MV Agusta BRUTALE 910 S Workshop Manual

Workshop engine manual

MVAGUSTA BRUTALE 910 SMVAGUSTA BRUTALE 910 S

© 2005
The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A.

Part. N° 8A00A6440 - Edition N° 1
Printed – December 2005

Workshop engine manual

MVAGUSTA BRUTALE F4 910 S

- 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 ........................................................................................

ENGINE ....................................................................................................................

- 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

WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

Left side

Left side

Right side

Right side

Cylinder 3

Cylinder 4

Cylinder 1

Cylinder 2

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.

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

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

SUMMARY

General description

GENERAL DESCRIPTION

ENGINE .................

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.

Below is an example of the designation of the frame registration number:

ZCG F4 11 ?? ? V ??????

Manufacturer identification

Vehicle model

Version

MY

Establishment

Progressive frame number

B

- 1 -

Engine

SECTION B

Revision 0

- 2 -

Engine

B

SUMMARY

TABLE OF CLAMPING TORQUES ..........................................................................................................PAG. 3

PLANNED MAINTENANCE SCHEDULE ..................................................................................................PAG. 5

THROTTLE BODY ADJUSTMENT AND TUNING........................................................................................PAG. 13

CYLINDER HEAD ......................................................................................................................................PAG. 20

DISTRIBUTION CONTROL UNITS............................................................................................................PAG. 24

CYLINDER AND PISTON GROUP ............................................................................................................PAG. 44

CLUTCH ....................................................................................................................................................PAG. 50

GEAR AND GEAR CONTROL ..................................................................................................................PAG. 57

ELECTRICAL COMPONENTS ..................................................................................................................PAG. 64

OIL PUMP ..................................................................................................................................................PAG. 66

WATER PUMP............................................................................................................................................PAG. 68

STARTING..................................................................................................................................................PAG. 72

MOTOR SHAFT..........................................................................................................................................PAG. 74

BEDPLATE ................................................................................................................................................PAG. 76

CAPS ..........................................................................................................................................................PAG. 77

LUBRICATION COMPONENTS: OIL TUBING SUPPORT PLATE ..........................................................PAG. 86

LUBRICATION COMPONENTS: OIL FILTER SUPPORT ........................................................................PAG. 87

REPLACEMENT OF OIL FILTER ..............................................................................................................PAG. 90

LUBRICATING COMPONENTS: OIL RADIATOR ....................................................................................PAG. 93

B

Engine

- 3 -

TABLE OF CLAMPING TORQUES

DESCRIPTION N·m Thread blockers

HEAD
Camshaft and gear screws 21 strong
Sliding block distribution screws 8 medium
Stand screws 12
Valve cap screws 8
Chain tightening screws 8
Chain tightening cap 12
CLUTCH
Clutch nut 140 medium
Disk thrust plate screws 10
GEAR SHIFT
Pinion nut 140 medium
Gear selection drum tightening screws 25 medium
M6 gear control screws 8 medium
BEDPLA TE ACCESSORIES
Alternator tightening screws 25
Motor starter tightening screws 10
Water pump tightening screws 8
Neutral switch screws 10
FREE WHEEL STARTING
Flexible coupling generator control screws 25 medium
Flexible coupling nut 55 strong
Flange tightening screws together with free wheel 10 medium
OIL CUP
Oil cup tightening screws 10

TIGHTENING TORQUES: CONVERSION FACTORS

To convert a tightening torque, refer to the following table.

