12.-F4 1000 R (2010) WORKSHOP MANUAL (Ingles) 7510036966512279755

Cop.M.O.Mototel.F5_GB_Ed.1.
fh 20-05-2010 11:02 Pagina 2

C M Y CM MY CY CMY K
Colori compositi
© 2010
The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A.
Part no. 8A00B4301 - Edition no. 1

Printed – May 2010
Motorcycle workshop manual
MV AGUSTA F4 1000
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 profes-
sional training of the technician.
With purpose of making the reading of this manual immediately comprehensible, the para-
graphs 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 prob-
lems, MV Agusta S.p.A. reserves the right to make modifications to its products and tech-
nical 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.
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Freni
General Index
GENERAL DESCRIPTION........................................................................................ A
Rev. 0
MAINTENANCE ........................................................................................................ B
Rev. 1
BODYWORK ............................................................................................................ C
Rev. 0
AIR INTAKE INJECTION SYSTEM .......................................................................... D

Rev. 1
ELECTRICAL SYSTEM ............................................................................................ E

Rev. 1
SUSPENSION AND WHEELS .................................................................................. F

Rev. 0
FRAME ...................................................................................................................... G
Rev. 1
BRAKES.................................................................................................................... H
Rev. 0
COOLING SYSTEM .................................................................................................. L

Rev. 0
SPECIAL TOOLS ...................................................................................................... M

Rev. 1
TORQUE PRESSURES ............................................................................................ N

Rev. 1
DIAGNOSTICS .......................................................................................................... O
Rev. 0
ANALYTICAL INDEX ................................................................................................ P

Rev. 1
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General description
SECTION
Revision 0
A
-1-
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 5
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 6
OBSERVATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 8
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 8
OPERATIVE TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 9
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General description
HOW TO CONSULT THIS MANUAL A

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.
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.
EXAMPLE
Steering pin tightening
10°
Screw in the steering pin flange ring, without tighten- 2
ing.
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).
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 prod-
uct 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.
-3-
General description
A GLOSSARY AND SYMBOLS

This signifies that the lack
ATTENTION of or the incomplete
observance of this advice Use the recommended suspension fluid.
can be gravely dangerous
for your safety and for the
safety of other persons.
This signifies that the lack Use the recommended coolant.

WARNING of observance of these
instructions can bring the
risk of damage to the
motorcycle and the equip-
ment.
NOTE Supplies key information for the best fulfil- Use the recommended thread-locking
ment of the operation. fluid.
Utilise a specific tool or equipment for

the correct carrying out of the operation Use the recommended sealant.
described.
Tighten to the specified torque. Use the recommended adhesive.
Tolerance or limit of use. Carry out accurate cleaning.
Utilise the tester. Use new components.
Use the recommended oil. Substitute the component.
Use the recommended grease. Do not leave litter about.
Use the recommended brake fluid.
-4-
General description
RIGHT HAND AND LEFT HAND STANDARD A

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.
Cylinder 3 Cylinder 2
Cylinder 4 Cylinder 1
Left side
Right side
Left side Right side
-5-
General description
A SAFETY
The information contained in this paragraph is fundamental so that the operations carried
ATTENTION
out on the motorcycle can be conducted with minimum risk to the mechanic.
Carbon Monoxide
• Exhaust gases contain carbon monoxide (CO) that is poisonous. Carbon monoxide can cause the loss of con-
sciousness 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, abundantly rinse with water and consult a doctor immediately.
• 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 recommended to
go to an authorised MV Agusta dealer who is 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 nec-
essary call a doctor.
• Do not remove the radiator cap when the engine is still hot. Being under pressure, the engine coolant can be vio-
lently 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 advisable to go to the authorised MV Agusta dealer who is equipped to deal
with the collection 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.
-6-
General description
Brake fluid
A
• 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 vomit-
ing 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.
Battery
• The battery produces explosive gases. Keep it away from sparks, flames or cigarettes. During recharging, ade-
quately 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 treat-
ment 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 advisable to substitute it at
an MV Agusta dealer that is equipped to dispose of this product in respect of the norms in force.
• Do not dispose of used batteries in the environment.
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.
-7-
General description
A WARNING
The information contained in this
WARNING 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 con-
tainers 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 pre-
scribed. 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.
INDEX
GENERAL INDEX SUMMARY OF EACH CHAPTER
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General description
OPERATIVE TECHNICAL SPECIFICATIONS A

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.
2) Engine registration number
1) Frame registration number

3) Homologation date
Below is an example of the designation of the frame registration number:
ZCG F6 10 AA Y V 000000
Manufacturer identification
Vehicle model
Progressive frame number
-9-
General description
- 10 -
Maintenance
SECTION
Revision 1
B
-1-
Maintenance
SUMMARY
TECHNICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

PERIODICAL MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 6
B MAINTENANCE AND TUNING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 8
ENGINE OIL AND OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 8
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 11
ELECTRIC COOLING FANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 14
VALVE MECHANISM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 15
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 25
FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 27
FUEL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 33
TUBES / FUEL FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 36
FUEL TUBE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 36
THROTTLE BODY ADJUSTMENT AND CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 37
BRAKES AND CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 44
BRAKE / CLUTCH / GEARCHANGE COMMANDS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 47
BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 49
THROTTLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 49
LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 51
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 53
TRANSMISSION CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 53
TYRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 56
FRONT WHEEL BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 56
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 57
REAR WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 57
SWINGARM BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 57
REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 58
SIDE STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 59
FRONT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 60
NUTS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 60
TUBE FASTENING BANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 60
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 60
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 60
WARNING LIGHTS AND INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 61
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 82
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 87
FRONT HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 90
-2-
Maintenance
TECHNICAL INFORMATION
2100 750
830
115
1430
TECHNICAL DATA
Description F4 1000
CHARACTERISTICS
Wheelbase (mm) (*) 1430
Total length (mm) (*) 2100
Maximum width (mm) 750
Seat height (mm) (*) 830
Ground clearance (mm) (*) 115
Trail (mm) (*) 100,4
Dry weight (kg) 192
Fuel tank capacity (lt) (**) 17
Fuel reserve (lt) (**) 4
Sump oil quantity (kg) 3,5
ENGINE
Type Four-cylinder, four-stroke, 16 valves
Bore (mm) 76
Stroke (mm) 55
Displacement (cm3) 998
Compression ratio 13,1 : 1
Starter system Electrical
Cooling Cooling with separate liquid and oil radiators
Engine casing and covers Die-cast
Cylinder head and cylinders Chill-cast
Valves Bimetal / single-metal
* : The data declared are not binding. They are susceptible to variations due to riding conditions.
** : The data declared are not binding. They are susceptible to variations due to external temperature, engine temperature and the evaporation point of the petrol used.
-3-
Maintenance
TECHNICAL DATA
Description F4 1000
TIMING
Type D.O.H.C. radial valves
LUBRICATION
B Type
IGNITION - FUEL FEED SYSTEM
Wet sump
Type “Magneti-Marelli” IAW 7BM integrated ignition-injection system with Mikuni throttle body;
inductive discharge electronic ignition; “Multipoint” phased sequential electronic injection;
variable lenght intake funnel with Torque Shift System (TSS)
Spark plugs NGK CR9 EB
Spark gap (mm) 0,7 ÷ 0,8
CLUTCH
Type Multiple-disc in oil bath with mechanical anti-surging device
PRIMARY DRIVE
N° teeth - engine crankshaft Z = 50
N° teeth - clutch gear Z = 79
Transmission ratio 1,58
SECONDARY DRIVE
N° teeth - pinion wheel Z = 15
N° teeth - crown wheel Z = 41
Transmission ratio 2,73
TRANSMISSION
Type Removable, six-speed gearbox with constant-mesh gears
Gear ratios (total ratios)
1st 2.64 (11.39)
2nd 2.06 (8.88)
3rd 1.72 (7.42)
4th 1.50 (6.47)
5th 1.32 (5.69)
6th 1.19 (5.13)
FRAME
Type CrMo steel tubular trellis (TIG welded)
Fork fulcrum plates Aluminium alloy
FRONT SUSPENSION
Type “Upside down” telescopic hydraulic fork with external and separated
adjustment of rebound and compression damping and of spring preload
Ø stems (mm) 50
Telescopic movement (mm) 120
REAR SUSPENSION
Type Progressive, single shock absorber with rebound-compression
(high speed/low speed) damping and spring preload adjustment
Wheel travel (mm) 120
Mono-arm fork Aluminium alloy
FRONT BRAKE
Type Dual floating disc with steel braking band
Ø Discs (mm) 320
Disc flanges Aluminium
Calipers (Ø pistons mm) Radial-type, single-piece with 4 pistons (Ø 34)
REAR BRAKE
Type Single steel disc
Ø Discs (mm) 210
Calipers (Ø pistons mm) 4-piston (Ø 25.4)
FRONT RIM
Material Aluminium alloy
Dimensions 3,50” x 17”
REAR RIM
-4-
Maintenance
TECHNICAL DATA
Description F4 1000
TYRES
Front 120/70-ZR 17 (58 W)
Rear 190/55-ZR 17 (75 W)
Brand and type PIRELLI - Diablo Supercorsa SP B
DUNLOP - Sportmax Qualifier RR
Tyre pressure (*) At a speed lower than 300 km/h At a speed higher than 300 km/h
Front 2.3 bar (33 psi) 2.5 bar (36 psi)
Rear 2.3 bar (33 psi) 2.9 bar (42 psi)
EXHAUST SYSTEM
Type 4 in 2 in 1 in 2 in 4
ELECTRICAL SYSTEM
System voltage 12V
Headlight bulb PHILIPS XenStart D1S 35W
Tail light bulb 12V 5W
Battery 12V - 8,6Ah
Alternator 350 W at 5000 r.p.m.
HEADLIGHT
Type Centrally mounted high/low beam bi-function polyellipsoidal
BODYWORK
Fairing Thermoplastic material
Front fairing Thermoplastic material
Rear side panels Thermoplastic material
Fuel tank Thermoplastic material
Air box Thermoplastic material
Air scoops Thermoplastic material
Air box side panels Thermoplastic material
Front mudguard Thermoplastic material
Chain guards Thermoplastic material
Exhaust pipe guard Aluminium
Heat shield Thermoplastic material
License-plate holder Thermoplastic material
* : If tyre brands other than those recommended are used, refer to the tyre pressure indicated by the manufacturer on the tyre side wall.
-5-
Maintenance
PERIODICAL MAINTENANCE SCHEDULE

The table that follows indicates the recommended intervals between periodical maintenance operations.
Periodical maintenance is necessary to keep the motorcycle in an optimum condition. The intervals are expressed
in kilometres.
B For motorcycles used in particularly severe conditions, maintenance operations must be
WARNING
carried out more frequently.
We respect and defend the environment.

Everything that we do has repercussions on the whole planet and on its resources.
MV Agusta, to protect the interests of the everyone, ask clients and technical assistance operators to use
the motorcycle and dispose of its used parts with respect to the norms in force in terms of environmental
pollution, disposal and recycling of refuse.
Programmed maintenance schedule
0 1000 6000 12000 18000 24000 30000 36000
Km (mi) covered (600) (3800) (7500) (11200) (14900) (18600) (22400)
Service Pre- A B C D E F G
delivery
Description Operation
G G G G G G G
Engine oil Substitution
At least once a year
Substitution G G G G G G G
Engine oil filter (utilise only original MV
Agusta oil filters) At every substitution of engine oil
Check level and top-up G G G G G G G G

Engine coolant
Substitution At least every two years
Cooling system Check for leakages G G G G G G G G
Electric fans Check functioning G G G G G G G G
Valves Check / adjustment G G G
Check G G
Timing chain
Substitution G
Check / Substitution G G
Mobile timing chain guide G

Substitution
At least every substitution of the timing chain
Timing chain tensioner Check / Substitution G G G
Check / Substitution G G G
Spark plugs
Substitution G G G
Fuel filter Check / Substitution G G G
Throttle body Check and adjust G G G G G G G
Air filter Check / Substitution G G G G G G
Check level G G G G G G G
Brake and clutch fluid G

Substitution
At least every two years
Check functioning G G G G G G G G
Brakes and clutch
Check circuit G G G G G G G G
Brake pads
Check / Substitution G G G G G G G
(front and rear)
Check for defectsand leakages G G G G G G G

Fuel tubes
Substitution At least every three years
Throttle control Check functioning G G G G G G G G
Check/adjust play G G G G G G G G
Choke control Check functioning G G G G G G G G
-6-
Maintenance
Programmed maintenance schedule

0 1000 6000 12000 18000 24000 30000 36000
Km (mi) covered (600) (3800) (7500) (11200) (14900) (18600) (22400)
Service Pre- A B C D E F G
delivery
Description Operation
Transmission and flexible controls Check / adjust G G G G G G G G
B
Check / adjust G G G G G G G G
Drive chain Lubricate G G G G
Substitution G G G
Check G G G G
Front sprocket / stop washer G G G

Substitution
At least at each substitution of the transmission chain
Check G G G G
Rear sprocket G G G
Substitution
At least at each substitution of the transmission chain
Rear sprocket spring drive Check / Substitution G G G
Steering head flange ring Check / adjust G G G G
Check / adjust G G G G
Steering bearings
Lubricate G
Check pressure G G G G G G G G
Tyres
Check for wear G G G G G G G
G G G G G G G
Wheel rims Visual check
Every tyre substitution
G G G G G
Check
Front wheel bearings Every tyre substitution
Substitution G
Side stand Check functioning G G G G G G G G
Side
stand switch
lubricate roller
Check / bearings G G
Rear wheel hub lubricate roller
Substitution / bearings G
Swingarm bearings Check / lubricate G
Drive chain pads on swingarm Check / substitution G G G G G G G
Drive chain pads on frame plate Check / substitution G G G G G G G
Rear shock absorber Check / adjust G G G G
Front fork oil Substitution G
Battery connections Check and clean G G G G G G G
Electrical system Check functioning G G G G G G G G
Instruments Check functioning G G G G G G G G

Check Lamp
Lights / visual signals functioning / replacement G G G G G G G G
Horn Check functioning G G G G G G G G
Front headlight
Adjust At every variation of the riding set-up of the motorcycle
Ignition switch Check functioning G G G G G G G G
Locks Check functioning G G G G G G G G
Torque settings - nuts and bolts Check / tightness G G G G G G G G
Tube band fasteners Check / tightness G G G G G G G G
General lubrication G G G G G G G G
General check G G G G G G G G
-7-
Maintenance
Table of lubricants and fluids

