MV Agusta F4 Brutale 2003 Owner's manual
M.V. AGUSTA F4 BRUTALE ORO - S
Information
MV Agusta S.p.A. is committed to a policy of constant improvement; therefore, you may find slight differences between the information provided in this document and the vehicle you purchased. MV Agusta motorcycles are exported in several countries, in which different rules and regulations (concerning both the
Highway Code and the homologation procedures) are in force. Relying on your understanding, MV Agusta
S.p.A. deems it necessary to reserve the right to change its products and the related documentation at any
time and without notice.
Respect and defend natural environment
Everything we do affects the whole planet as well as its resources.
MV Agusta, in order to protect the interests of the community, awakens the Customers and the Technical
Assistance operators to use the vehicle and dispose of its replaced parts respecting the laws in force concerning environmental pollution and waste disposal and recycling.
© 2003
This document may not, in whole or in part, be reproduced without prior consent, in writing, from MV Agusta S.p.A.
Part No. 8A0099358 - Edition No. 1
Printed in May 2003
Use and maintenance manual
Il presente Manuale di uso e manutenzione è disponibile nelle edizioni in lingua sotto specificate:
This Manual is available in the languages listed below:
Le présent livret d’utilisation et d’entretien est disponible dans les éditions rédigées dans les langues
spécifiées ci-dessous:
Die vorliegende Bedienungs- und Wartungsanleitung ist in folgenden Sprachen erhältlich:
Las ediciones del presente manual de uso y mantenimiento están disponibles en los siguientes idiomas:
Codice/Code/Code
Bestell-Nr./Código
Edizione Italiana
Italian Edition
Edition Italienne
Italienische Ausgabe
Edición en Italiano
800099358
Edizione Inglese
Edizione Francese
Edizione Tedesca
Edizione Spagnola
Edizione USA
English Edition
French Edition
German Edition
Spanish Edition
USA Edition
Edition Anglaise
Edition Française
Edition Allemande
Edition Espagnole
Edition USA
Englische Ausgabe
Französische Ausgabe
Deutsche Ausgabe
Spanische Ausgabe
USA Ausgabe
- 2 -
Edición en Inglés
Edición en Francés
Edición en Alemán
Edición en Español
Edición USA
8A0099358
8B0099358
8C0099358
8D0099358
800099361
Dear Customer,
We wish to thank you for your preference and congratulate you on purchasing your new F4 Brutale.
MV Agusta, thanks to the passionate effort of its technicians, offers to its customers a motorcycle with a
new aesthetic design combined with a refined framework: these are the elements which have distinguished every vehicle created by MV Agusta throughout its glorious history.
The result of this effort is an exclusive motorcycle with functional and aesthetic characteristics that place
it above the finest motorcycles currently available on the market, making it an exclusive and sought-after
item.
In fact, the technologies and solutions applied give to the F4 Brutale unique characteristics common to
all the MV Agusta models, strenghtening a design phylosophy that involves continuous research, technological innovation and love for detail. This way, MV Agusta gives to all the bikers who freely live their
passion the chance to possess a unique object, which surely represents a strong reference worldwide.
This manual has been drawn up with a view to providing you with a clear and practical guide to operating and maintaining your new motorcycle while safeguarding your warranty rights.
For further information, please feel free to contact the MV Agusta Customer Care Service.
Have a good time!
