Mv Agusta F4 1000 2010 Maintenance Manual
Maintenance manual
English Version
chap. Subjects covered page
1MAINTENANCE 3
1.1. Symbols 3
1.2. Tables of scheduled maintenance and checks 4
1.3. Tools and accessories supplied 14
1.4. Table of lubricants and fluids 15
1.5. Removing/fitting the side fairing 16
1.6. Checking the engine oil level 18
1.6.1. Topping up the engine oil level 19
1.7.
Checking the coolant level
21
1.7.1.
To pp i ng up t he co o la n t l e ve l
22
1.8. Checking the wear of the brake pads 24
1.9. Checking the brake fluid level 25
1.10. Checking the clutch fluid level 27
1.11. Checking and replacing the tyres 28
1.12. Checking and lubricating the drive chain 34
1.13. Checking the idle speed 38
1.14. Replacing parts - General information 39
1.14.1. Replacing the fuses 39
1.14.2. Replacing the license plate light bulb 44
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chap. Subjects covered page
1.15. Battery 47
1.16. Cleaning the motorcycle 49
1.17. Prolonged inactivity 51
2TROUBLESHOOTING FLOW CHART52
2.1. Engine problems 52
2.2. Electrical equipment problems 57
3TECHNICALINFORMATION 60
3.1. Motorcycle overview 60
3.1.1. Front brake circuit 62
3.1.2. Rear brake circuit 63
3.1.3. Clutch circuit 64
3.1.4. Engine lubrication 65
3.1.5. Coolant circuit 66
3.1.6. Fuel system 67
3.2. Specifications 68
3.3. Bodywork parts reference colours 76
3.5. Frame parts reference colours 78
CONTENTS
MAINTENANCE 1
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1.1. Symbols
Sections of text that are particularly important in terms of personal safety or possible damage to the
motorcycle are marked with the following symbols:
Danger - Failure to observe these prescriptions, even in part, may pose a serious hazard
to the driver’s and other people’s safety.
Caution - Failure to observe these prescriptions, even in part, may result in damage to the
motorcycle.
The following symbols give an indication of who is supposed to perform the different adjustments and/or
maintenance operations:
Information on operations that can be carried out by the user.
Information on operations that
must be carried out only by authorized personnel.
The following symbols are used to provide further information:
The “ ” symbol points out the requirement to use a tool or a special equipment in
order to correctly perform the described operation.
§ The “ § ” symbol refers the reader to the chapter identified by the number that follows.
GB
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1.2. Tables of scheduled maintenance and checks
The main periodic checks and maintenance operations are
shown in the following tables. These operations are necessary
to keep the motorcycle safe and in perfect running order.
The intervals indicated in the periodic maintenance and lubrication tables must be intended as a general guide under normal riding conditions. It could be necessary to reduce these
intervals according to the climate, the ground conditions, the
geographic position and the conditions of use.
Some of the operations can be carried out by the user, providing he or she possesses the requisite skills. If unskilled, have
the operations performed by an authorized service centre.
As a rule maintenance operations must be performed while
the motorcycle is on the rear stand after switching off the
engine and setting the start switch to OFF. On the contrary,
while checking the fluid levels it is advisable to keep the motorcycle in an upright position without using the rear stand.
After the first 36,000 km (22,400 mi) the operations must be
performed at the same intervals shown in the tables.
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WARNI NG
•Impropriety or lack of recommended maintenance operations can lead to an increase of
the risk of accidents and damage to the motorcycle.
•Always use genuine MV Agusta spare parts. Using non-genuine spare parts can accelerate the wear of your motorcycle and shorten its life.
•Failure to perform the recommended operations, as well as using non-genuine spare
parts, could cause the warranty not to be operating.
•To replace or top up the lubricants and fluids of your motorcycle, use only the products
given at paragraph 1.4.
WARNI NG
If you use the motorcycle on race track, we recommend to have the bike checked before
and after using it by skilled personnel belonging to the MV Agusta Service Centers network.