Description Recommended product Specifications
Engine oil AGIP RACING 4T 10W/60 (*) SAE 10W/60 - API SJ
Ethylene-glycol
Engine coolant AGIP ECO - PERMANENT diluted with
50% distilled water
B Brake and clutch fluid AGIP BRAKE FLUID DOT4 DOT4
Chain lubrication oil MOTUL CHAIN LUBE ROAD –
* : To find the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers.
AGIP Racing 4T 10W/60 has been manufactured for the F4 engine. If the described oil is not available, MV
Agusta suggests using completely synthetic oils with characteristics equal or better than the
ones prescribed in the following standards:
– Conforming to API SJ
– Conforming to ACEA A3 Engine oil
SAE 10 W-60
– Conforming to JASO MA
– Grade SAE 20 W-50 o 10 W-60 API SJ
ACEA A3
The above specifications indicated are marked either on their own or together JASO MA
NOTE
with others on the container of the lubricating oil.
NOTE If the vehicle is used in races, use Agip

Racing 4T 20W50 oil.
MAINTENANCE AND TUNING OPERATIONS

Each operation of periodical maintenance is described
in this chapter.
ENGINE OIL AND OIL FILTER

Engine oil
Substitute:¡ at the first 1000 kilometres and then
every 6000 kilometres.
Oil filter
Substitute:¡ at the first 1000 kilometres and then
every 6000 kilometres (or at least
every oil change).
To accede to the oil filter and the discharge and filling

holes of the engine oil, it is necessary to carry out cer-
tain operations beforehand:
Place the motorcycle on the rear stand.
Remove the two side fairings (see chapter C
“Bodywork”).
Remove the under-engine fairing (see chapter
C “Bodywork”).
NOTE The substitution of the engine oil must

be done with a hot engine as opposed to
the oil-check that is done with a cold
engine.
1
Using the supplied 10 mm hexagonal bar fitted to a
specially designed tool (see figure), remove filler plug
(1) on the right side of the vehicle so as to facilitate the
outflow of the oil.
-8-
Maintenance
Place a container underneath the engine to collect the

used oil.
Remove the oil discharge plug (1).
Recover the oil in an appropriate container.

B
Do not scatter the drainage oil into the envi-
ronment.
1
Allow the lubrication system to drain completely.
Substitution of the oil filter

Remove the 4 fixing screws (2) of the oil filter cover.
Remove the cover and take out the oil filter.
-9-
Maintenance
Replace the oil filter and put the cover back on.
On the oil discharge plug there is a magnet to attract

any metal residues that could form in the engine during
rotation.
Before replacing the cap, make sure it is completely

clean. Replace the sealing washer with a new one.
Screw in the oil discharge plug and tighten it to the

specified torque.
Torque pressure oil discharge plug: 35 N·m
35 N•m
Pour around 3 kg of engine oil (as specified in the table

on page B-8) into the filling hole. 2 1
Close the filler hole using the appropriate cap.
Before replacing the filler cap, grease the O-ring (1)

with silicone grease (see figure). 1
Tighten the cap (2) to the prescribed tightening torque.

35 N•m
Tightening torque: 35 N·m
- 10 -
Maintenance
Switch on the engine for several minutes.

After switching off the engine, wait at least ten minutes
and then check the oil level.
Ensure that the motorcycle is placed on level ground
and is in a vertical position.
The correct level must be as close as possible to the
B
“MAX” mark shown on the engine casing. Do not sur- MAX
pass this limit.
Check any oil leakages. MIN
Avoid turning the engine over with the oil

level lower than minimum. It could compro-
mise the correct functioning of the engine.
If the level after the topping-up, is over the
“MAX” reference notch, correct it by emp-
tying a little oil out of the engine.
Oil pipes
During ordinary maintenance operations, ensure that

the different components are properly fitted and that no
oil is leaking from the parts involved in engine lubrica-
tion and in particular from:
– The crankcase.
– The oil feed pipes connecting the oil pump to the
cylinder head.
If even the slightest leakage is found, overhaul

the components as described in the F4 engine
workshop manual (Part No. 8000B4302).
ENGINE COOLANT
Check / top-up level ¨ At the pre-delivery, at
the first 1000 kilome-
tres and then every 1
6000 kilometres.
Keeping the motorcycle in a vertical position, check

that the level of engine coolant is between the «MIN»
and «MAX» mark found on the expansion tank (1).
Max. level
Min. level
- 11 -
Maintenance
If the level is under the minimum line, proceed with top-

ping-up as follows:
With the engine cold, top up the level using the filler 2
hole (2) of the expansion tank.
B
Open the expansion tank only when the
engine is cold; the discharge of boiling liquid
could cause burns.
If the liquid comes into contact with the skin
or the eyes, rinse abundantly with water.
- 12 -
Manutenzione
Maintenance
Engine coolant substitution
2
Substitution¡ every two years
Before proceeding the emptying of the system, B

remove:
The ignition switch cover (see “Engine coolant
level check”);
The under-engine fairing;
The left fairing panel (see chapter C
“Bodywork”);
Place a container under the engine to collect the
used coolant;
open the radiator filler cap;
Remove the coolant discharge screw 1 situated 1 8÷10 N•m
on the coolant pump 2, thereby letting the coo-
lant flow out.
Wait for the engine coolant to completely flow out.
Tighten the engine coolant discharge plug 1 to the

specified torque, after having checked the condition of
the gasket.
Torque pressure, engine coolant discharge

plug: 8 ÷10 N·m
Lift the front part of the motorcycle as shown in the

figure.
Fill the cooling system with a suitable liquid described
in the table (see page B-8) until you reach the level of
the bar of the radiator filler cap. Do this in stages to sta-
bilise the liquid level.
Close the cap and move the motorcycle to a horizontal

position.
Switch on the engine and keep it running until the

water becomes hot enough to automatically switch on
the electric cooling fan. Switch off the engine. Repeat
the operation at least once, then wait some minutes for
the engine to cool down.
Carefully check for leaks, blow-bys, dam-

aged tubing, etc. If there are leaks or damage
in the cooling system, proceed with the over-
haul as described in the chapter “Cooling
system”.
- 13 -
Maintenance
Check once again the level of the coolant inside the

expansion tank, which should be between the «MIN»
and «MAX» mark found on the expansion tank.
If the level is inferior to the «MIN» mark, top up the
coolant level by pouring new coolant into the filler hole.
B
Max. level
Min. level
Complete the assembly of the motorcycle.
ELECTRIC COOLING FANS

Check ¡ on pre-delivery and at the first 1000
kilometres and then every 6000 kilome-
tres.
To carry out the check on the functioning of the electric

cooling fans, switch on the engine and heat it up.
The electric cooling fans must enter in function when

the temperature on the temperature gauge of the
instrument panel shows that the system has reached
100°C. If the electric cooling fans do not switch on,
carry out the checks on the various components as
described in chapter L “Cooling system”.
- 14 -
Maintenance
VALVE MECHANISM ADJUSTMENT

Check and adjust ¡ at 1000 kilometres and every
12000 kilometres
Remove in order the following components to carry out B

the measuring of the play between the camshaft and the
valve cups:
• Left side fairing panel • LH fuel tank side panel

• Right side fairing panel • RH fuel tank side panel
• Under-engine fairing • Rear side panels
• Front fairing • Fuel tank
• Right air intake conduit cover • LH airbox side panel
• Left air intake conduit cover • RH airbox side panel
• Left air intake conduit • Air box
• Right air intake conduit • Throttle body
NOTE: For all removal operations, including the rela-

tive attention notes, please refer to the specific sec-
tions in this manual.
An analogous reference is utilised for the reassembly

of the parts after the maintenance operation.
After having removed the indicated components, the

motorcycle is shown in the condition described by the
photograph on side.
Before proceeding with the various maintenance oper-

ations, it is advisable to thoroughly wash and clean the
motorcycle.
Place the motorcycle (now without the components list-
ed above and clean) on a workstation as indicated in
the figure.
Apply adhesive paper tape to the frame tubes.
This operation will protect the paintwork from knocks,

scratches and abrasions that could occur during the
work activity.
Ensure that all the surfaces of the frame are protected

by the application of the adhesive tape.
Apply the same adhesive tape to the air intakes of the

engine.
- 15 -
Maintenance
Remove the locking bracket of the plug-top coils.

Remove the 4 plug-top coils as shown in Chapt. G
"Frame".
To install the locking bracket of the plug-top coils, make

sure the bends of the bracket are turned upwards, as
shown in the figure.
Systemise the HT leads, positioning them as indicated

in the following figure.
- 16 -
Maintenance

figure.
Remove the plastic covers (1) and remove the 8 fixing

screws of the cover of the engine head (2).
Remove the wiring clamps on the right side of the

frame.
- 17 -
Maintenance
Disconnect the connectors shown in the figure.
Remove the wiring from the frame.
Operating as shown in the figure, slightly lift up the

cylinder head cover.
To carry out this operation, use only the work surfaces

indicated.
Take care to not ruin or deteriorate the motorcycle

parts in the proximity of the work area.
- 18 -
Maintenance
Proceed with the removal of the engine head cover as

Utilising a syringe, remove the surplus oil that is left in

the various niches in proximity to the valve cups.
Proceed with the removal of the timing wheel cover by

unscrewing the five fixing screws.
- 19 -
Maintenance
Rotate the camshaft by turning the central nut in an

anti-clockwise direction to bring piston N° 1 of the
engine to the Top Dead Centre position (T.D.C.) when
the piston is at its uppermost part of the compression
stroke.
B
Check the timing of the engine by ensuring that the inci-

sion stamped on tooth A of the timing wheel is in line B
with the “tooth” B that is present on the engine casing.
The following photograph illustrates clearly the correct

position.
The position of the timing wheel is clearly seen in the

enlargement in respect of the mark on the engine cas-
ing. Also the marks present on the toothed wheels of
the camshaft must be aligned together when the timing
wheel is in this position.
- 20 -
Maintenance
Utilising a feeler gauge of the type shown in the figure,

measure the play between the camshaft and the valve
cups.
The correct measuring of the play is a fun-

damental operation for the correct function- B
ing of the engine.
Carry out the measuring of the play of the following valves:
Cylinders 1 and 2 intake valves (n° 1, 2, 3, 4)

Cylinders 1 and 3 exhaust valve (n° 11, 12, 15, 16)
Scrupulously, make a note of the order of the values

measured in the form of a table.
For example, here is a hypothesis of a table in which

are written the various values measured.
Date Vehicle Engine registration n° Frame registration n° Kilometres travelled
Values measured before substituting the valve cups:
CYLINDER 1 CYLINDER 2 CYLINDER 3 CYLINDER 4

INTAKE Valve n° 1 Valve n° 2 Valve n° 3 Valve n° 4 Valve n° 5 Valve n° 6 Valve n° 7 Valve n° 8
Valve play
Pad thickness

EXHAUST Valve n° 9 Valve n° 10 Valve n° 11 Valve n° 12 Valve n° 13 Valve n° 14 Valve n° 15 Valve n° 16
Valve play
Pad thickness
Values measured after substituting the valve cups:

INTAKE Valve n° 1 Valve n° 2 Valve n° 3 Valve n° 4 Valve n° 5 Valve n° 6 Valve n° 7 Valve n° 8
Valve play
Pad thickness

EXHAUST Valve n° 9 Valve n° 10 Valve n° 11 Valve n° 12 Valve n° 13 Valve n° 14 Valve n° 15 Valve n° 16
Valve play
Pad thickness
- 21 -
Maintenance
The progressive numeration of each valve is illustrated EXHAUST

in the photograph on the right.
16 15 14 13 12 11 10 9
Note the anti-clockwise direction of the numeration.
B
1 2 3 4
1 2 3 4 5 6 7 8
INTAKE
To facilitate the operation, it is possible to note before-

hand and in order the play values revealed on the strip
of adhesive tape applied to the openings of the air
intake conduits.
These must anyway also be written in the table previ-

ously illustrated.
Rotate the crankshaft 360° by turning the central nut.
The rotation of the crankshaft must always be done in

an anti-clockwise direction.
The operation just described is completed when piston

n° 4 is in the Top Dead Centre position (T.D.C.) of the
compression stroke.
- 22 -
Maintenance
Check again the timing of the engine, ensuring that the

incision stamped on the timing wheel is aligned with
the “tooth” on the engine casing.
Continue with the measuring of the play of the follow-

ing valves:
Cylinders 3 and 4 – intake valves (n° 5, 6, 7, 8).