Claudio Castiglioni
MV Agusta
Chairman
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CONTENTS
chap. Subject covered page
1 GENERAL INFORMATION 10
1.1. Purpose of the manual 10
1.2. Symbols 11
1.3. Warranty Booklet and Service Coupons 12
1.4. Identification data 13
2 SAFETY INFORMATION 22
2.1. Safety 22
2.1.1. Note on tampering 22
2.1.2. Safety rules 23
2.1.3. Precautions for children 25
2.1.4. Installing accessories 26
2.1.5. Vehicle load 27
2.1.6. Modifications 29
2.1.7. Competitions 29
2.1.8. Recommendations for safe riding 30
2.1.9. Protective clothing 33
2.1.10. Suggestions against theft 34
2.2. Safety labels - Location 35
2.3. Safety - Visual and acoustic signals 39
3 CONTROLS AND INSTRUMENTS 40
3.1. Location of controls and instruments 40
chap. Subject covered page
3.2. Sidestand 42
3.3. Handlebar controls, left side 43
3.4 Handlebar controls, right side 45
3.5. Ignition switch and steering lock 46
3.6. Gear lever 52
3.7. Instruments and warning lights 53
3.7.1. Warning lights 54
3.7.2. Multifunction display 55
4 OPERATION 56
4.1. Using the motorcycle 56
4.2. Running-in 57
4.3. Starting the engine 59
4.4. Selecting and setting the display functions 61
4.4.1. Selecting the display functions 62
4.4.2. Setting the measurement units 63
4.4.3. Resetting the trip mileage counters 66
4.4.4. Setting the clock 69
4.5. Refuelling 71
4.6. Glove compartment 73
4.7. Parking the motorcycle 75
4.8. Preriding checks 77
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CONTENTS
chap. Subject covered page
4.9 Riding 79
5 ADJUSTMENTS 80
5.1. List of adjustments 80
5.2. Table of adjustments 83
5.3. Adjusting the front brake lever 84
5.4. Adjusting the clutch lever 84
5.5. Adjusting the rearview mirrors 85
5.6. Adjusting the front suspension 86
5.6.1. Spring preload 87
5.6.2. Rebound damper (front suspension) 87
5.6.3. Compression damper (front suspension) 88
5.7. Adjusting the rear suspension 89
5.7.1. Rebound damper (rear suspension) 90
5.7.2. High speed compression damper
(rear suspension) 91
5.7.3. Low speed compression damper
(rear suspension) 91
5.8. Headlight adjustment 92
6 MAINTENANCE 94
6.1. Tables of scheduled maintenance and
checks 94
chap. Subject covered page
6.2. Tools and accessories supplied 104
6.3. Table of lubricants and fluids 105
6.4. Checking the engine oil level 106
6.4.1. Topping up the engine oil level 107
6.5.
Checking the coolant level
6.5.1.
Topping up the coolant level
6.6. Checking the wear of the brake pads 112
6.7. Checking the brake fluid level 113
6.8. Checking the clutch fluid level 115
6.9. Checking and replacing the tyres 116
6.10. Checking and lubricating the drive chain 121
6.11. Checking the idle speed 125
6.12. Replacing parts - General information 126
6.12.1. Replacing the fuses 126
6.12.2. Replacing the low beam bulb 129
6.12.3.
Replacing the high beam bulb
6.12.4 Replacing the front parking light bulb 132
6.12.5. Replacing the front turn indicator bulbs 133
6.12.6. Replacing the rear turn indicator bulbs 134
6.12.7. Replacing the rear light and brake light
bulb 135
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109
110
131
CONTENTS
chap. Subject covered page
6.12.8. Replacing the license plate light bulb 136
6.13. Battery 138
6.14. Cleaning the motorcycle 140
6.15. Prolonged inactivity 143
7 TROUBLESHOOTING FLOW CHART 144
7.1. Engine problems 144
7.2. Electrical equipment problems 149
8 TECHNICAL INFORMATION 152
8.1. Motorcycle overview 152
8.1.1. Front brake circuit 154
8.1.2. Rear brake circuit 155
8.1.3. Clutch circuit 156
8.1.4. Engine lubrication 157
8.1.5. Coolant circuit 158
8.1.6. Fuel system 159
8.2. Specifications 160
8.3. Carbon components 167
8.5. Magnesium components 168
8.5. Accessories 169
8.6. Clothing 170
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A
Accessories 169
– installation 26
Adjustments
– clutch lever 84
– front brake lever 84
– front suspension 86
– headlight 92
– list 80
– rear suspension 89
– rearview mirrors 85
– table 83
B
Battery 138
Brakes
– fluid level, check 113
– front brake circuit 154
– front brake lever, adjustment 84
– pads, wear check 112
– rear brake circuit 155
Bulbs, replacement of
– front turn indicators 133
– high beam 131
– license plate light 136
– low beam 129
– parking light 132
INDEX
– rear light and brake light 135
– rear turn indicators 134
C
Carbon components 167
Chain
