove pivot play..........
Drum pit width.........................
Ø fork pivot.............................
Minimum idle gear
axial play.................................
Maximum gear fork play........
Gear limit
Primary...............................
Secondary..........................
Fork selection gear limit
Primary (5a - 6a)...............
Secondary (1a-2a, 3a-4a).
Fork – pit play.........................
BEDPLATE – DRIVE SHAFT
Bed bearing
functioning play.......................
Connecting rod bearing
Functioning play......................
Drive shaft axial play...............
STANDARD
0,35 ÷ 0,15 mm.........................
7,05 ÷ 7,15 mm.......................
6,8 ÷ 6,9 mm.............................
0,10 mm
...................................................
...................................................
...................................................
...................................................
...................................................
0,2 ÷ 0,3 mm
0,012 ÷ 0,038 mm.....................
0,036 ÷ 0,061 mm.....................
0,2 mm
WEAR LIMIT
0,65 mm
7,35 mm
6,7 mm
0,7 mm
5,6 mm
4,6 mm
4,65 mm
3,65 mm
0,7
0,06 mm
0,08 mm
- 9 -
B
Maintenance
Cleaning the parts
All of the parts must be cleaned with special
biodegradable solvents and dried with compressed air.
Proceed with the cleaning process of all the parts
before disassembling them as well as after the particular parts have been disassembled. Clean each part
even before reassembling.
Connections
In order to allow the motor to function in the best conditions it is absolutely necessary that all of the connections meet the standards established by the manufacturer. A connection with reduced standards could
cause seizing, while a connection with excessive toleration causes vibrations which accelerate the wear of
the components.
General norms for assembling the parts
For reassembling invert the disassembling procedure,
paying careful attention to the specified procedures.
Gaskets, oil spill protector, metallic locks. Tightening
rings in deformable material and self blocking nuts
must always be substituted.
The bearings are dimensioned for a determined number of working hours. Substitution is therefore recommended in consideration of the difficulty in checking
wear. The above mentioned is in addition suggested
for dimensional controls of the single components
mentioned in the relative paragraphs.
It is absolutely necessary to carefully clean all of the
components; the bearings and all of the other parts
subject to wear must be lubricated with motor oil before
reassembling. Nuts and screws must be locked to the
pre established torques.
Following are the descriptions of the disassembling,
revision and reassembling procedures of the various
parts and sub parts constituting the motor, in the finalized sequence of a completely disassembled motor.
Disassemble the motor from its frame as described in
the relative paragraph;
Drain the oil from the oil cup;
Remove the spark plugs covering the openings with
clean rags to avoid small objects (rings, etc.) from
falling into the motor.
Measuring compression in the cylinder
The following tools are necessary in order to carry out
this procedure:
Spark plug key: n° 800089013
Compression measurer
Adapter for the compression measurer.
A)Heat the motor to the usual functioning temperature
(of regime);
B)Turn the motor off, remove covering structure, tank,
air box and remove the spark plugs;
C)Measure cylinder compression.
Drag the motor into rotation by means of the starting
motor with the butterfly valve completely open until the
compression measurer indicator (compessionmeter)
no longer rises; the compression measurement
obtained is the maximum.
Be sure the battery is completely charged.
- Repeat the procedure for the other cylinders.
N.B.: If the compression in the cylinder is lower than
the minimum value of the reported range, check the
following points:
A) carbon deposits on the walls of the combustion
chamber and on the piston ceiling;
B) lthe head gasket is not of the correct measurements;
N.B.: If the compression in the cylinder is lower than
the minimum value of the reported range, check the
following points:
A) The seat of one or more valves is damaged and
the valves do not maintain the compression pressure;
B) One or more valves have null functioning play;
C) The piston, cylinder play is excessive;
D) The cylinder head is twisted and/or the head gasket is damaged;
E) Excessive play between ring and cable.
- 10 -
Maintenance
B
NOTE
Before carrying out the compression trial,
accurately check the battery tension since
the compression value which appears is
quite influenced by the rotation velocity of
the motor, and consequently by the battery tension.