Cylinders 2 and 4 – exhaust valves (n° 9, 10, 13, 14).
Make a note of the measured values ensuring that they

are scrupulously written in the correct order of the pre-
viously illustrated table.
- 23 -
Maintenance
B Valve play between the valve

cup and the cam
Camshaft
Upper cup for

the springs
Adjustment pad
Valve cup
Valve
The play values measured between the valve cup and cam must be the following:
For all intake valves 0.15 ÷ 0.24 mm
For all exhaust valves 0.20 ÷ 0.29 mm
If different values are encountered even for one valve, substitute the camshaft/valve cup play adjustment pads as
described in the F4 1000 workshop engine manual F4 1000 (Code 8000B4302).
If the values are correct, reassemble in reverse order to disassembly. Consult the F4 1000 workshop engine man-
ual (Code 8000B4302) for the specific torque pressures and the necessary products.
- 24 -
Maintenance
Timing chain, mobile timing chain guide and timing

chain tensioner
Timing chain and mobile timing chain guide:

Check ¡ Every 12000 kilometres B
Substitute ¡ Every 36000 kilometres
Timing chain tensioner:

Check / substitute ¡ Every 12000 kilometres
To disassemble these parts and not being a part of nor-

mal maintenance, it is necessary to proceed as
described in the overhaul section of the F4 workshop
engine manual (Part. Cod. 8000B4302).
SPARK PLUGS
Check/substitute ¨ At 6000 kilometres and then
every 12000 kilometres
Substitute ¨ Every 12000 kilometres
The following components must be removed to accede

to the spark plugs:
• Under-engine fairing • Tail unit

• Left fairing side panel • LH fuel tank side panel
• Right fairing side panel • RH fuel tank side panel
• Cupolino • Fuel tank
• RH wire harness cover • LH airbox side panel
• LH wire harness cover • LH airbox side panel
• Left air intake conduit • Airbox
• Right air intake conduit
Remove the plug-top coil fixing plate. Pull out the four
plug-top coils.
Remove the spark plugs utilising the appropriate 16
mm hexagonal spark plug spanner.
- 25 -
Maintenance
Heat Grade
Check the heat grade of the spark plugs.
Sparks: - NGK CR9 EB
B
DO NOT use non-resistive spark plugs.
Spark plug gap

If appropriate (see Technical Data table), measure the
spark gap with a thickness metre. Adjust the gap if
necessary on the basis of the following information:
Sparks Spark plug gap

NGK CR9 EB 0,7 ÷ 0,8 mm
Electrode condition
Check the electrodes for wear or burning. If they are
extremely used or burnt, substitute the spark plugs.
Also substitute the spark plugs in the case of breakage
of the ceramic isolation or damage to threading.
When the spark plugs are renewed, check the

thread pitch size and the length of the thread. If
the threading is too short, carbon deposits will
be placed on the threading of the cylinder head
plughole thereby risking damage to the engine.
Manually insert the spark plugs into their seats to avoid

damage to the threading of the cylinder head. When
completely screwed in by hand, tighten to the specified
torque pressure.
12 N•m
Spark plugs torque pressure: 12 N·m
- 26 -
Maintenance
FUEL FILTERS
Check and substitute ¡ Every 12.000 km
For the checking or substitution of the engine intake

system filters (fuel filter, fuel pump filter), it is neces-
sary to remove in sequence the following parts:
B
• Fuel tank side panels
• Driver and passenger seat
• Rear side panels
• Fuel tank
NOTE: Consult chapter C “Bodywork”.
Carry out the following operation.
Fuel filler cap removal
Insert the ignition key in the fuel filler cap lock and
rotate in a clockwise direction to open the fuel filler cap.
Remove the four screws (1) indicated in the figure.
For reassembly, carry out the removal operations in

reverse order, tightening the screws to the torque pre-
scribed.
Fuel filler cap fixing screws torque pres-

sure: 5 N·m
5 N•m
- 27 -
Maintenance
Completely empty the fuel tank utilising a pump as

illustrated in the figure.
Petrol flange assembly removal
Turn the tank upside down and remove the eight

screws for fixing the flange to the tank (1).
Lift up the flange (1) and disconnect the tubes (2) on

both sides of the flange.
Remove the two CLIC R 96105 fasteners utilising the
specified pincers. 1
Specified pincers: CLIC R 205

Part code 800095850
- 28 -
Maintenance
Extract the complete flange assembly (1).
Disconnect the electric connectors of the fuel pump (1).
Checking and replacing the O-Ring

Check the condition of the O-Rings (1) which seal the
flange (2).
Make sure that the components are perfectly intact and

lubricate with silicone grease.
We recommend applying silicone grease also to the
housing of the die-cast flange.
If damaged, replace with new flanges.
2 1
- 29 -
Maintenance
During re-assembly, if the O-Rings have been repla-

ced, lubricate surface lightly with silicone grease.
The use of worn O-Rings can lead to a leaka-

B ge of petrol from the tank with a consequent
risk of fire for the vehicle.
Replacing the thermistor

If the thermistor needs to be replaced, the cable clamp
must be cut.
Disconnect the connector of the thermistor cabling.
- 30 -
Maintenance
Take the thermistor out of its housing and replace with

a new one.
Reconnect the connector and fix a new clamp (Cod.

800056783).
B
Replacing the filter cartridge

If the filter cartridge needs to be replaced, it is first
necessary to remove the lower clamp and take the
tube out of the cartridge.
Remove the upper clamp in the same way and take out
the tube.
- 31 -
Maintenance
Remove the filter cartridge and replace with a new one.
Insert the upper tube in the new cartridge and fix with
a clamp taken from the new kit, using the special tool.
Pneumatic pincer: Oetiker HO 3000 ME
Insert the lower tube in the new cartridge and fix with a
clamp taken from the new kit, using the special tool.
Pneumatic pincer: Oetiker HO 3000 ME
- 32 -
Maintenance
FUEL PUMP ASSEMBLY
- 33 -
Maintenance
Fuel flange unit assembly
Before starting the assembly of the flange to the fuel

tank, check the condition of the two small overflow
tubes connected to the lower part of the fuel filler cap.
If these components are not in perfect condition, sub-
stitute them and position the band fasteners as shown
in the figure.
- 34 -
Maintenance
Position the flange unit (1) inside the fuel tank.

Check that the two small overflow tubes (2) remain out- 1
side of the fuel tank.
Insert two CLIC R 96 105 band fasteners (1) onto the

small tubes. Insert the two small rubber tubes (2) onto
the appropriate spigot on the die-cast flange. Tighten
the band fasteners by using the CLIC 205 pincers. 1
Specific pliers: CLIC R 205

Part code 800095850
Gently press down the flange assembly into its seat

and then tighten the eight locknuts (3). 6÷8 N•m
Torque pressure: 6÷8 N·m
Proceed with the assembly of the parts removed by fol-

lowing the removal operation in reverse order to that
shown in chapter C “Bodywork”.
• Fuel tank
• Seats
• Fuel tank side panels 3
- 35 -
Maintenance
TUBES / FUEL FITTINGS

Check for leaks ¨ First 1000 kilometres and then
every 6000 kilometres
B Carry out a visual check for eventual leakages from the

fuel feed tubing and the unions (see figure).
Substitute damaged parts if leaks or evaporation are
found.
FUEL TUBE ASSEMBLY
Substitute ¨ At least every three years

The procedure to follow in the case of substitution of
the feed tubing is as follows:
Remove in this order:
• Fairing side panels
• Under-engine fairing
• Fuel tank side panels
• Fuel tank
• Airbox side panels
• Air filter compartment
Press the two stop tabs simultaneously and take out

the tube.
Insert the new fuel tube onto the union of the throttle
body, until it has locked into place.
UTILISE ONLY NEW PARTS.
- 36 -
Maintenance
ADJUSTMENT AND CALIBRATION OF THROTTLE BODY

After connecting to the control unit diagnostic software
and before starting the engine, immediately check the
throttle position:
2.3 degrees (min 1.9, max 2.6)
If the position should not enter within the recommended B
field, reset with the TPS function, WITHOUT TOUCHING
THE MECHANICAL ADJUSTMENT SCREWS OF THE
THROTTLE.
Select the reset function for the throttle potentiometer
from the TPS dropdown menu by means of the "screw-
driver" icon on the Display/Calibration/Cancel errors
menu.
Before starting the engine, verify the position of the
exhaust valve: from the "Enable/Disable" dropdown
menu, it is possible to select the EXHAUST command to
reset the exhaust valve. After making these adjustments,
remove the ignition key for about 20 seconds to enable
the control unit to store new resets.
Then connect the vacuum gauge and the engine will start
warming 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 soft-
ware 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 sec-
onds, with the Lambda % controller fixed at -25% or
+25%, the system will send out a ‘Lambda probe volt-
age’ alarm.
In this case, check the electric connection between the
Lambda probe and the system or replace the Lambda
probe.
Levelling of intake manifold settings

To check this, use a mercury vacuum gauge of the type
Then, level the vacuum inside the intake manifolds.
- 37 -
Maintenance
Twist off the plugs that close the vacuum tubes. The
number of the cylinder to which the rubber plug is con-
nected is written on the plug itself (A).
The vacuum tubes are located on the right and left side
of the vehicle.
B
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 con-
nected.
Fit the starter key and start the vehicle.

Once the system engine steadies, the throttle body will
begin pairing. For proper engine operation, adjust the
throttle body so as to allow the idle speed control to
work in "middle band".
To do this you must follow these instructions:
- check that all by-pass adjustment screws (1) of the 4
cylinders are pre-positioned at an opening of 1.5 turns
from the fully closed position
- choose the cylinder corresponding to the highest
column of the vacuum gauge
- tighten the by-pass screws of the other 3 cylinders
1
until the levels of the relative mercury columns are ali-
gned to the highest column. In this way it is possible to
obtain alignment of the low-pressure values on the four
in the four suction ducts.
The following positions are accepted for the by-pass

screws of all the cylinders:
IDEAL 1.5 turns (min 0.5 - max 3.5 turns)
In the event of a minimum by-pass opening of one of

the 4 cylinders of 0.5 turns, slightly open all screws rai-
sing all 4 columns (maintaining alignment) to find a
balance of minimum control, without exceeding the
maximum position allowed of 3.5 opening turns.
- 38 -
Maintenance
The number of engine revs at idling should be kept at

the following values:
IDEAL 1150 rpm (min 1100 - max 1200)
The system is able to balance engine running around

the target speed 1150 rpm - 50 rpm acting automati-
B
cally on the ignition advance.
It is however necessary to adjust the air flow as outli-
ned below without unbalancing the throttle body pairing
just carried out:
If the "Advance Correction" channel is NEGATIVE,
remove air by closing the by-pass, maintaining pairing
until the "Advance Correction" parameter positions for
work in a field between -4° and + 4° (the optimal con-
dition is reached when the working parameter is close
to zero).
If the "Advance Correction" channel is POSITIVE, add
air by opening the by-pass, maintaining pairing until
the "Advance Correction" parameter positions for work
in a field between -4° and +4° (the optimal condition is
reached when the working parameter is close to zero).
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 hap-
pen 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 % con-
troller work slightly ABOVE ZERO, the GAIN ADATTI-
VO setting WILL INCREASE and will bring the Lambda
% channel back to about 0 ±3%.
You will notice that, when the Lambda probe % con-
troller work slightly BELOW ZERO, the GAIN ADATTI-
VO setting WILL DECREASE and will bring the
Lambda % channel back to about 0 ±3%.
- 39 -
Maintenance
Air Filter
Check/substitute ¨ Every 6000 kilometres
Certain parts must be removed in sequence before

B acceding to the air filter. See chapter C “Bodywork”.
• Seats
• Right side panel tank
• Left side panel tank
• Rear right side panel
• Rear left side panel
• Right side panel Airbox
• Left side panel Airbox
• Fuel tank
Remove the four screws (two per side) by securing the

Airbox cover (1).
1
Lift and remove the Airbox cover (2).

2
- 40 -
Maintenance
Unhook the two front clips (3) and remove the cover
(4).
B
3
Remove the filter (5).
Check the condition of the air filter. If it is necessary to

substitute it, proceed as follows:
Prepare a new air filter.

Check that the inside of the air filter compartment is
clean and free from foreign bodies.
Insert the air filter, respecting the correct way of

assembly, as shown in the figure.
Reposition the cover and press the five fastening tabs

down until they click.
Make sure that the cover is fastened properly by awai-

ting the click of the five tabs.
- 41 -
Maintenance
Take the upper Airbox cover and remove the gasket

with the aid of a screwdriver.
Position the gasket on the edge of the lower Airbox.
Position the upper Airbox cover.
- 42 -
Maintenance
Fasten the cover with four screws (two per side) (6).
Proceed with the assembly of the parts listed below

and according to the procedure described in chapter C
“Bodywork”.
• Fuel tank
• Left side panel Airbox
• Right side panel Airbox
• Rear left side panel
• Rear right side panel
• Left side panel tank
• Right side panel tank
• Seats
- 43 -
Maintenance
BRAKES AND CLUTCH
Check the levels of

fluid in the systems¨ At pre-delivery, at first 1000
B kilometres and then every 6000
kilometres.
Check for leakages¨ At pre-delivery, at first 1000

kilometres and then every 6000
kilometres.
Substitute fluid¨ Every 24000 kilometres or at

least every two years
Commands check¨ At pre-delivery, at the first 1000

kilometres and then every 6000
kilometres.
Check brake and clutch fluid levels

The procedure described below is to be used for the
front brake fluid reservoir and the clutch fluid reservoir.
Place the motorcycle in a vertical position with the han-
dlebars straight.
Check the fluid levels in the brake and clutch fluid
chambers observing the lines for the level marked on
the chambers.
If the level of the fluid is lower than the lines marked on
the chambers, add recommended brake fluid accord-
ing to the procedure indicated as follows:
Remove the two screws of the fluid chamber cover;
Remove the three elements of the cover.
It is advisable to remove the screen of the nose fairing to

carry out this operation.
Add brake fluid until the correct level is reached in the

chamber.
Recommended brake fluid: AGIP DOT 4 or

equivalent.
Do not use brake fluid that comes from old

containers, has already been used or does
not come from a sealed container. Do not
use brake fluid that is left over from previous
maintenance or stored for long periods.
Utilise only the recommended brake fluids.
- 44 -
Maintenance
Before completing the operation, clean and wash accu-

rately with alcohol the three components of the fluid
chamber cover and blow to dry them.
Clean the edge of the fluid chamber with a clean cloth.