Using the motorcycle on road track is allowed only occasionally and, however, not for competitive purpose, even during amateur events.
Using the motorcycle on road track could cause a considerable increase of the wear of its
components, which would bring to a reduction of their life duration with reference to a normal use on road or highway route.
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Tab les of sch edule d main tena nce
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
D
ESCRIPTION OPERATION
km (mi) covered
Service coupon A B C D E F G
Replace
( Use only MV Agusta
genuine spare parts )
Check level Every time vehicle is used
Engine oil
Renew
!!!!!!!
At least once a year
Engine oil filter
!!!!!!!
Every time engine oil is changed
Check / Restore level Every time vehicle is used
Coolant Check / Restore level !!!!!!!!
Renew At least every two years
Cooling system Check for leakage !!!!!!!!
Electric fans Check operation !!!!!!!!
Val ves Ch eck / Ad jus t !!!
Timin g chain
Check !!
Replace !
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Tab les of sch edule d main tena nce
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
D
ESCRIPTION OPERATION
km (mi) covered
Service coupon A B C D E F G
Timin g movable s hoe
Check / Replace !!
Replace
!
Every time timing chain is replaced
Timin g chain stretc her Chec k / R eplace !!!
Spark plugs
Check / Replace !!!
Replace !!!
Fuel filter Check / Replace !!!
Throttle body Check and Adjust !!!!!!!
Air filter Check / Replace !!!!!!
Check level Every time vehicle is used
Brakes / Clutch fluid
Check level !!!!! !!
Renew
!
At least every two years
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Tab les of sch edule d main tena nce
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
D
ESCRIPTION OPERATION
km (mi) covered
Service coupon A B C D E F G
Check operation Every time vehicle is used
Brakes / Clutch Check operation !!!!!!!!
Check lines for leakage !!!!!!!!
Brake pads
Check wear Every 1000 Km ( 600 mi )
(front and rear )
Check / Replace !!!!!!!
Fuel lines and connections
Check for leakage !!!!!!!
Replace At least every 3 years
Check operation Every time vehicle is used
Throttle control Check operation !!!!!!!!
Check / Adjust play
!!!!!!!!
Choke control Check operation !!!!!!!!
Flexible controls
and transmissions
Check / Adjust
!!!!!!!!
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Tab les of sch edule d main tena nce
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
D
ESCRIPTION OPERATION
km (mi) covered
Service coupon A B C D E F G
Check Every 1000 Km ( 600 mi )
Lubricate Every 1000 Km ( 600 mi ) and after riding under the rain
Drive chain Check / Adjust !!!!!!!!
Lubricate !! ! !
Replace !!!
Check !! ! !
Front sprocket / Tab washer
Replace
!!!
Every time drive chain is replaced
Check !! ! !
Rear sprocket
Replace
!!!
Every time drive chain is replaced
Rear sprocket spring drive Check / Replace !! !
Steering head tube ring Check / Adjust !!!!
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Tab les of sch edule d main tena nce
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
D
ESCRIPTION OPERATION
km (mi) covered
Service coupon A B C D E F G
Steering bearings
Check / Adjust !!!!
Lubricate !
Check pressure Every time vehicle is used; at least every 10 days
Tyre s
Check wear Every time vehicle is used; at least every 500 Km ( 300 mi )
Check pressure !!!!!!!!
Check wear !!!!!!!
Wheel rims Inspect visually
!!! !!!!
Every time tyre is replaced
Check
!!!!!
Front wheel bearings Every time tyre is replaced
Replace !
Sidestand
Check operation Every time vehicle is used
Check operation !!!!!!!!
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Tab les of sch edule d main tena nce
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
D
ESCRIPTION OPERATION
km (mi) covered
Service coupon A B C D E F G
Lubricate
needle bearing
Lubricate
needle bearing
Side stand switch
Check operation Every time vehicle is used
Check operation !!!!!!!!