– check 121
– lubrication 123
Cleaning the motorcycle 140
Clutch
– circuit 156
– fluid level, check 115
– lever, adjustment 84
Competitions 29
Controls and instruments, location 40
Coolant
– level, check 109
– circuit 158
– topping up 110
D
Damper
– compression (front suspension) 88
– compression (rear suspension) 91
– rebound (front suspension) 87
– rebound (rear suspension) 90
Display, multifunction 55
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INDEX
– selecting functions 62
– setting functions 63
E
Electrical equipment, troubleshooting 149
Engine
– lubrication 157
– oil level, check 106
– oil level, topping up 107
– serial number 13
– starting 59
– troubleshooting 144
F
Fuel system 159
Fuses, replacement 126
G
Gear lever 52
Glove compartment 73
H
Handlebar controls
– left side 43
– right side 45
Headlight, adjustment 92
– high beam, bulb replacement 131
– low beam, bulb replacement 129
I
Identification data 13
Idle speed, check 125
Ignition switch and steering lock 48
Instruments and warning lights 53
L
Levels
– brake fluid 113
– clutch fluid 115
– coolant 109
– engine oil 106
License plate light, bulb replacement 136
Location of controls and instruments 40
Lubricants and fluids, table 105
M
Magnesium components 168
Maintenance and checks, tables 94
Motorcycle color combination 20
Motorcycle overview 152
P
Parking 75
Parking light, bulb replacement 132
Precautions for children 25
Preriding checks 77
Prolonged inactivity 143
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Purpose of manual 10
R
Rear light and brake light,
bulb replacement 135
Rearview mirrors, adjustment 85
Refuelling 71
Replacing parts, general information 126
Running-in 57
S
Safety 22
– labels, location 35
– recommendations for safe riding 30
– rules 23
– visual and acoustic signals 39
Scheduled maintenance tables 94
Sidestand 42
Specifications 160
Spring preload 87
Suspensions
– front, adjustment 86
– rear, adjustment 89
Symbols 11
INDEX
T
Tampering, note 22
Tools and accessories supplied 104
Topping up
– coolant 110
– engine oil 107
Troubleshooting flow chart
– electrical equipment 149
– engine 144
Turn indicators
– front, bulb replacement 133
– rear, bulb replacement 134
Tyres, check 116
– puncturing 117
– replacement 118
V
Vehicle
– identification number 13
– load 27
– modifications 29
W
Warning lights 54
Warranty
– Booklet, Service Coupons and Dealers’
Guide 12
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GENERAL INFORMATION 1
1.1. Purpose of the manual
1
In addition to providing directions on operation and maintenance, this manual contains important information about general safety: READ THE MANUAL OVER CAREFULLY
BEFORE FIRST USING THE MOTORCYCLE.
The manual describes the model with the maximum equipment at print time.
This manual must be considered as a part of your motorcycle.
It must always be kept inside it, and it must be included with
the vehicle even if this one is sold back to another owner.
The manual must be kept in the glove compartment placed
under the passenger’s seat.
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GENERAL INFORMATION 1
1.2. 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
The following symbols are used to provide further information:
Information marked with the symbol “ ★ “ only refers to the “ BRUTALE “ ORO model.
★
The “ ” symbol points out the requirement to use a tool or a special equipment in
order to correctly perform the described operation.
must be carried out only by authorized personnel.
§ The “ § ” symbol refers the reader to the chapter identified by the number that follows.
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1
GENERAL INFORMATION 1
1.3. Warranty Booklet and Service Coupons
1
Besides this Use and Maintenance Manual, the vehicle is
accompanied by the following documents: a Warranty Booklet
containing a Warranty and Pre-Delivery Certificate and recommended service coupons, and the MV Agusta Dealers’Guide.
IMPORTANT
The copy of the Warranty and Pre-Delivery Certificate to be
sent to MV Agusta must be filled in by the dealer and returned
to the factory within 10 days from the date of registration.
Every time the vehicle is serviced by a dealer, the user must
produce the Warranty Booklet so that the dealer can fill in the
service coupon and return it to MV Agusta within 10 days from
the date of the servicing.