Close the fluid chamber with the two relative screws.
B
Imperfect cleaning of these parts could
cause the discharge of small quantities of
brake fluid during riding. Brake fluid has
strong corrosive properties.
Check eventual leaks and blow-bys of brake and clutch

fluid on the unions and tubing.
If any breakages are seen, substitute the damaged
parts as described in chapter H “Brakes”.
Brake fluid leakages are dangerous and

immediately discolour painted surfaces.
Before riding, check the tubes and joints of
the brakes for damage and signs of leaks.
- 45 -
Maintenance
Checking the level of the rear brake fluid

No parts of the vehicle need to be removed from the
vehicle to check the level of the rear brake fluid.
If the fluid is below the low level mark, follow these

steps to top up with brake fluid complying with the spec-
ifications:
remove the saddle and the fuel tank;

remove the 2 screws from the reservoir cap;
remove the three cap elements.
Pour fresh fluid until it reaches the prescribed level in

the reservoir.
Recommended brake fluid: AGIP DOT 4 or

equivalent.
Do not use brake fluid that comes from old

containers, has already been used or does
not come from a sealed container. Do not
use brake fluid that is left over from previ-
ous maintenance or stored for long periods.
Utilise only the recommended brake fluids.
Follow a similar procedure to the one used for the front

brake fluid reservoir.
Substitution and bleeding of the brake/clutch fluid

The substitution of the brake/clutch fluid and the suc-
cessive bleeding of the circuit are operations that
require particular caution and precision.
To carry out these operations, it is therefore necessary
to follow the procedure described in chapter H
“Brakes” of this manual.
- 46 -
Maintenance
BRAKE/CLUTCH/GEARCHANGE COMMANDS CHECK

It is possible to effectuate the adjustment of the posi-
tion of the levers of the front brake, the clutch and also
the gearchange lever. Such adjustments have been
created to optimise the grip and the movement of the B
commands with regards to the needs of the motorcy-
clist.
The commands of the motorcycle are initially calibrat-
ed to a standard position, but can be altered as follows.
Front brake and clutch lever adjustment
Never carry out adjustments whilst riding

the motorcycle.
Pull the lever to neutralise the push of the spring and

at the same time, adjust the position by rotating the
ring in a clockwise or anti-clockwise direction.
In a clockwise direction: The lever goes further away

from the handgrip.
In an anti-clockwise direction: The lever comes closer

to the handgrip.
Whenever the command levers do not func-

tion correctly or have excessive play, con-
sult chapter H “Brakes” for the overhaul of
the same.
- 47 -
Maintenance
Gearchange/rear brake lever adjustment

To carry out the adjustment of the rear brake lever and 1
the gearchange lever, slacken the screw (1) utilising a
5 mm Allen key. Adjust the position according to the
B requirements of the rider utilising the same key and on
the hexagonal hole (2).
Tighten the screw (1) to the torque prescribed.
Brake lever adjustment torque pressure: 6 N.m

2
Operate on both the gearchange and rear brake levers

in the same way.
6 N•m
- 48 -
Maintenance
BRAKE PADS
Wear check / substitute ¨ At the first 1000 kilo-
metres and then every
6000 kilometres
B
Check the condition and thickness of the brake pads
on the calipers.
Front brake caliper Rear brake caliper
Measure the thickness of the pad linings. If the thick-

ness of the linings is equal to or less than the wear limit
shown below, replace the pads as described in chapter
H “Brakes”.
Disc
Wear limit: 1 mm
Pads
If the brake pads are substituted, it is nec-

essary to effectuate a proper running-in
period before reaching an optimal braking
efficiency.
Wear limit 1 mm
THROTTLE CONTROL
Throttle control play check¨ At the pre-delivery check,
at the first 1000 kilome-
tres and then every 6000
kilometres. 1
The throttle control should not be too tight or too slack
(excessive play) in its movement.
It must also be free of play and looseness when turning it.
For optimum adjustment it is necessary to work on the
two upper nut adjusters (situated on the throttle control
handgrip).
The lack of play on the closure of the throt-
tle control (1) can stop the complete closing
of the throttle valve and the throttle control
could remain in the open position, thereby
leaving the engine with a fast tickover.
- 49 -
Maintenance
After making adjustments, check that the throttle

valves open slightly by activating the choke lever (1) as
indicated in the following figure.
B 1
If interventions have been carried out on

the throttle bodies, the transmission of the
throttle control must be analysed not only at
the throttle control handgrip but also near
to the throttle bodies.
It is therefore necessary to consult chapter
D “Air intake injection system”.
As a final control and after having reassembled all the

components, switch on the engine and check that, with
the choke lever activated, the tickover of the engine
does not exceed 2500 r.p.m.
- 50 -
Maintenance
LOCKS
Check ¨ At the pre-delivery, at the first 1000
kilometres and then every 6000 kilo-
metres.
B
Ignition/steering block switch
This switch has four operating positions.
Do not attach key rings or other objects to

the ignition key that could obstruct the rota-
tion of the steering.
The ignition switch activates and disactivates the elec-

trical system and the steering lock. The four control
positions are as follows: “OFF” position “ON” position
“OFF” position
All electrical circuits are disactivated. The key can be
pulled out.
“ON” position
All electrical circuits are activated, the instruments and
warning lights carry out self-diagnosis and the engine
can be switched on. The key cannot be pulled out.
Do not attempt to change the functions of

the ignition switch whilst the motorcycle is
being ridden. It could cause the rider to lose “LOCK” position
control of the machine.
“LOCK” position
Turn the handlebar left or right. Press the key down
and rotate it to the “LOCK” position.
All electrical circuits are disactivated and the steering
is blocked. The key can be pulled out. Left side Right side
“P” position
Rotate the key from the “LOCK” position to the “P”
position. All electrical circuits are disactivated except
for the sidelights. The steering is blocked. The key can
be pulled out.
If the ignition switch unit is damaged (it does not allow

the positioning of any one of the four positions), it must
be substituted with a new ignition switch unit following
the sequence of the disassembly as described in chap-
ter G “FRAME”.
“P” position
- 51 -
Maintenance
Fuel cap lock

Lift up the anti-dust cover.
Insert the key, rotating it in a clockwise direction and lift
up the cap.
B
After refuelling, press the cap down and rotating the

key contemporaneously to facilitate the closure. Let the
key go free, bring it into a longitudinal position and pull
it out.
If the fuel filler cap does not function (the cap does not
close, the lock blocks, etc.) substitute it with a new one
as described in chapter C “Bodywork”.
Personal compartment lock

Insert the key.
Push the passenger seat downwards at the back and
at the same time turn the key in a clockwise direction.
Lift up the passenger seat at the back end, let it slide
backwards and remove.
In order to reassemble the above mentioned part, you

must perform the following operations:
• Rotate the key into the lock
• Press down the passenger seat
• Release the key
• Press down the seat once more, so to make sure of
its firm coupling to the frame.
If the seat lock is blocked, consult chapter C

“Bodywork” for the substitution.
- 52 -
Maintenance
STEERING
Check and adjust ¨ At the first 1000 kilometres
and then every 12000 kilo-
metres.
B
Check the steering components regularly according to
the above-mentioned intervals.
If it is necessary to carry out adjustments, operate as
described in chapter F “Suspension and wheels”.
TRANSMISSION CHAIN
metres.
Substitute¨ Ogni 12000 km

The chain tension check should be effectuated with the
motorcycle having a static set-up quota equal to the
standard value (see chapter F “Suspension and
wheels”).
50 mm
The axis of the chain lower portion must be 50 mm
from the lower chain guard.
Manually turn the rear wheel and perform the check at
different points along the chain.
As the wheel is turned, the play should remain virtual-
ly the same. If, on the other hand, the play of the chain
varies considerably, it means that some of the links are
flattened, jammed or elongated.
Visually check the transmission chain for the following
defects:
• Slack pins • Excessive use Grease
• Damaged rollers • Incorrect chain adjustment O-ring
• Dry and rusty links • Damaged O-rings
• Bent or seized links
The chain must be substituted if any one of these
defects is found.
When substituting the transmission chain, substitute

also the crown and pinion wheel.
For the substitution of the chain, pinion, crown wheel and
to check the wear of the chain guide, follow the sequence
described in chapter F “Suspension and wheels”.
- 53 -
Maintenance
Regulation¨ At the first 1000 kilometres and then

every 6000 kilometres.
To adjust the chain tension, proceed as follows:

Slightly slacken the two screws of the rear wheel hub.
B Loosen the 2 rear wheel hub screws.
Using the special spanner as indicated in the figure,

move the eccentric adjuster nut backwards or forwards
respectively slackening or tightening the chain, until
the correct play is reached (as described previously).
Successively tighten the screws of the rear wheel hub

to the torque pressure indicated as follows: 28÷32 N•m
NOTE Tighten the screws to the specified torque

in several steps and in an alternate pattern.
Rear hub eccentric adjuster screw torque

pressure: 28 ÷ 32 N·m
Grease only the first threads.
- 54 -
Maintenance
Chain lubrication
Lubricate¨ At the first 1000 kilometres and at

6000 kilometres and then at every
12000 kilometres.
B
The chain is of the O-ring type.
Clean the chain with a clean cloth and/or a jet of air.
Apply the lubricant after cleaning.
Utilise only the recommended lubricants or

the equivalent (see page B-8).
Aim the spray at the inner link, so it will lubricate the

surface of the O-rings and penetrate into the chain roll.
- 55 -
Maintenance
TYRES
Check pressures¨ At the pre-delivery, at the first
1000 kilometres and then every
6000 kilometres.
Check wear ¨ At the first 1000 kilometres and
B then every 6000 kilometres.
If the tyre pressures are too high or too low, the ride is
affected and tyre life duration is accentuated.
Therefore maintain the correct tyre pressures to obtain
better roadholding and the maximum wear from the
tyres. The cold tyre pressures are indicated in the
table.
Tyre pressures
Brand and type PIRELLI - Diablo Supercorsa SP
At a speed lower than 300 km/h At a speed higher than 300 km/h
Front 2,3 bar (33 psi) 2,5 bar (36 psi)
Rear 2,3 bar (33 psi) 2,9 bar (42 psi)
The use of the motorcycle with excessively worn tyres

diminishes the roadholding and is therefore danger-
ous. It is highly recommended to change the tyres
when the tyre tread reaches a minimum of 1.5 mm.
Ride with extreme care during the initial kilo-

metres after replacing the tyres.
Utilise exclusively the tyres recommended.
Tyre tread minimum limit = 1.5 mm
1.5 mm
FRONT WHEEL BEARINGS
Check ¨ Every 6000 kilometres and at every

tyre change.
Substitute ¨ Every 36000 kilometres.
If excessive play of the front wheel bearings is found

during checks, then substitute them as indicated in
chapter F “Suspension and wheels”.
- 56 -
Maintenance
WHEELS
Visual check ¨ At the first 1000 kilometres and
then every 6000 kilometres (at
least every tyre change)
B
After having visually checked or following even light
collision damage, it is necessary to check the planari-
ty, the eccentricity and the ovalisation of the wheel.
See the control procedures described in chapter F
“Suspension and wheels”.
REAR WHEEL HUB

Check and lubricate bearings ¨ Every 12000
kilometres
Substitute ¨ Every 36000
kilometres
To check and overhaul the rear wheel hub unit, it is
necessary to carry out certain preliminary operations
by consulting the relative chapters.
Remove the rear wheel (see chapter F “Suspension
and wheels”). Lift up the motorcycle by utilising a
mechanic’s lift. Remove the Seeger ring of the crown
wheel fixing nut (see chapter F “Suspension and
wheels). Slacken the fixing nut of the wheel axis (see
chapter F “Suspension and wheels”).
Remove the brake caliper (see chapter H “Brakes”).
Check and overhaul the rear wheel hub unit (see chap-
ter F “Suspension and wheels”).
SWINGARM BEARINGS
Check and lubricate ¨ Every 36000 kilometres
If excessive play is found on the swingarm, due to the

bearings assembled on the central pin of the
swingarm/frame, substitute them as described in chap-
ter F “Suspension and wheels”.
- 57 -
Maintenance
REAR SHOCK ABSORBER

Check and adjust ¨ At the first 1000 kilometres
and then every 12000 kilo-
metres.
B Carry out a check on the length of the rear shock
absorber spring; check for leakages and trickles of oil
and also check the adjustment function.
Spring adjustment standard A:

- F4 1000: A = 170,5 mm
The shock absorber contains gas under

high pressure. Do not touch the shock
absorber valve. Do not attempt in any way A
to remove the shock absorber.
Extension and compression adjustments (rear suspen-

sion):
(See adjustments Table - chapter "F - SUSPENSION
AND WHEELS" - page 38).
The adjustments can be performed with the

rear shock absorber fitted on the vehicle.
To conduct further checks on the ball joints
of the rear shock absorber links, follow the
removal procedure described in chapter F
"Suspensions and Wheels".
- 58 -
Maintenance
SIDE STAND
Functional check ¨ At the pre-delivery, first 1000

kilometres and then every
6000 kilometres
B
Make sure the bike cannot be started when the stand
is down and the bike is in gear. Also check that with the
engine switched on, when the side stand is lowered
and a gear is engaged, the engine switches off auto-
matically.
If not, the cause could be a faulty switch mounted on

the side stand. If this is the case, substitute the switch
by carrying out the following procedure.
5÷7 N•m
Disconnect the electrical connectors.
Remove the two fixing screws situated inside the side
stand. Remove the switch.
After having substituted the switch, tighten the two
screws to the prescribed torque.
Torque pressure: 5 ÷ 7 N·m 2
Apply Loctite Media 243
Reconnect the electrical connector.
Check that the side stand is not worn.
To remove the stand, follow these steps:
- remove the sidestand switch and release the two

1
springs;
- remove the nut located behind the stand mount;
- remove screw (1). 25 N•m
Tightening torque for stand nut:
25 N·m
In case you should have to replace the bracket plate,

remove the bracket switch, then the 3 fixing screws (2).
To refit the stand, follow the same steps in reverse

order, taking care to tighten the nut to the prescribed
torque. 2
Tightening torque for stand plate screws (2):

23 ÷ 25 N·m
Apply Loctite Media 243
The substitution of the springs must be car-

ried out utilising the appropriate tool.
1
Before reattaching the springs, ensure that
the stand can swing freely (with no friction
or sticking). 23÷25 N•m
- 59 -
Maintenance
FRONT FORK
Substitute oil ¨ every 24000 kilometres
The front fork is vitally important for the handling and

B stability of the motorcycle. It is therefore necessary to
substitute the fork oil at the prescribed intervals.
Quantity oil:
- F4 1000: 720 cc (*)
(*): approximate quantity calculated in relation to the

actual maintenance level
Oil type used: SAE 7,5

Recommended oil: Marzocchi EBH16 SAE 7,5
To substitute the fork oil and to do a complete overhaul

of the forks, carry out the described operations in chap-
ter F “Suspension and wheels”.
SCREWS AND NUTS

Check and tighten ¨ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilometres.
Carry out an accurate check of the tightness of the nuts and screws on the motorcycle at the intervals prescribed.
Consult the table in chapter N “Torque pressures” for the correct values.
TUBE BAND FASTENERS
Check and tighten ¨ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilometres.
Carry out a general check on all tube band fasteners for their condition and tightness.
Substitute damaged band fasteners by following the relative procedure delineated in the various sections.
ELECTRICAL SYSTEM
Check the functioning ¨ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilometres.
Carry out a detailed check on the various parts of the electrical system, the contacts between components and
their good functioning. Consult chapter E “Electrical system” for these checks.
BATTERY
Check and clean connections ¨ at the first 1000 kilometres and then every 6000 kilometres.
Consult chapter E “Electrical system” for the check on the battery condition.
If it is necessary to disconnect the battery and remove it during overhauls carried out on the motorcycle, follow
the procedure in chapter E “Electrical system”.
- 60 -
Maintenance
INSTRUMENTS AND WARNING LIGHTS