NOTE
Cylinder compression control (280 rpm-min.)
Engine Type Min. Press.(bars) Max Press. (bars)
F4 1078 7,5 14
- 11 -
B
Maintenance
ADJUSTMENT AND CALIBRATION OF THROTTLE
BODY
After connecting the diagnostic software to the central
unit, before starting the engine check the position of
the throttle valve:
2.33 degrees (min. 2.1, max 2.5).
If it does not fall within the range, use the TPS feature
to reset it, WITHOUT TOUCHING THE MECHANIC
ADJUSTING SCREW OF THE THROTTLE.
After resetting the throttle (TPS) start the engine to
warm it up.
You will see that after starting the engine the Lambda
channel (mvolt), which was next to zero, will start to
rise.
After starting the Lambda control (Lambda % range),
the Lambda (mvolt) will range between a high of 1000
mvolt and a low of 0 mvolt (minus the diagnostic software lag). To see the range more clearly, adjust the two
graphic settings.
The above behaviour means the Lambda probe is in
working order.
Otherwise, if the Lambda (mvolt) shows a fixed value
of about 0 mvolt or 1000 mvolt, after about thirty seconds, with the Lambda % controller fixed at -25% or
+25%, the system will send out a ‘Lambda probe voltage’ alarm.
In this case, check the electric connection between the
Lambda probe and the system or replace the Lambda
probe.
Levelling of induction manifold settings
To check this, use a mercury vacuum gauge of the type
shown in the figure. Then, level the vacuum inside the
induction manifolds.
- 12 -
Maintenance
B
Twist off the plugs that close the vacuum tubes. The
number of the cylinder to which the rubber plug is connected is written on the plug itself (A).
The vacuum tubes are located on the right and left side
of the vehicle.
Left side: Cylinders 1 and 2
Right side: Cylinders 3 and 4
Connect the measuring device with the rubber pipes.
Each pipe must match the cylinder to which it is connected.
Fit in the Starter key and start the vehicle.
All bypass adjusting screws (1) must first be opened by
turning them 1.5 turns off the ‘all closed’ position.
For this adjustment, it is compulsory to begin with cylinder 2 to make sure the EBS valve will work properly.
Cylinder 2 provides the following positions:
min. 0.5 revs – max 3.5 revs
Select the position that offers the best alignment with
the other cylinders.
After finding the right position for cylinder 2, adjust it by
turning the bypass screws of cylinders 1, 3 and 4 until
the vacuums inside the four induction manifolds are
aligned. The mercury columns must have the same
height (see Figure on the side).
Cylinders 1, 3 and 4 too provide the following positions.
min. 0.5 revs – max 3.5 revs
When idling, the revs of the engine must range
between 1100 revs/min and 1200 revs/min.
- 13 -
B
Maintenance
To align the throttle body, use the diagnostic software.
For the engine to work properly, adjust the throttle body
so that the idling regime control works at “mid-range”.
To do this, after finding the correct alignment, proceed
as follows:
If the “lead correction” channel is NEGATIVE, close the
bypass valves to take air out, keeping it aligned until
the “Lead correction” setting goes to work within a
range of -4° to +4°.
If the “Lead correction” channel is POSITIVE, open the
bypass valves to add air, keeping it aligned until the
“Lead correction” setting goes to work within a range of
-4° to +4°.
When the adjustment is over, turn off the vehicle,
remove the connection pipe and replace the four protective plugs.
Not required adjustment of carbon oxide rate (CO).
CO ADJUSTMENT IS NOT REQUIRED.
The system can correct its (stoichiometric) carburetion
through the Lambda probe control. This does not happen straightaway but depends on the Lambda probe
switching speed for a water temperature of 85 to 105 °C.
You will notice that, when the Lambda probe % controller work slightly ABOVE ZERO, the ADOFFPL setting WILL INCREASE and will bring the Lambda %
channel back to about 0 ±3%.
You will notice that, when the Lambda probe % controller work slightly BELOW ZERO, the ADOFFPL setting WILL DECREASE and will bring the Lambda %
channel back to about 0 ±3%.
- 14 -
Maintenance
B
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