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GENERAL INFORMATION 1
2) engine serial number
1.4. Identification data
1) vehicle identification number
2) engine serial number
3) homologation data
4) “limited series” number★
Motorcycle identification
The motorcycle is identified by the vehicle identification number. When placing orders for spare
parts, in addition to this number, you may be
4) “limited series” number ★
1
1) vehicle identification number
3) homologation data
required to provide the engine serial number, the
colour code and the key identification.
We recommend writing down the main numbers
in the spaces provided below.
FRAME No.:
ENGINE No.:
★ This motorcycle has been produced in a limited
series. Each vehicle is identified by a serial number
stamped on a 24-carat gold plate.
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GENERAL INFORMATION 1
Here below you can find a description of a vehicle identification number:
1
ZCG F4 01 AA Y V 000000
Manufacturer’s Letter Code
Motorcycle model
Progressive vehicle number
The vehicle identification number must be provided each time you need to contact the MV Agusta
Technical Assistance Service, in order to guarantee the traceability of your motorcycle.
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GENERAL INFORMATION 1
Motorcycle key identification
Akey is supplied in duplicate for both the ignition and all
the locks. Keep the duplicate in a safe place.
It is essential to provide the key identification number if
you place an order for a spare motorcycle key. We
recommend writing down this number in the space provided below:
KEY No.:
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key identification number
1
GENERAL INFORMATION 1
1
3 5
4
10
2
1
9
- 16 -
11
6
7
8
GENERAL INFORMATION 1
Bodywork parts reference colours
Bodywork parts are painted with the following reference colours, according to the corresponding
motorcycle colour combination (see page 20):
1. - Rear side fairing, right-hand;
2. - Rear side fairing, left-hand;
3. - Fuel tank:
Brutale ORO/
Brutale S (Colour combination A) :
CRC Red Painting
(Code Palinal 926XH348D)
Brutale S (Colour combination B) :
Brutale Metal Matt Black Painting
(Code Palinal 925XH982)
4. - Tail piece;
5. - Air box side fairings;
6. - Ignition switch cover;
7. - Dashboard cover;
8. - Fuel tank left-hand side fairing;
9. - Fuel tank right-hand side fairing;
Brutale ORO:
No painting
Brutale S:
Brutale Metal Anthracite Grey Painting
(Code Palinal 926XH893 Multicryl)
10. - Right-hand rearview mirror;
11. - Left-hand rearview mirror:
Brutale Metal Anthracite Grey Painting
(Code Palinal 926XH893 Multicryl)
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1
1
GENERAL INFORMATION 1
2
1
3
7
9
8
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4
5
6
GENERAL INFORMATION 1
Frame parts reference colours
Frame parts are painted with the following reference colours:
1.- Frame;
2.- Rear frame;
3.- Silencers clamp:
Brutale ORO / Brutale S:
Brutale Metal Anthracite Grey Painting
(Code Palinal 211XH893)
4.- Steering base;
5.- Swingarm;
6.- Left-hand frame plate;
7.- Right-hand frame plate:
Brutale ORO:
Brutale Gold Magnesium Painting (Code
Palinal 8814338 + Code Palinal 211E359)
Brutale S:
Black Colour Anodizing
8.- Front wheel rim;
9.- Rear wheel rim:
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1
Brutale ORO:
Brutale Gold Magnesium Painting
(Code Palinal 8814338 +
Code Palinal 211E359)
Brutale S:
Aluminium Grey Painting
(Code Sebino 35204189) +
Transparent Painting
(Code Sebino 35209052)
GENERAL INFORMATION 1
1
Identification of motorcycle colour combination
The colour code must be mentioned when ordering
body spares. It can be read on the internal side of the
dashboard cover.
In order to get to the colour code label, it is necessary
to remove the two lateral fixing screws of the dashboard
cover.
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GENERAL INFORMATION 1
After removing the screws, lift the dashboard cover so
to expose the colour code label placed on its internal
surface. On this label you can read the motorcycle
colour combination, which determines the painting of
the bodywork parts.
We recommend writing down the colour code in the
space provided below:
COLOUR CODE :
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colour code label
1
2.1. Safety
SAFETY INFORMATION 2
2.1.1. NOTE ON TAMPERING
2
Tampering with the noise control system is prohibited. In particular, the law prohibits the following acts:
1. The removal or rendering inoperative, other
than for purposes of maintenance, repair, or
replacement, of any device or element of
design incorporated into any new vehicle for the
purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use.