Check ¨ At the pre-delivery, at the first 1000 “SET” button
Warning lights
metres.
B
The instrumentation check must be carried out com-
pletely on all its functions as listed in the following list.
If even one of the functions does not function correct- Tachometer display
ly, consult chapter E “Electrical system” for complete
details.
Turning the ignition key to the “ON” position activates

“HAZARD” button
the instruments and the warning lights. After an initial
check-up (approximately seven seconds) the informa-
tion received correspond to the general condition of the “OK” button
motorcycle at that moment. Multifunction display
Warning lights
1 Neutral warning lights (green)
It turns on when the gear is in “Neutral”. 6
2 Turn indicator light (green) 5 7 8
Lights up when the turn indicators are activated. 4
3 Headlights (blue) 3
2
It turns on when the headlights are on.
1
4 Battery charge indicator (red)
Lights up when the alternator does not supply enou-
gh current to charge the battery. If the indicator
comes on while riding, contact an authorized service
centre.
5 Engine oil pressure warning lights (red)
Lights up when the oil pressure is insufficient.
If the warning light comes on while riding,
stop the motorcycle immediately. Check the
oil level and if necessary have it restored. If
the warning light comes on even if the oil
level is correct, do not resume riding and con-
tact a MV Agusta authorized service centre.
6 Sidestand down warning light (red)
Lights up when the sidestand is down.
7 Reserve fuel indicator (orange)
Comes on when approximately 4 litres of fuel are
left.
8 Rev limiter warning light (red)
It turns on when the engine exceeds 10800 rpm;
the rev limiter limits the rpm to 13500.
- 61 -
Maintenance
Multifunction display
13
10 Thermometer 12
11
It displays the temperature of the coolant by turning 10 14
on a variable number of segments on a graduated
B scale. When the temperature falls outside the nor-
mal operating range, it may display one of the fol-
lowing information:
- the display shows just one blinking segment; it
means that the temperature is low;
- all segments are on, while the upper segment is
blinking; it means that the temperature is high.
Danger - Attention: in case of high tempe-

rature, stop the motorcycle and check the
15
cooling liquid level. If liquid must be topped 16
up, wait for the engine to cool down. Do not 17
open the cooling liquid filler cap while the
engine is hot. If the indicator lights up even
though the level is correct, not continue to
run and contact an authorised service cen-
tre.
11 Gear display
It displays the currently engaged gear.
“N” stands for “neutral”.
12 Speedometer
It displays the speed of the motorbike. It can be
given in kilometres per hour (Km/h) or in miles per
hour (Mph). The full scale measures 350 Km/h (217
Mph).
13 “SPORT” Mode
It puts the injection unit in Sport Mode.
14 “SET” button
Press it to select and set the figures on the display.
15 “OK” button
Press it to confirm the new settings.
16 “TOTAL” odometer:
It displays the total distance covered; from 0 to
999999 (Km or miles)
Trip counter 1, “TRIP 1”
It displays the length of a trip; from 0 to 999.9 (Km
or miles)
Trip counter 2, “TRIP 2”
It displays the length of a trip; from 0 to 999.9 (Km
or miles)
Chronometer
It displays the time measured by the chronometer
17 “HAZARD” button
Press it to turn on the emergency lights.
- 62 -
Maintenance
Selecting and setting the display functions

Some of the main measurements of the instruments
may be changed.
The available options include:
B
- Select an operating mode:
“RUN” (Odometer)
“TC” (Traction control)
“CHRONO” (Chronometer)
“NIGHT/DAY” (Night/Day Mode)
- Reset the trip counter:
Trip counter 1 “TRIP 1”

Trip counter 2 “TRIP 2”
- Turn on the chronometer
- "IMMOBILIZER" function (Anti-theft system)
- Control unit mapping selection
Selecting the display functions

The following settings may be changed on the display:
• “RUN” (Odometer)
• “TC” (Traction control)
• “CHRONO” (Chronometer)
• “NIGHT/DAY” (Night/Day Mode)
To display the operating modes, press “SET” for less

than four seconds. When pressed, the display shows
all modes, in a sequence. Select the desired mode.
WARNING
The operation must be performed while the
engine off, the gears are in neutral, the
motorcycle is stationary, and with the feet
on the ground. Do not set the display func-
tions while riding.
- 63 -
Maintenance
“RUN” mode
In addition to the speedometer, the display shows the
following functions:
• Total odometer “TOTAL”

B • Trip counter 1 “TRIP 1”
alternatively:
• Total odometer “TOTAL”

• Trip counter 2 “TRIP 2”
“TC” Mode
This Mode adjusts the engine traction control level to
your driving requirements.
“CHRONO” Mode
This mode turns on the Chronometer and saves the
recorded information. The following is displayed:
• Chronometer Current lap “CURRENT LAP”

• Chronometer Fastest lap “BEST LAP”
• Chronometer Last lap “LAST LAP”
• Rev counter Total laps covered “N° LAP”
- 64 -
Maintenance
“NIGHT/DAY” Mode
This function enables the background colour of the dis-
play to be converted in order to adapt its visibility
depending on the time of day or night the vehicle is
used.
B
Trip reset
To reset “TRIP 1” and “TRIP 2”, proceed as follows.
WARNING
The display modes may be changed or set
when the engine off, the gear in neutral, the
motorbike stationary with your feet on the
ground. The display may not be changed
while driving.
- Access the “RUN” mode; the total speedometer

("TOTAL”) and partial speedometer 1 (“TRIP 1”) will
appear on the display.
- By pressing the “OK” key for more than four seconds,

the “TRIP 1” value will be reset to zero.
- 65 -
Maintenance
- Press the “OK” key for less than four seconds until the
partial speedometer 2 function (“TRIP 2”) appears on
the display.

the “TRIP 2” value will be reset to zero.
“TC” Mode
- Press the "SET" button to switch on "TC" mode, then
press the "OK" button for less than four seconds until
the message "TC LEVEL" appears. The current trac-
tion control level is the value displayed.
WARNING
ground. Do not change the display while dri-
ving.
- 66 -
Maintenance
- Press “SET” for less than four seconds: the traction

control level rises up to the next value. Such value
may range between 0 and 8.
- Press “OK” for over four seconds to confirm the selec-

ted traction control level.
B
Chronometer
Lap timing acquisition
- Turn on the chronometer (“CHRONO” mode) to
record the time taken to cover a lap.
- Press the headlight button to start recording the time.

The colon that separates the minutes from the
seconds and from the tenths of a second will start
blinking. Now, the instrument is recording the time.
- 67 -
Maintenance
- Press the headlight button again to record the time

taken to cover the 1st lap. At the same time, the
instrument starts recording the time taken to cover the
second lap.
B The time measurement for the first lap is stored in the
memory and is visualised on the display for ten sec-
onds, after which the time measurement for the follow-
ing lap appears.
- If using the chronometer again, every time you press

the headlight button, it records a time. The instrument
can record up to100 consecutive times.
When the time for the lap which has just concluded is
displayed, the symbol “+” or “-” appears if the time
recorded is respectively higher or lower than the time
measured during the previous lap.
Data display
Once all times have been recorded, they may be
displayed.
- Access the “CHRONO” mode; the time of the fastest

lap (“BEST LAP”) and the time of the last lap (“LAST
LAP”) appears on the display.
WARNING
when the engine off, the gear must be in
neutral, the motorbike must be stationary
with your feet on the ground. Do not change
the display while driving.
- 68 -
Maintenance
- Press “OK” for less than four seconds until “LAPS

VIEW” appears.
- By repeatedly pressing the key of the flashing high

beam headlight, all the times previously acquired
starting from the last lap memorised can be displayed
in sequence.
- Once all the data have been displayed, press the

“SET” key to return to the “LAPS VIEW” mode and
then to the following mode.
- 69 -
Maintenance
How to delete data
To delete the saved data, proceed as follows:
WARNING
B The display modes may be changed or set
ving.
- Cancellation of individual time recordings: Access the

“CHRONO” mode and press the “SET” key for less
than four seconds until the words “SINGLE LAP
RESET” appear on the display.
- Press the “OK” key for less than four seconds; the
value of the last lap time memorised will start flashing.
- Now, press “OK” for over four seconds to delete the

value. Otherwise, press “SET” for less than four
seconds to stop the deletion procedure.
- 70 -
Maintenance
- Subsequently, by pressing the flashing high beam

headlight key followed by the “OK” key for more than
four seconds, all the previously acquired times can be
cancelled.
- Once all the data have been cancelled, press the

B
“SET” key to return to the “SINGLE LAP RESET”
mode and then to the following mode.
- Cancellation of best time: Access the “CHRONO”

mode and press the “SET” key for less than four
seconds until the words “BEST LAP RESET” appear
on the display.
value of the fastest last lap time memorised will start
flashing.
- 71 -
Maintenance
- Now, press “OK” for over four seconds to delete the

value. Otherwise, press “SET” for less than four
seconds to stop the deletion procedure.

B “SET” key to exit the “BEST LAP RESET” mode and
then pass to the following mode.
- Cancellation of all times recorded: Access the

“CHRONO” mode and press the “SET” key for less
than four seconds until the words “ALL LAPS RESET”
appear on the display.
display will ask you to confirm cancellation of all the
data present in the memory.
- 72 -
Maintenance

all the previously acquired times will be cancelled. By
pressing the “SET” key for less than four seconds, the
cancellation procedure will be interrupted.

B
“SET” key to exit the “ALL LAPS RESET” mode and
to return to the “CHRONO” mode.
“NIGHT/DAY” Mode
- To convert the display background colour, access the

“NIGHT/DAY MODE” and press the “OK” key for less
than four seconds.
WARNING
ving.
- By pressing the "SET” key, the daytime and night-time

display modes can be changed repeatedly.
- Once the display background colour has been defi-

ned, press the “OK” key for more than four seconds in
order to confirm the chosen display mode and to
return to the “NIGHT/DAY MODE”. The defined back-
ground colour will be maintained in all the subsequent
modes of use of the dashboard.
- 73 -
Maintenance
“IMMOBILIZER” function
The "IMMOBILIZER" function allows the engine to be

started up only after an original ignition key is recogni-
sed. It is in fact an anti-theft system integrated into the
B electronic circuit of the vehicle, since it prevents use by
any unauthorised individuals.
The "IMMOBILIZER" mode on the dashboard must
only be used in case of malfunction. In fact, if for any
reason this system is not able to recognise the code on
the ignition key, you will have to manually enter the
secret code printed on the MV Code Card received
upon delivery of the vehicle to obtain engine start-up
consent.
- Remove the lid from the box on the back of the MV

Code Card and read the secret electronic code of the
starter key (the figure shows a random code, for infor
mation only).
- From "RUN" mode, press the "SET" button for more

than eight seconds to access "IMMOBILIZER" mode.

ving.
- Press the "OK " button for less than four seconds to set
the first number of the code.
- Press the "OK " button for less than four seconds to
vary the first number value between 0 and 9.
- 74 -
Maintenance
- Once the digit has been selected, press “OK” for over
four seconds to confirm the first digit of the code.
Now, you can set the second digit of the code.
- Do the same to set the other four digits of the code.

B
- Once the full code has been entered, “CONFIRM

CODE” appears on the display. Press “OK” for over
four seconds to confirm the code.
- If the entered code is recognised by the system,

“VALID CODE” appears. The dashboard display goes
back to “RUN”. The engine may be started.
- If the entered code is wrong, “NOTVALID CODE”

appears. The system will not let the engine start; the
display goes back to “IMMOBILIZER”. Repeat the
code entry procedure from the start, taking care of
setting all the right digits shown on your MV Code
Card. If the problem persists, contact a MV Agusta
licensed service centre.
- 75 -
Maintenance
How to select the mapping of the control unit
It is possible to select special mapping on the control

unit of the F4 1000 model which allows you to obtain
higher power and performance characteristics for deci-
B dedly sporty use of the vehicle.
The mapping of the control unit can be selected by

pressing the start button when the engine is switched
on. “SPORT” appears on the dashboard display to
show the mapping has been selected.
WARNING
Control unit mapping selection operations
must be carried out with the engine running
on neutral, with the motorcycle stopped
with the stand on the ground. Changing
display settings while running is prohibited.
Error / malfunction messages
The dashboard can signal a fault or malfunction during

different motorcycle use conditions.
- Engine start-up: Turning the ignition switch to "ON",

the instrumentation and indicators run diagnostic
tests. When a vehicle fault is present, the display will
show an error message as shown in the figure to the
side. In particular, the motorcycle unit or component
where the malfunction was detected is highlighted.
- 76 -
Maintenance
- Press the "OK" button and the dashboard will pass

into "RUN" mode.
WARNING
Whenever the diagnostic tests detect a fault
with the vehicle stopped, do not start up the
B
machine and contact an authorised MV
Agusta service centre.
- Vehicle running: When a vehicle fault is detected

while running, an error message, shown to the side,
is shown on the lower part of the display.
WARNING
Whenever a fault is detected while the vehi-
cle is running, stop running and contact an
authorised MV Agusta service centre.
- When the vehicle is stopped, the display will show an

error message detailing the motorcycle unit or com-
ponent where the malfunction was detected.
- 77 -
Maintenance
- High cooling liquid temperature: If the system detects

an excessively high cooling liquid temperature, an
error message will appear on the display as shown to
the side. The screen in question can appear during
any condition of vehicle use.
B
WARNING: In case of high temperature,
stop the motorcycle and check the cooling
liquid level. If it is necessary to top up coo-
ling liquid, contact an authorised MV Agusta
service centre. If the indicator lights up
even though the level is correct, do not con-
tinue to run and contact an authorised ser-
vice centre.
Dealer Menu
The instrumentation provides the opportunity to opera-

te on an additional set of parameters.
The auxiliary functions available are:
• “SERVICE” (Scheduled maintenance expiration)