N·m Kg·m ft·lbs

N·m ------ 0,10197 0,7375

Kg·m 9,807 ------ 7,233

ft·lbs 1,3559 0,13826 ------

- 4 -

Engine

B

CLAMPING TORQUES TABLE

DESCRIPTION N·m Thread blockers

BEDPLATE
Clutch cap M6 screws 8
M6 bearing clamp screw 12 medium
Extractable gear change cap M8 screws 25
M6 torque screws 10
M8 torque screws 25
Plate screws for oil radiator connectors 10
Support screws for oil filter 40
Inlet/outlet connectors for radiator oil 30 medium
CONNECTING ROD
Cap screws (*)

(*) See fitting notes

Engine

- 5 -

B

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

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 fan 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 ● ●●●●●●●

fFrequency Km (mi)

Coupon

AB C DE F G

Substitution

(Use only MV Agusta original
oil filter)

Cleaning of contact lever /
pump piston area

- 6 -

Engine

B

0 1000 6000 12000 18000 24000 30000 36000

(600) (3800) (7500) (11200) (14900) (18600) (22400)

Pre-delivery-

Description Procedure

Check / Regulation

● ●●●●●●●

Check / Regulation

● ●●●●●●●

Drive chain Lubrification ● ●●●

Substitution ●●●
Check

● ●●●

Pinion / Stop washer

Substitution

●●●

Every time drive chain is replaced

Check

● ●●●

Ring gear

Substitution

●●●

Comunque ad ogni sostituzione della catena di trasmissione

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 ●
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

AB C DE F G

needle bearing

lubrfication
needle bearing

lubrfication

Frequency Km (mi)

Coupon

Cleaning of contact lever
area with side stand

Engine

- 7 -

B

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 40 per cent

distilled water
Clutch and brake fluid AGIP BRAKE FLUID DOT4 DOT4
Chain oil MOTUL CHAIN LUBE ROAD –

Table of lubricants and fluids

*

: 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
– ACEAA3
– 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

- 8 -

Engine

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....................................

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....................................

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

+0,3
0

+0,3
0

+0,2

-0,3

+0
+0,012

B

Engine

- 9 -

ITEM

CYLINDER AND PISTON

Piston ovalization...................

Piston-cylinder play................

Piston-pin play........................

Pin-foot connecting rod play.....

Segment thickness

1

st

......................................

2

nd

......................................

Oil scraper.........................

Maximum segment-cylinder play

1st......................................

2

nd

......................................

Scraper.............................

CLUTCH

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.........................................

..................................................

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
57,9 mm

-0,01

-0,03

-0,03

-0,08

0

-0,02

- 10 -

Engine

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

Engine

- 11 -

B

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 tem

perature (of regime);

B) Switch off the engine, remove the tank, air box

and sparkplugs;

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.

- 12 -

Engine

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.)

Motore Tipo Press. Min (bar) Press. Max (bar)

910 S 7,5 14

Engine

- 13 -

B

THROTTLE BODY ADJUSTMENT AND TUNING
(Tickover check, CO synchronisation and check)

Check and adjust

➝ First 1000 kilometres and

then every 6000 kilome­tres

The throttle body adjusting should be performed star­ting the engine of the motorcycle, therefore you should
use a flue gas exhauster in order to not saturate the
environment with burnt gas.

The following described operations are fundamental
for the correct functioning and the maximum perfor­mance of the engine.

When carrying out operations on throttle bodies, it is
advisable to remove certain parts of the bodywork
such as:

• Passenger seat

• Rider seat

• Tank side panels

• Ignition switch cover

• Fuel tank

Attention: before adjusting the throttle body verify
accurately:

- the absence of any cracks or damages on the pipes
to check the depression;

- the absence of gas leakages from drain pipes joint;

- that the fuel pipe unions are not buckled and crushed.

You should provide the motorcycle with tank placed on
an auxiliary support. Therefore you should connect the
hydraulic extensions of the fuel pipes and the electrical
extension for feeding fuel pump.

- 14 -

Engine

B

Verify the parameters of the injection-ignition system
by the MDST diagnosis software.

Connect the tool cable of the MDST diagnosis with the
“Diagnostics” tap on the right side of the motorcycle
near the expansion tank of the coolant.

Start the MDST diagnosis software and go to the
“Display instrument panel” screen.
Set the ignition switch to ON.
Select the “Connect” option from the toolbar. Now the
software displays the main operating parameters of the
injection-ignition system: verify that the temperature
and pressure sensors have coherent readings.