2. The use of the vehicle after such device or element of design has been removed or rendered
inoperative.
Acts presumed to constitute tampering include:
1. The removal or piercing of the exhaust
silencer, the diaphragm, the manifolds, or any
other components involved in the transmission
of exhaust gases.
2. The removal or piercing of any part of the
intake system.
3. Poor maintenance.
4. The replacement of any movable parts of the
vehicle or of any intake or exhaust components with parts or components other than
those prescribed by the manufacturer.
NOTE
If you notice a progressive increase of the noise
level of your motorcycle, MV Agusta recommends
to have your noise control system controlled and
if necessary replaced.
Otherwise, riding with a defective muffler can
subject you to the penalties prescribed by state
and local provisions.
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SAFETY INFORMATION 2
2.1.2. SAFETY RULES
IMPORTANT: READ BEFORE USE
Before riding, carefully read this manual so as
to familiarize yourself with the controls, characteristics, working and limits of the motorcycle. The
manual is aimed at providing information on some
of all the possible techniques and methods required for safe riding.
Do not attach a sidecar, a trailer or any other
accessory to the motorcycle. Failure to observe
this warning may make the vehicle unstable and
cause serious accidents.
To ensure maximum reliability and maintain
the vehicle in perfect working order, it is essential
to perform the servicing detailed in the Scheduled
Maintenance Table and to follow all the instructions provided in this manual. For further information, speak with your dealer, who will have the
necessary technical skills and information to assist you.
MV Agusta continually strives to improve the
quality of all of its motorcycles. Therefore, modifications that improve the performance of the bike
are made as soon as they are developed.
Therefore, your motorcycle may not be described
exactly by the illustrations and text contained in
this manual.
If you find difficulties in understanding any picture or information contained in this manual, contact your MV Agusta dealer to obtain the necessary explanations.
If you find difficulties in reading any information
contained in this manual, contact your MV Agusta
dealer.
In order to avoid compromising handling and
stability of your motorcycle, you should obey the
following warnings:
• do not attach any object to the vehicle;
• do not remove any part and/or component;
• do not modify the vehicle in any way;
• do not wear garments that could adversely
affect control and handling of the motorcycle.
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2
SAFETY INFORMATION 2
Do not ride this motorcycle if you do not pos-
sess a regular driving licence. Failure to heed this
warning constitutes a breach of the Highway
Code, besides posing a serious hazard to the dri-
2
ver’s and other people’s safety.
Do not try to service or repair this motorcycle if
you do not possess the necessary skills.
Motorcycle riding demands your complete
attention. Do not ride if you are ill, in poor physical condition, or because of worry, etc., unable to
concentrate on the task at hand.
Always wear a helmet, even on short rides.
Always wear suitable clothes, especially when
travelling by night (e.g. garments with fluorescent
bands).
When refuelling, switch off the engine and
refrain from smoking.
Since petrol is highly flammable, avoid spilling
the fuel onto the tank and the exhaust pipes when
refuelling.
When refuelling, stay away from the vehicle to
avoid inhaling harmful fumes. Should the fuel
come into contact with the skin or clothes, immediately wash with water and change the contaminated garments.
When travelling during the day, use the low
beam.
Do not start the engine in closed places.
Exhaust gases are toxic and can quickly saturate
the air and cause fainting or even death.
Before starting the engine in a closed place,
ensure that the area is well ventilated.
While the vehicle is in motion, always rest the
feet on the specially designed supports.
While riding, always keep both hands on the
handlebars.
Do not cover your motorcycle with a canvas
soon afterwards riding. Before covering your
motorcycle, wait until the engine and the exhaust
pipes have thoroughly cooled.
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SAFETY INFORMATION 2
If your motorcycle has been involved in an accident, check all levers, wires, hoses, brake calipers and
other main parts for damage. Do not use the vehicle if you detect a damage that could adversely affect
safety. Have all the main parts checked by an authorized MV Agusta dealer, in order to verify the absence of defects and/or damages that the owner could not be able to detect.