• “UNIT CHANGE” (Changes unit of measurement)
Viewing and editing modes of operation is performed in

accordance with the procedures outlined in the para-
graphs below.
WARNING
The modification or adjustment of display
functions must be carried out with the engi-
ne off and running on neutral, with the
motorcycle stopped with the stands on the
ground. Changing display settings while
running is prohibited.
- 78 -
Maintenance
“SERVICE” Mode
This operating mode displays the mileage range with

respect to expiration of the next scheduled maintenan-
ce.
B
NOTE
When the mileage range upon maintenance servicing
is less than 1000 km, its relative value automatically
appears after the start-up screen of the motorcycle.
“UNIT CHANGE” Mode
This function allows for simultaneous editing of the fol-

lowing units of measure:
• Speed
• Distance covered
“SERVICE” Mode
- Press the "SET" and "OK" buttons at the same time

for more than ten seconds to access the "DEALER
MENU".
WARNING
- 79 -
Maintenance
- Press the "OK " button for less than four seconds until
the message "SERVICE" is displayed. The mileage
range with respect to expiration of the next scheduled
maintenance is shown on this screen.
B
- Mileage range resetting: After performing scheduled

maintenance, the mileage range must be reset using
the following procedure.
- Access "SERVICE" mode and press the "OK" button

for less than four seconds until the message "RESET
KM" appears and the mileage range indicator light will
begin to flash.
- Press the "OK " button for more than four seconds
and the mileage range will be reset. The mileage
range with respect to expiration of the next scheduled
maintenance is shown on this screen.
- The next press of the "SET" button for less than four
seconds will allow the user to return to the dashboard
start screen.
- 80 -
Maintenance
Changing the unit of measurement
Allows for simultaneous editing of the following units of

measure:
• Speed
B
• Distance covered
WARNING
- Access the "SERVICE" mode as described in the pre-

ceding pages, and press the "SET" button for less
than four seconds to until the message "UNIT CHAN-
GE" appears.
- Press the "OK " button for less than four seconds and
the unit on the speedometer will begin to flash.
- Press the "SET" button to pass from Km/h to Mph and

vice-versa. Changing the unit of measurement on the
speedometer automatically varies the following sizes:
• Odometer (total and partial): Km –> mi
If you press the "OK" button for longer than four

seconds, the modification procedure of the measure-
ment units will be interrupted.
- 81 -
Maintenance
- Press the "OK " button for more than four seconds
and the new unit of measurement configuration will be
confirmed. The display returns to the "RUN" mode.
LIGHTS
metres.
If any of the warning lights or the main lights are burnt

out, replace them as follows.
Driving/dipped beam - Bulb replacement
NOTE
To facilitate operations when replacing the dri-
ving/dipping beam bulb, it is advisable to remove
the motorcycle beam. To do this, you must remove
the vehicle headlight fairing as described in Chapt.
C "Superstructures."
Remove the cover.
- 82 -
Maintenance
Turn the holding device counter-clockwise.
Remove the bulb.
Disconnect the connector.
- 83 -
Maintenance
Connect the connector on the new bulb.

Insert the new bulb, blocking it in position as shown in
the figure.
Caution: Do not touch the bulb glass with

B your hands. In case of contact, clean with a
degreasing product.
Turn the holding device clockwise.
Replace the cover.
NOTE
In the event that the headlight is removed from the
motorcycle, proceed with reassembling previously
removed components, operating in the opposite
order of removal.
- 84 -
Maintenance
Replacing the license plate light bulb
- Remove the fixing screws of the lower cover of the

license plate holder.
B
- Remove the lower cover.
- 85 -
Maintenance
- Extract the bulb socket sliding it from its seat.
- Extract the bulb.
- Insert the new bulb.
- Reposition the bulb socket.
- Reassemble the lower cover of the license plate holder.
Caution: Before reassembling pay special

attention to positioning the tail light harness
correctly, in order to avoid any damage (see
figure).
- 86 -
Maintenance
Replacing the fuses
- The battery recharge fuse is located on the solenoid

starter of the motorcycle. To expose it, remove the
rider’s saddle.
B
Solenoid
starter
CAUTION
Turn the ignition key on the “OFF” position
before checking or replacing the fuses, in
order to avoid a short circuit with subse- Recharge fuse (40 A)
Spare fuse (40 A)
quent damage to other electric parts of the
motorcycle.
- To replace the fuse, you must swap the recharge fuse

with the spare fuse.
WARNING
Never replace a fuse with a rating other than
that precribed, in order to avoid damage to
the electrical equipment of the motorcycle
which could lead to a fire.
- 87 -
Maintenance
- The service fuses are located on the left side. To

expose them, remove the side fairing
- Release the two clamps and lift the fuse box cover.
B
CAUTION
Turn the ignition key on the “OFF” position
before checking or replacing the fuses, in
order to avoid a short circuit with subse-
quent damage to other electric parts of the
motorcycle.
- Replace the blown fuse and refit the cover.
- 88 -
Maintenance
- To identify the position and function of the fuses, refer

to the information shown in the enclosed electrical
diagram. The reference letters in the figure corre-
spond to those shown in the diagram.
Remember that the tool bag contains three spare
fuses.
B
WARNING
Never replace a fuse with a rating other than
that precribed, in order to avoid damage to
the electrical equipment of the motorcycle
which could lead to a fire.
- 89 -
Maintenance
FRONT HEADLAMP
Check adjustment ¨ At every variation of the motorcycle set-up.
The headlight should be adjusted every time the geometry of the vehicle is altered and before carrying a pillion
B passenger. The motorcycle is not equipped with external adjusters and the front projector unit is fixed to the frame.
Headlight adjustment
Place the vehicle at a distance of 10 m from a vertical wall. Make sure that the motorcycle is placed on an even
horizontal surface, and that the headlight’s optical axis is perpendicular to the wall.
The vehicle must be held in an upright position. Measure the “X” distance between the headlight center and the
ground surface, then trace a small cross on the wall at the same height.
When you turn the headlight on, the upper boundary line between the dark area and the lighted area must be at
an height equal or lower than the 9/10 of the headlight center height.
Headlight center
The light beam can be adjusted vertically by turning the

screw illustrated. If turned in a clockwise direction: the
optical unit tilts upwards. If turned in an anti-clockwise Counterclockwise
direction: the optical unit tilts downwards. It can be tilt-
ed up to an angle of ±4° from the standard position.
Clockwise
The light beam can be adjusted horizontally by turning

the screw illustrated. If turned in a clockwise direction:
the optical unit tilts to the left. If turned in an anti-clock- Counterclockwise
wise direction: the optical unit tilts to the right. It can be
tilted up to an angle of ±4° from the standard position. Clockwise
- 90 -
Bodywork
SECTION
Revision 0
C
-1-
Bodywork
SUMMARY
FAIRING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

TAIL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 6
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 12
C
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 20
HEAT SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 25
MUDGUARD - CENTRAL SPOILER - RADIATOR PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 28
-2-
Bodywork
FAIRING ASSEMBLY
Right side
Left side
• This exploded view demonstrates the position of the bodywork and the method of disassembly and assembly.
-3-
Bodywork
Fairing side panel removal
Remove the seven fixing bolts (1) situated on the right

fairing side panel.
1
C
Remove the fairing side panel, sliding it off from the

front side.
Repeat the operation for the left fairing side panel.
To separate the air manifold from the side panels,

removing the two fixing screws (2).
-4-
Bodywork
Under-engine fairing removal
Remove the three fasteners (1) placed respectively:

1 on the right side;
1
1 on the left side;

1 on the front central part;
Remove the underfairing, sliding it off from the bracket

(2).
2
-5-
Bodywork
Front fairing removal

With a small flat-tip screwdriver, remove the connector
(1) of the front headlight. Push the screwdriver forward
to unhook the connector.
Remove the two fixing screws (2) of the right rear-view

mirror.
Remove the connector and take off the right rear-view

mirror (3).
3
Repeat operations for the left mirror.
-6-
Bodywork
Remove the two fixing screws (1) of the headlight fair-

ing to the instrument panel support.
Remove the two fixing screws (2) of the headlight fair-

ing support on both sides.
Remove the headlight fairing, sliding it toward the front

part. The headlight will remain fastened to the fairing.
-7-
Bodywork
TAIL UNIT
-8-
Bodywork
Tail unit removal
Insert the ignition key into the seat lock.

Press lightly on the rear part of the passenger seat as
Turn the key and unlock the TAIL UNIT.
Lift up the passenger seat.
Press the driver seat release lever (1) and remove,

sliding it from the rear part.
-9-
Bodywork
Remove the tank side fairings (1) on both sides,

unhooking it from the pin and sliding it toward the rear
part of the motorcycle (page C.12).
Remove the right under seat side fairing removing the

5 screws (2).
- 10 -
Bodywork
Remove the side fairing toward the outside, taking care

of the rear pin anchored in the support brackets.
- 11 -
Bodywork
FUEL TANK
- 12 -
Bodywork
Side fairing removal
Extract the left and right side fairing support as indicat-

ed in the figure.
Extract the rear part of the support first (A) then grad-
ually withdraw the support from its front seat fixing (B). A
C
B
Remove the vent tube.
Fuel tank removal
Remove the rear fixing screw of the fuel tank (1).
- 13 -
Bodywork
Remove the two fixing screws (1) of the tank support

bracket.
Lifting the rear part of the tank, remove the bracket.
Lift up the fuel tank.
While lifting the tank take care not to dam-

age the airbox.
- 14 -
Bodywork
Then position the special tank support tool in corre-

spondence with the hole (1) on the seat seal and with 1
the two tank support bracket fixing holes (2) on the rear
frame.
Special tool Code 8000B4414
Insert the tank on the tool support spindle as shown in

the figure and disassemble electrical connections.
Disconnect the gas tubes, taking care of the internal

pressure of the tubes.
- 15 -
Bodywork
To disconnect the fuel tube, press and slide

the retaining slide as shown in the figure.
Disconnect the electrical system connector.
Disassemble the duct cover panels
Remove the two connecting screws (1) of the right

panel (2) of the frame.
1
- 16 -
Bodywork
Lift the panel and unhook it from the two pins.

Remove it outward.
Repeat operations for the left panel.
Disconnect the air temperature sensor connector.
Remove the sensor electrical cable from the guides on

the right duct.
- 17 -
Bodywork
From the left duct, remove the left direction indicator

light electrical cable from the guides.
Left and right air intake conduit removal
Unhook the connector pin (1) on the ducts.
Remove the right air intake conduit.
Proceed with disassembly of the right air duct (2), turn-

ing the front part outward. 2
Repeat operations for the left duct.
- 18 -
Bodywork
Remove the right and left suction duct unions (1)

before removing the airbox.
Air filter compartment side panels

Remove the left and right air filter compartment side
panels by unscrewing the two relative screws (1).
Before reassembly, check the integrity of the elastic

nuts and replace if necessary.
- 19 -
Bodywork
AIR INTAKE SYSTEM
- 20 -
Bodywork
Airbox removal
Remove the 4 fixing screws (2 per side) of the airbox

cover.
Remove the air box cover.
Remove the cover by lifting it up.
- 21 -
Bodywork
Remove the two fixing screws (1) of the control unit

support plate and remove the plate.
Unhook the clamp with the clip grippers on the valve of

the TSS and disconnect the tube.
2
Unhook the gas tube pressing the coloured button (1)

to unhook it from the union (2).
1
2
- 22 -
Bodywork
Unhook the oil vapour tube.
Lift the air box from its rear part, removing the rubber
tube.
Disconnect the upper injector cable connector.
- 23 -
Bodywork
Remove the cable.
With the appropriate gripper, loosen the secondary

valve tube clip and remove the tube.
Lift and remove the airbox.
- 24 -
Bodywork
HEAT SHIELD
- 25 -
Bodywork
Heat shield removal
After having removed the seats and the rear fairings as

previously described, proceed as follows:
Remove the silencers (see chapter F “Suspension and

wheels”).
C
Remove the battery (see chapt. E - electrical system).
Remove the rear headlight connector fastening clip

and disconnect the connector.
Remove the four fixing screws, two upper (1) and two
lower (2), of the rear headlight support and remove the
support. 1
- 26 -
Bodywork
Remove the headlight support.
Remove the 6 fixing screws of the heat guard.
Lower and remove the guard toward the rear part.
- 27 -
Bodywork
MUDGUARD - CENTRAL SPOILER - RADIATOR PROTECTION
Right side
Left side
- 28 -
Bodywork
Central manifold disassembly
Remove the flashing relay (1) toward the rear part.
C
1
Remove the two fixing screws (2) and remove the cen-
tral manifold (3).
Front mudguard disassembly
Unscrew and remove the 4 fixing screws (1) on the

mudguard (2 per side).
- 29 -
Bodywork
Remove the number plate holder toward the front part.
Oil radiator protection disassembly
Unscrew and remove the two screws (1), one per part. 1
To remove the radiator protection, slide it downward

removing the reference pin.
- 30 -
Air intake injection system
SECTION
Revision 1
D
-1-
SUMMARY
INJECTION SYSTEM TECHNICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

INJECTION TIME COMPENSATION (VOLUME) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 4
INJECTION ARREST CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 4
FUEL FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 5
FUEL PRESSURE ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 6
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 6
FUEL PUMP CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 7
ECU (ELECTRONIC CONTROL UNIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 8
D SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 8
ATMOSPHERIC AIR TEMPERATURE/PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 8
THROTTLE BODY POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 10
INJECTOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 11
FUEL PUMP CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 11
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 13
DIAGNOSTICS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 14
AIR INTAKE SYSTEM TECHNICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 15
TECHNICAL SPECIFICATIONS – SECONDARY AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 16
POSITIONS OF ENGINE-CONTROL SYSTEM PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 17
INJECTION SYSTEM ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 18
ENGINE CONTROL UNIT PINOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 19
-2-
INJECTION SYSTEM TECHNICAL CHARACTERISTICS
INJECTION TIME (INJECTION VOLUME)

The factors for the determination of the injection time are the basic injection time that is calculated on the basis
of the r.p.m. of the engine, the opening of the accelerator and various compensations that are determined accord-
ing to signals coming from various sensors that reveal the condition of the engine and the riding conditions.
Engine r.p.m. signal D

Camshaft position sensor
BASIC
Accelerator opening signal
Accelerator position sensor INJECTION
TIME
Engine timing signal and firing sequence

Under throttle pressure sensor
ECU
Various signals COMPENSA-
Various sensors TION
FINAL
Injection signal INJECTION
Injectors TIME
-3-
INJECTION TIME COMPENSATION (VOLUME)
The various sensors allow the injection time (volume) compensations to be carried out on the basis of the fol-
lowing signals.
SIGNAL DESCRIPTION
When the atmospheric pressure is low, the sensor