Rear wheel hub
Check / !!
Replace / !
Swingarm bearings Check / Lubricate !
Drive chain pads on swingarm
Check / Replace !!!!!!!
Drive chain pads on frame plate
Check / Replace !!!!!!!
Rear shock absorber Check / Adjust !!!!
Front fork oil Renew !
Battery connections Check and clean !!!!!!!
Electrical equipment Check operation !!!!!!!!
Instrument panel
Check operation Every time vehicle is used
Check operation !!!!!!!!
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Tab les of sch edule d main tena nce
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
D
ESCRIPTION OPERATION
km (mi) covered
Service coupon A B C D E F G
Check operation /
Every time vehicle is used
Lights / Visual signals
Replace bulbs
Check operation /
!!!!!!!!
Replace bulbs
Horn
Check operation Every time vehicle is used
Check operation !!!!!!!!
Check operation Every time vehicle is used
Headlight Check operation !!!!!!!!
Adjust Every time geometry is changed
Ignition switch
Check operation Every time vehicle is used
Check operation !!!!!!!!
Locks
Check operation Every time vehicle is used
Check operation !!!!!!!!
Screws and nuts Check / Tighten !!!!!!!!
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Tab les of sch edule d main tena nce
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
D
ESCRIPTION OPERATION
km (mi) covered
Service coupon A B C D E F G
Hose clamps Check / Tighten !!!!!!!!
General lubrication !!!!!!!!
General test !!!!!!!!
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1.3. Tools and accessories supplied
Abag in the glove compartment contains the following
tools:
-1 hexagonal bar (10 mm hexagon);
-6 Allen keys (2,5 - 3 - 4 - 5 - 6 - 8 mm hexagons);
-1 spanner for rear wheel eccentric with extension;
-1 fuse puller;
-3 fuses (15A).
The following accessories are also supplied:
-1 spark plug wrench (16 mm hexagon);
-1 document holder.
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Description Recommended product Specifications
Engine lubrication oil AGIP RACING 4T 10W/60 (
*
)SAE 10W/60 - API SJ
Ethylene glycol diluted
Coolant AGIP ECO - PERMANENT with 50 percent
distilled water
Brake and clutch fluid AGIP BRAKE FLUID DOT4 DOT4
Drive chain lubrication oil MOTUL CHAIN LUBE ROAD –
1.4. Table of lubricants and fluids
*
:MV Agusta suggests to refer directly to its authorized dealers in order to purchase the recommended
product. The AGIP Racing 4T 10W/60 engine oil has been expressly produced for the F4 motorcycle
engine. If the above described lubricant is not available, MV Agusta
suggests to use a fully synthetic engine oil having characteristics
equal or better than the ones prescribed in the following standards:
– Consistent with: API SJ
– Consistent with: ACEA A3
– Consistent with: JASO MA
– SAE Rating: SAE 20 W-50 o 10 W-60
NOTE
The above standard denominations must be written, alone or
together, on the engine oil container label.
Engine oil
SAE 10 W-60
API SJ
ACEA A3
JASO MA
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1.5. Removing/fitting the side fairing
Pull off the quick fastenings and then remove the side
fairing.
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Fit the side fairing, taking care to position the front
profile as shown in figure A.
Fasten the panel by positioning the tab in the
lower part of the fairing as shown in figure B.
AB
Side fairing front
profile
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1.6. Checking the engine oil level
Check the oil level while the engine is not running, and
has been allowed to cool down for at least ten minutes
after a ride.
The check must be performed after placing the motorcycle in an upright position on a horizontal surface.
The level must be between the MAX and MIN marks on
the crankcase.
If the oil level is below the MIN mark, top up as
described in § 1.6.1.
WARNI NG
Do not start the engine if the oil level is below
the MIN mark.