2.1.3. PRECAUTIONS FOR CHILDREN
WARNING
• Park the vehicle where it is unlikely to
be bumped into or damaged. Even slight or involuntary bumps can cause the
vehicle to topple over, with subsequent
risk of serious harm to people or children.
• To prevent the vehicle from tipping
over, never park it on soft or uneven
ground, nor on asphalt strongly heated
by the sun.
• Engine and exhaust pipes become
very hot during riding. Always park
your motorcycle where people or children can not easily reach these parts,
in order to avoid serious burns.
- 25 -
Parts at high temperature
2
SAFETY INFORMATION 2
2.1.4. INSTALLING ACCESSORIES
MV Agusta provides a range of accessories spe-
cially designed for your vehicle. It is essential that
2
these accessories are installed by an MV Agusta
dealer.
WARNING
Use only MV Agusta original accessories. The use of non-genuine accessories can make the vehicle unsafe by
reducing its handling, stability and the
effectiveness of the braking system. For
this reason, the installation of any nongenuine accessory makes the warranty
null and void and relieves MV Agusta of
all responsibility.
Every time you apply accessories that affect
the weight and/or the aerodynamic characteristics
of your motorcycle, they must be assembled on its
lower side and near to its center, as much as it is
possible. The brackets and the anchor bolts must
be carefully checked after the assembling, to
ensure a stable framework and an unmovable
support for the accessory. In fact, an eventual
breaking of these stands could cause dangerous
situations during riding.
Verify that the assembling of the accessories
does not cause a reduction of the minimum ground
clearance and of the inclination of your motorcycle. Moreover, verify that the assembling of the
accessories does not cause any interference with
the handling of the steering system, with the travel
of the suspensions and/or with the movement of
any other component involved in driving.
Any accessory positioned on the handlebar or
on the front fork can reduce the handling and
adversely affect the stability of the vehicle.
Therefore, the choice of the accessories should
be accurate and restricted to components of light
weight and small dimensions only.
Your motorcycle could undergo lightening or
other instability effects in case of wind blowing
- 26 -
SAFETY INFORMATION 2
sideways and transversely; this may also happen
when your motorcycle runs into or it is overtaken
by vehicles of great dimensions. Under these conditions, the accessories adversely affect your driving safety, especially if they are incorrectly
assembled or of the wrong type. It is therefore
necessary to pay great attention in choosing and
assembling any accessory.
Some accessories force the rider to drive in an
unnatural position. This may obviously restrict
your freedom of movement and cause loss of control of the vehicle.
Additional electric accessories can cause an
overload of the electrical system of your motorcycle; this could damage the wires, causing danger
of short circuit and electric shock.
2.1.5. VEHICLE LOAD
Your motorcycle is designed for use by the rider
and it can also seat a passenger. To use the vehicle in complete safety and in accordance with the
Highway Code provisions, it is compulsory that
the following maximum load conditions are never
exceeded:
BRUTALE ORO 361 kg
BRUTALE S 370 kg
These values come out from the sum of the following weights, according to the European standard CEE 92/61:
• weight of the motorcycle;
• weight of the driver;
• weight of the passenger;
• weight of the load and all the accessories.
- 27 -
2
SAFETY INFORMATION 2
2
WARNING
Since the load can strongly affect handling, braking, performance and safety
characteristics of your motorcycle, you
should always keep in mind the following warnings.
• NEVER OVERLOAD YOUR MOTORCYCLE! Driving an overloaded motorcycle can cause damage to the tyres, loss of
control of the vehicle and serious injury.
Verify that the total weight (including the
weight of the motorcycle, the driver, the
passenger, the load and all the accessories) does not exceed the maximum load
values specified for your vehicle.
• Before riding, always check the wear
and the pressure of the tyres.
• Never carry any incorrectly fastened
object on your motorcycle, because it
could move from its position during
riding.
• Steadily fasten the heaviest objects
near the center of the motorcycle, and
equally divide the load on both sides of
the vehicle.
• Do not insert any object or accessory
in the spaces on the frame trellis, in
order to avoid interferring with the
movable parts of the motorcycle.
• Adjust the suspensions according to
the load.
• Even if the motorcycle is correctly
loaded, drive with caution and never
exceed 130 km/h when you carry a load.
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