ATMOSPHERIC PRESSURE SENSOR SIGNAL sends a signal to the ECU to reduce the injection
time (volume).
En phase de démarrage le même capteur est utilisé
pour aligner l'injectée et la scintille dans les 4 bancs.
D
ENGINE COOLANT TEMPERATURE SENSOR SIG-
When the temperature of the engine coolant is low,
NAL
the injection time (volume) is increased.
AIR INTAKE TEMPERATURE SENSOR SIGNAL When the temperature of the intake air is low, the
injection time (volume) is increased.
BATTERY VOLTAGE SIGNAL The voltage of the battery is supplied to the ECU for
the functioning of the ECU and this voltage is
revealed and utilised as a signal for the compensa-
tion of the injection time (volume). A low voltage
determines a longer injection time for the adjustment
of the volume of the injection.
STARTER SIGNAL When the engine is switched on, a greater volume of

fuel is injected during the starting period.
ACCELERATION/DECELERATION SIGNAL During acceleration, the injection time of the fuel

(volume) is increased in proportion to the opening of
the accelerator and the r.p.m. of the engine. During
deceleration, the injection of fuel is diminished in
proportion to the speed of closure of the accelerator
handgrip and of the engine r.p.m.
INJECTION ARREST CONTROL
SIGNAL DESCRIPTION
R.P.M. LIMITER SIGNAL The functioning of the fuel injectors is interrupted

when the level of engine r.p.m. reaches its limit. The
r.p.m. limiter interrupts the ignition system and the
interruption signal of the ignition is therefore sent to
the ECU.
-4-
FUEL FEED SYSTEM
The fuel feed system consists of the tank, pump, filter, feed tube, feed tubes (including the fuel injectors) and the
regulator of the pressure. The fuel in the tank is pumped into the feed tubing at a controlled pressure by the rel-
ative regulator and maintained at a certain constant value higher than the suction generated by the motor. The
fuel is injected into the air intake conduit when the injector opens, following a law generated by the ECU.
DISCHARGE OF WATER AND FUEL

TO THE GROUND (TOO FULL)
DISCHARGE OF
FUEL VAPORS
FUEL FILTER
FUEL PUMP
FUEL FEED TUBE
DISCHARGE OF WATER AND

FUEL TO THE GROUND
-5-
FUEL PRESSURE REGULATOR
The fuel pressure regulator is a diaphragm pressure release valve that consists of a diaphragm, spring and valve.
It always maintains the pressure of the fuel sent to the injector at 3.0 kg/cm2 (300 kPa).
When the pressure of the fuel rises above 3.0 kg/cm2 (300 kPa) the excess fuel opens the valve of the regulator
and therefore can return to the fuel tank.
FUEL INJECTOR
The fuel injector consists of a solenoid, piston, needle valve and a filter.
The injector is a small electromagnetic injection nozzle that injects fuel into the carburettor according to the sig-
nal coming from the ECU.
When the solenoid is agitated by the ECU, it becomes an electromagnet and attracts the piston. At the same time,
the needle valve incorporated in the piston opens and the injector, under pressure of the fuel, injects the fuel in a
conical dispersion. Given that the opening of the needle valve is constant, the volume of fuel injected at any one
time is dependent on the time that the solenoid is agitated (injection time).
-6-
FUEL PUMP CONTROL SYSTEM

When the ignition switch is turned to the ON position, the fuel pump motor is started by the current supplied by
the battery.
As the CPU possesses a timer function, the pump motor stops turning three seconds after the ignition switch has
been brought to the "ON" position. If the starter motor turns the electric motor shaft during or after the three sec-
onds, the motor rotation signal is sent to the CPU that, by controlling the pump relay, makes the pump motor func-
tion continuously.
When the ignition switch is switched to the "OFF" position, the control of the pump relay is interrupted and con-
temporaneously also the control of the injectors and the ignition coils, thereby causing the engine to switch off.
-7-
ECU
The ECU is situated under the tank behind the cylinder
blocks.
The ECU consists of a CPU (Central Processing Unit),
a memory unit and I/O sections (input/output).
The signal of each individual sensor is sent to the input
section and then to the CPU. On the basis of the sig-
nals received, the ECU calculates the volume of fuel
and the ignition advance necessary by utilising pre-
pared schemes for the various conditions of the engine
and sending them respectively to the injectors and the
ignition coils.
D
SENSORS
ATMOSPHERIC AIR TEMPERATURE/PRESSURE
The suction air sensor (1) is situated on the right suc-
tion duct in the front part of the vehicle and indicates
both the atmospheric pressure and the air temperatu-
re.
1 INTAKE AIR PRESSURE SENSOR

The sensor (2) reveals the pressure of the intake air
and this pressure is therefore converted into voltage
that is sent to the ECU.
The signal involved has a double purpose, one 1
being that of phasing the injection and ignition of the
cylinders and the second being that of adjusting the
base fuel injection time (volume); this is in fact
determined depending on the tension of the signal
(output tension).
The voltage increases when the pressure of the
intake air is high.
Output voltage
(V)
High
Low
Pressure of the
intake air (mmHg)
2
Low High
-8-
2 INTAKE AIR TEMPERATURE SENSOR

The temperature of the intake air is found by con-
verting the resistance of the Thermistor into voltage
and then sending it to the ECU. The volume of the
injection increases when the air temperature is low.
The resistance of the Thermistor increases when the

air temperature is low and diminishes when the tem-
perature is high.
D
Resistance value
High
Low
Low High Temperature
AIR TEMPERATURE A - B
Air temperature sensor characteristics

Temperature (°C) Resistance (kΩ))
-10 9,5
0 6
10 3,8
20 2,5
30 1,7
40 1,2
60 0,6
A B
-9-
THROTTLE BODY POSITION
The sensor of the throttle position (1) is located in the

centre of the throttle body.
This sensor is a potentiometer with a resistance which 1
varies according to the opening angle of the accelera-
tor.
The sensor is supplied by the ECU at a stabilised vol-
tage of 5V and supplies an output voltage proportiona-
te to the throttle angle.
The basic injection time of the fuel (volume) is deter-
mined according to the output voltage of this sensor.
The voltage increases when the accelerator opening is
D increased.
RESISTANCE TEST A - C
FEED TEST (~ 4,9 ± 1 volt)
A – – (pin 16)
B – + 5V (pin 14)
C – Signal (pin 30)
- 10 -
INJECTOR CHECK
To check the injectors proceed as follows:

- Disconnect a connector from one of the injectors.
- Check between green-red and earth. For approxi-
mately two seconds the voltage at the ends of the
leads should be that of the battery.
- Carry out the check on each injector.
- Proceed with the check of the coils of each injector.

- Between the two pins of the injector the contact must
not be open. Also the resistance value must be
between (~ 12,0 - 12,3 Ω).
If otherwise, proceed by substituting the injector that
does not function correctly.
FUEL PUMP CHECK
Check the condition of the fuel pump fuse.

To check the condition of the fuel pump, proceed as fol-
lows:
- After having removed the fuel tank, proceed with the
check of continuity between pin 1 and 2 on the con-
nector of the pump as indicated in the figure.
- 11 -
- Check the functioning of the fuel pump, connecting

respectively:
Pin 1 of the connector to the + pole of the battery.
Pin 2 of the connector to the – pole of the battery.
- If the fuel pump unit does not continue to function

correctly after the above-described tests, proceed
with relative relay control (1) on the left side of the
motorcycle, identified by a ring marked with "I" loca-
ted on the cable bundle.
- 12 -
ACTUATORS
Fuel injector
The fuel injector consists of a solenoid, piston, needle valve and a filter.
The injector is a small electromagnetic injection nozzle that injects fuel into the carburettor according to the signal
coming from the ECU.
When the solenoid is agitated by the ECU, it becomes an electromagnet and attracts the piston. At the same time,
the needle valve incorporated in the piston opens and the injector, under pressure of the fuel, injects the fuel in a
conical dispersion. Given that the opening of the needle valve is constant, the volume of fuel injected at any one
time is dependent on the time that the solenoid is agitated (injection time).
TECHNICAL DATA: Winding resistance 12 Ω

D
Ignition coils
The ignition coils are of the top plug type (they are assembled directly on the spark plugs. This avoids the use of
the HT leads and enhance the overall system reliability.
- 13 -
DIAGNOSTICS SYSTEM
Ignition and injection system diagnostics

For the diagnosis of the ignition and injection system A
Weber-Marelli diagnostic software is available which is
capable of identifying and recording the faults present
or that were present previously on the motorcycle. This
software is equipped with a guide book for the use of
the software itself to carry out checks on each indivi-
dual component of the system.
The MDST software allows to carry out the following

operations:
- reading of engine parameters
- reading of faults and their deletion
- active diagnosis
- 14 -
AIR INTAKE SYSTEM TECHNICAL CHARACTERISTICS
This motorcycle utilises direct induction in the air intake system. The frontal pressure of the air during normal rid-
ing conditions is conducted to the air filter compartment in such a way that the incoming air is pressurised there-
by improving the air intake efficiency to obtain greater power from the engine.
AIR FILTER
INCOME AIR-BOX
TSS SYSTEM
INTAKE MANIFOLD
- 15 -
SECONDARY AIR SYSTEM TECHNICAL CHARACTERISTICS
F4 bikes use an additional system for the secondary flow of induction air. Through this system, part of the air from
the Airbox is channelled near the exhaust pipes of the cylinder through a set of on/off valves and passageways
inside the engine head. So, when needed, the system promotes the post-combustion of any un-burnt hydrocar-
bons in the exhaust gases, thereby reducing the emission of pollutants into the atmosphere..
SECONDARY AIR VALVE
- 16 -
POSITIONS OF ENGINE-CONTROL SYSTEM PARTS
- 17 -
A Instrument panel H Fuel injectors Q Lambda sensor

B Engine coolant temperature sensor I Fuses/relays R Exhaust valve
C Ignition coils L Engine control unit
D Camshaft position sensor M Solenoid starter
E Intake air pressure/temperature sensor N Phase sensor
F Fuel pump O Secondary air valve
G Accelerator position sensor P Tilt sensor
D
D
Ignition key in the “ON” position SAFETY SWITCH
Safety switch in the “RUN” position SOLENOID
KEY SWITCH STARTER
Start not activated
NEUTRAL CLUTCH
SERVICE FUSE
MAIN RELAY
INJECTOR FUSE
FULE PUMP,
COIL, ECU FUSE

SWITCH SWITCH BATTERY
INJECTORS RELAY
FUEL PUMP - COILS -
Side stand out
Gear engaged
Clutch released
Engine switched on
FUEL TANK
INJECTION SYSTEM ELECTRICAL DIAGRAM
- 18 -
TILT SENSOR
PLUG-TOP
COILS
PRESSURE SENSOR
THROTTLE BODY
UNDER THROTTLE
UPPER INJECTRS
SIDE STAND SWITCH
PICK-UP WHEEL
THROTTLE BODY
LOWER INJECTRS
Engine control unit pinout, MV Agusta F4 Connector