Max
Min
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1.6.1. Topping up the engine oil level
Remove the oil filler plug by using the 10 mm
hexagonal bar supplied, assembled on a proper
key (see figure). Pour an appropriate amount of
engine oil of the recommended type. Never exceed
the MAX level mark. At the end of the operation,
place back the oil filler plug and reassemble the
right-hand side fairing.
WARNI NG
Before reassembling the oil filler plug,
grease its O-Ring by using AGIP Grease
30.
At last, perform the tightening of the oil
filler plug at the tightening torque of 35
Nm, by using a dynamometric key.
CAUTION
To av oid cl utch sl iding and da mage to
the engine, never add chemical additives to the engine oil, nor use an engine
oil different from the one specified in the
table at § 1.4. Make sure that no foreign
body gets in the crankcase while topping up the engine oil.
Oil filler plug
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WARNI NG
New or exhaust engine oil can be dangerous. Engine oil is highly toxic for
people and domestic animals. Avoid
ingestion and contact. It has been
proved that prolonged contact with
engine oil can cause skin cancer on
guinea pigs. Even a brief contact with
engine oil can cause skin irritation.
•If the engine oil comes in touch with
your skin, wash it away with soap and
water.
•Keep new or exhaust engine oil out of
reach of children and domestic animals.
•In the event of an engine oil ingestion,
immediately call a doctor and do not
cause vomiting, in order to avoid inhalation of engine oil in lungs.
•While topping up the engine oil, wear
a long-sleeved shirt and a pair of waterproof gloves to protect your skin.
•Correctly recycle or dispose of the
exhaust engine oil, in order to avoid
environmental pollution.
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1.7. Checking the coolant level
Check the coolant level while the engine is off and cold.
The check must be performed after placing the motorcycle in an upright position on a horizontal surface.
Ensure that the coolant level is between the MIN and
MAX mark, as shown in the figure.
If the coolant level is below the MIN mark, top up the
coolant as described at paragraph 1.7.1.
WARNI NG
Do not start the engine if the coolant level is
below the MIN mark.
MAX
MIN
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1.7.1. Topping up the coolant level
Remove the coolant filler cap and top up
with the recommended coolant (see
§1.4).
WARNI NG
Perform the topping up of the
coolant when the engine is off
and cold. Never attempt to
remove the coolant filler cap
when the engine is hot, in order
to avoid the risk of burns. The
cooling system is under pressure!
After topping up, carefully replace the
previously removed parts.
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WARNI NG
Under certain conditions, ethylene glycol contained in the coolant can become
flammable. When it is lighted, it produces an invisible flame.
Avoid spilling coolant on hot parts of
the motorcycle, because the subsequent combustion of ethylene glycol
could cause serious burns.
WARNI NG
Coolant is a highly toxic fluid. Avoid
contact and ingestion. Keep coolant out
of reach of children and domestic animals. In the event of a coolant ingestion,
immediately call a doctor and do not
cause vomiting, in order to avoid inhalation of coolant in lungs. If the coolant
comes in touch with your skin or eyes,
immediately wash it away with water.
CAUTION
To top up t he c oola nt l evel and /or r enew
the coolant, use only the product specified in the table in section 1.4. Do not
mix nor dilute the coolant with additives
or different fluids. If the coolant specified in section 1.4. is not available, use a
coolant having technical characteristics
consistent with the prescribed product.
CAUTION
Coolant can damage painted and plastic
parts. When you top up the coolant
level, be careful not to spill coolant on
any part of the motorcycle. If you do
spill coolant on your motorcycle, immediately wipe it away using a clean cloth.
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1.8. Checking the wear of the brake pads
Periodically check the width of the friction material layer of the
pads, making sure it never falls below the wear limit (1 mm).
WARNI NG: If the brake pads are exc ess ively
worn out, the effectiveness of the braking
system decreases, increasing the risk of accidents. If the pads have worn to near the wear
limit, have both pads replaced by an authorized service centre. Ensure that the new pads
are suitably broken in.
Front brake caliper
Rear brake caliper
Disc
Pads
Wear limit 1 mm
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