Vehicle Engine
Pin name Description of associated function Type
Pin n° Pin n°
IGN4 Output coil control N°4 OFA,LOW-SIDE 1
SNSSPLY2_GND Analogic mass 2 SENSOR-GROUND 4
PPWS_GND Control unit protected power mass POWER-GROUND 5
SNSSPLY1_GND Analogic mass 1 SENSOR-GROUND 6
INJ1_1 Injector control output Nr. 1 block 2 high injectors OFA,LOW-SIDE 8
O2SENS+1 Input Lambda sensor (+) N°1 IA,DIFFERENZIALE 10
ENGINETEMP Input water temperature sensor signal IA,PULL-UP,RATIO 12
SERIALLINE Serial line K diagnostics and download BC,ISO9141 14
PWS_GND Mass power POWER-GROUND 16
SNSSPLY_GND Analogic mass 1 SENSOR-GROUND 17
RPM- Input r.p.m. sensor (-) (VRS -) IFA,DIFFERENZIALE 20 D
O2SENS-1 Input Lambda sensor (-) N°1 IA,DIFFERENZIALE 22
MANPRES1 Input sensor of air pressure collector/barometric IA,PULL-DWN,RATIO 24
SNSSPLY1 Output VREF1 +5V, for TPS SENSOR-SUPPLY 25
DBW1- Output command- DCM exhaust butterfly valve OP,H-BRIDGE 29
HWRES_SPAR1 Suction valve control output OD,LOW-SIDE 31
O2HEAT1 Output PWM command Lambda heater N°1 OP,LOW-SIDE 32
INJ3_1 Injector control output N°3 block 2 high injectors OFA,LOW-SIDE 34
RPM+ Input r.p.m. sensor (+) (VRS +) IFA,DIFFERENZIALE 35
AIRTEMPA Input air temperature sensor signal IA,PULL-UP,RATIO 37
KEYREQ Input switch control panel key ID,PULL-DWN 40
DBW1+ Output command + DCM exhaust butterfly valve OP-HBRIDGE 41
PPWS_BAT Control unit direct protected power POWER-SUPPLY 42
O2HEAT2 Output PWM command EBS valve OP,LOW-SIDE 44
PHASEIN Input engine HALL phase sensor IFA,PULL-UP 47
TPS1 Throttle body throttle position input (TPS) IA,PULL-UP,RATIO 48
TPSRED1 Exhaust valve throttle position input IA,PULL-UP,RATIO 50
SNSSPLY1 Output VREF 1 +5V, for TPS SENSOR-SUPPLY 51
PWS Direct power supply to control unit POWER-SUPPLY 52
INJ1_2 Injector control output N°1 block 1 low injectors OFA,LOW-SIDE 53
WARNLAMP Output command “Warning Lamp” OD,LOW-SIDE 54
CANISTVALVE Output command “secondary Air” valve OP,LOW-SIDE 55
CLUTCHSW Input clutch sensor switch ID,PULL-UP 56
SNSSPLY2_GND Pressure sensor analog mass SENSOR-GROUND 57
ENGSTART Input switch “start engine” ID,PULL-UP 58
HARDWIRING Output light relay command OD,LOW-SIDE 60
FANRELA_FANVALVE Output relay command electric fan OD,LOW-SIDE 61
VENTVALV_TRBT Output TSS valve control OD,LOW-SIDE 62
SNSSPLY2 VREF2 +5V ,output, for atmospheric pressure sensor SENSOR-SUPPLY 63
NEUTRALSW Input switch sensor idle ID,PULL-UP 64
TIPOVER Input tilt switch sensor ID,PULL-UP 65
CANL CAN Line L ( HIGH SPEED ) BC,HIGHT SPEED 66
AB_AVVIA Output direct command remote control solenoid starter OD,LOW-SIDE 69
SIDESTAND Input switch side-stand ID,PULL-UP 70
IVGTPS Input analogic sensor gear IA,PULL-UP,RATIO 72
FPUMPREL Output power relay control (fuel pump - coil - injectors) OD,LOW-SIDE 73
TACHOUT R.p.m. counter control output OP,LOW-SIDE 75
SPAREDG Calibration map selection digital input ID,PULL-UP 76
RUNSTOPSW Input switch “engine stop” IA,PULL-DWN 78
VEHSPD Input HALL sensor vehicle speed IFT,PULL-UP 79
CANH CAN Line H ( HIGH SPEED ) BC,HIGHT SPEED 80
AI: Analog input - DI Digital input - AIF: Analog input frequency - DIF: Digital input frequency - FO: Frequency output -
DO: Digital output- PO: PWM digital output- BC: Communication line
- 19 -
- 20 -
Electrical system
SECTION
Revision 1
E
-1-
Electrical system
SUMMARY
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3
COUPLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3
SEMICONDUCTOR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 4
ELECTRICAL DIAGRAM F4 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 5
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 6
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 7
INITIAL CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 7
BATTERY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 8
RECHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 11
EFFICIENCY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 13
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 14
STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 18
STARTER MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 18
STARTER MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 18
E STARTER RELAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 19
TILT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 20
GEAR POSITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 21
SIDE STAND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 21
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 22
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 23
MAIN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 24
ENGINE PICK-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 25
TIMING WHEEL GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 26
RUN-OFF SAFETY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 26
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 27
OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 28
FUEL LEVEL WARNING LIGHT SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 28
WATER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 29
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 29
STARTER RELAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 30
TURN INDICATORS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 30
R.P.M. SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 30
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 31
LOW BEAM HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 31
HIGH BEAM HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 32
TURN INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 33
REAR TAIL LIGHTS AND BRAKE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 33
LICENCE PLATE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 34
ELECTRIC FAN COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 34
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 35
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 36
POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 37
-2-
Electrical system
CONNECTORS
• When a connector is connected, check that it clicks
into position.
• Check the connector for corrosion, dirt or a broken
cover.
CLICK
COUPLINGS
• Block couplings – ensure that the block is released CLICK
before disconnecting it to push it completely home
when connecting it.
• When disconnecting a coupling, ensure that the
body of the coupling is gripped and do not pull it
apart by the leads.
• Check that the terminals of the couplings are not
slack or bent.
• Check that the terminals are not corroded or dirty.
FUSES
• When a fuse burns out, always investigate why the
fuse has burnt out. Find the cause, repair and then
substitute the fuse.
• Do not utilise a fuse of a different capacity from the
original one.
• Do not utilise wire or any other substitute for the
fuse.
-3-
Electrical system
SEMICONDUCTOR PARTS
• Do not drop semiconductor parts such as those
INCORRECT
incorporated in the ECU.
• When checking these parts, carry out the instruc-
tions to the letter. The lack of using the correct pro-
cedure can cause grave damage.
-4-
Electrical system
ELECTRICAL DIAGRAM F4 1000
5B 5C 5A
-5-
Electrical system
Parts list Parts list
Ref. Description Ref. Description
1 CPU 33 Rear stop switch

2 Number plate light 34 Ignition switch
3 Right indicator 35 Safety and Front stop switch
4 Left indicator 36 Right indicator
5 Diagnostic connector (5A-serial line 37 Front headlight
RX; 5B-Ground; 5C-serial line TX) 38 Instrument panel
6 Main relay 39 Air pressure sensor
7 Rear and stop light 40 Left indicator
8 Neutral switch 41 Horn
9-10 Battery 42 Air temperature sensor
11 Fuel probe – pump 43 Light switch
E 12 R.p.m. sensor 44 Relay ballast headlight
13 Coil 45 Exhaust valve actuator
14 Coil 46 Immobilizer Antenna
15 Coil 47 Fan relay
16 Coil 48 Battery recharge
17 Alternator 49 Clutch switch
18 Speed sensor 50 Starter motor
19 Solenoid starter 51 Frame earth
20 General feed relay 52 Voltage regulator
21 Intermittency 53 TSS valve
22-23 Upper injectors 54 Additional CAN socket
24-25 Upper injectors 55 Angular switch
26 Throttle potentiometer 56 Secondary air system
27 Water temperature sensor – CPU 57 Lambda sensor
28 Oil switch 58-59 Lower injectors
29 Electric fan 60-61 Lower injectors
30 Fuses
31 Electric fan
32 Side stand switch
Wiring colour code Fuses list
Letter(s) Colour Ref. Amps Use

(A)
R Red
Y Yellow F1 15 Speed sensor - Lambda sensor -
B Blue Intermittence - Solenoid starter -
G Green Solenoid secondary air
W White F2 15 High beam
Bk Black F3 15 Ballast front light
P Pink
F4 15 Coils
V Violet
F5 15 Electric fans
Sb Sky blue
F6 15 Fuel pump - Injectors
Gr Grey
F7 15 Central unit - Stop light
O Orange
F8 40 Battery recharge
Br Brown
F9 40 Battery recharge supply
In combined colors, background and marking colors have
been pointed out. E.g.: Br/Bk.
-6-
Electrical system
BATTERY
The battery mounted on this motorcycle is a sealed
battery therefore no maintenance is required.
The following battery is used: KOYO KTZ-10S
This is a sealed battery with breather valve. No elec-

trolyte level checking is required.
Never remove the battery seal caps nor block

the breather opening.
CHARGING THE BATTERY

Charge the battery using the current and charging time
shown on the battery itself.
To avoid overcharging the battery, we recommend
using the constant voltage charging method as speci-
fied in the table below:
Method V C A Charging time

(voltage) (temperature) (charging current) (hours)
Normal 14,4 20 0,25xC 12-24
Fast 14,4 20 1xC 6-8
Should the engine fail to start, charge the battery again

using the same amperage and the same charging
time.
Overcharging the battery or charging it rapidly may

lower the level of the electrolyte, thus making the bat-
tery unusable.
NOTE Voltages lower than 11.8V shorten the life

and impair the operation of the battery.
Checking stored batteries once a month pro-
longs their life while keeping them in perfect
working order for future use.
-7-
Electrical system
BATTERY ASSEMBLY
1) Perform the initial charge of the battery according to
the instruction to page 7.
2) Insert the motorcycle key in the rear lock. Rotate the

key clockwise while removing the pillion. Then remove the
rider’s saddle as shown in the picture.
3) Remove the frame plate (1) to facilitate the following

operations.
4) Remove the solenoid starter (2) securing screw to

allow the insertion of the battery.
1
-8-
Electrical system
5) Insert the battery in its proper compartment.
6) Fit the 2 positive terminals (+) on the corresponding

battery pole, respecting their disposition as shown in
the figure. Rotate the positive terminals screw and tigh-
ten it at a torque equal to 7 ÷ 8 Nm. Afterwards, fit the
protective cap on the positive pole.
Torque pressure: 7 ÷ 8 N·m
7) Fit the 2 negative terminals (-) on the corresponding

battery pole, respecting their disposition as shown in
the figure. Rotate the negative terminals screw and
tighten it at a torque equal to 7 ÷ 8 Nm.
8) Reinstall disassembld parts by inversely performing

the operations described in the phases 2-3-4.
-9-
Electrical system
Wait at least twenty-four hours before positioning the battery in the compartment.
This is strictly necessary for this motorcycle as the battery is positioned horizontally, as shown
in the diagrams below
POSITIVE POLE (+) NEGATIVE CABLE (-) NEGATIVE POLE (-)
POSITIVE CABLE (+)
NEGATIVE CABLE (-)
E
PROTECTIVE CAP
• Check the voltage charge after about thirty minutes

at the battery terminals.
Voltage > 12,5 Volt.
- 10 -
Electrical system
CHARGING SYSTEM
Warning function
Conditions of abnormal operation of the battery char-

ging function (voltage ≥ 10V) is indicated by the war-
ning lamp on the dashboard.
As shown in the figure, the temperature influences the

characteristics of the regulator with steps of variation of
the regulated voltage.
-9-
Electrical system
A list of possible problems that could occur when the warning light is switched on.
PROBLEMS
SI OCCUR
RISCONTRANO PROBLEMI RESTORE OR O
RIPRISTINARE CLEAN CON-
PULIRE LA WARNING
SPIA LIGHT
ANCORA STILL ON
ACCESA
SULLA CONNESSIONE
WITH CONNECTION YES
SI NECTION
CONNESSIONE
POSITIVO
POSITIVE SU
ONBATTERIA
BATTERY
NO SI
YES
PROBLEMS
SI OCCUR PROBLEMI
RISCONTRANO RESTORE OR O
PULIRE LA WARNING
SPIA LIGHT
ANCORA STILL ON
ACCESA
WITH CONNECTION
SULLA CONNESSIONE YES
SI NECTION
CONNESSIONE
POSITIVE ON
POSITIVO SUREMOTE
TELERUTTORE
CONTROL SWITCH
NO YES
SI
E
PROBLEMS
SI OCCUR
RISCONTRANO PROBLEMI RESTORE OR O
PULIRE LA WARNING LIGHT
SPIA ANCORA STILL ON
ACCESA
WITH CONNECTION
SULLA CONNESSIONE
YES
SI NECTION
CONNESSIONE
NEGATIVESU
NEGATIVO ONBATTERIA
BATTERY
NO SI
YES
PROBLEMS OCCUR
SI RISCONTRANO PROBLEMI RESTORE OR O
PULIRE LA WARNING
SPIA LIGHT
ANCORA STILL ON
ACCESA
ON CONDITION
SULLO OF CONNEC-
STATO DEL YES
SI NECTION
CONNESSIONE
TOR OF THE SOLENOID
CONNETTORE SUL
STARTER
TELERUTTORE AVVIAMENTO
NO YES
SI
PROBLEMS OCCUR
SI RISCONTRANO ON
PROBLEMI RESTORE OR O
RIPRISTINARE CLEAN FUSE
PULIRE LE WARNING
SPIA LIGHT
ANCORA STILL ON
ACCESA
CONDITION
SULLO STATOOFDEL
FUSE OF
FUSIBILE
YES
SI ENDS
TERMINAZIONI DEL FUSIBILE
REMOTE CONTROL IGNI-
SUL TELERUTTORE
TION SWITCH
AVVIAMENTO
NO YES
SI
CHECK VOLTAGE
VERIFICARE ON TERMI-
LA TENSIONE SU VERIFICARE LO STATO
CHECK CONDITION OFDELLE
THE REPLACE ACG
SOSTITUIRE L'ACG
NALS OF VOLTAGE
TERMINALI REGULA-
DEL REGOLATORE
YES
SI TRE FASI
THREE PHASES OF THE YES
SI
TOR
DI TENSIONE ALTERNATOR
DELL'ALTERNATORE
NO
SOSTITUIRE
REPLACE IL REGOLATORE
VOLTAGE REGU-
LATOR
DI TENSIONE
- 12 -
Electrical system
BATTERY EFFICIENCY CHECK

Battery current loss check
• Remove the seats as described in chapter C
“Bodywork”.
• Turn the ignition switch to the “OFF” position.
• Disconnect the cable from the negative (-) pole of
the battery.
• Connect the multi-tester between the negative (-)
terminal and the negative (-) cable of the battery.
Losses are indicated if the tester measures more than

2÷2.5mA.
Battery current loss: less than 1mA.

E
First of all when using an ampmeter, utilise a
high range of the multi-tester because the
current losses in the case of malfunctioning
could be elevated
Do not turn the ignition switch to the ON
position while measuring the current.
If losses are found, search for the part where the tester
measures less than 2÷2.5mA by removing couplings
and connectors one at a time. Red lead Black lead
Charge feed check

• Remove the seats as described in chapter C
“Bodywork”.
• Start the engine and run it at 2000 rpm with the
lights switch in the high beam position Hl.
- 13 -
Electrical system
Measure the DC voltage between the positive (+) and

the negative (-) terminals of the battery with a multi-
tester. If the tester indicates less than 12.6V or more
than 14.5V the cause will be found in the generator.
Battery
NOTE When carrying out this check, ensure that
the battery is fully charged.
Feed charge
Standard: 12.6V – 14.5V at 2000 r.p.m.
STARTER SYSTEM
The diagram below represents the starter system.
START SWITCH CLUTCH LEVER GEAR POSITION STAND POSITION
RUN PULLED NEUTRAL UP
RUN PULLED NEUTRAL DOWN
RUN PULLED ANY UP
- 14 -
Ignition key in the “ON” position SAFETY SWITCH
SOLENOID
Safety switch in the “RUN” position KEY SWITCH STARTER
Start activated NEUTRAL
SERVICE FUSE
CLUTCH
MAIN RELAY
INJECTOR FUSE
FULE PUMP,
COIL, ECU FUSE

SWITCH SWITCH
INJECTORS RELAY
FUEL PUMP - COILS -
Side stand out BATTERY
Gear not engaged

Clutch not pulled in
Engine is starting
FUEL TANK
- 15 -
Electrical system
TILT SENSOR
PLUG-TOP
COILS
PRESSURE SENSOR
THROTTLE BODY UNDER THROTTLE
UPPER INJECTRS
PICK-UP WHEEL SIDE STAND SWITCH
THROTTLE BODY
LOWER INJECTRS
E
E
Ignition key in the “ON” position
SAFETY SWITCH
KEY SWITCH STARTER
Start activated
NEUTRAL
SERVICE FUSE
CLUTCH
MAIN RELAY
INJECTOR FUSE
FULE PUMP,
COIL, ECU FUSE

SWITCH SWITCH
INJECTORS RELAY
FUEL PUMP - COILS -
Side stand out BATTERY
Gear engaged
Clutch pulled in
Engine is starting
FUEL TANK
- 16 -
Electrical system
TILT SENSOR
PLUG-TOP
COILS
PRESSURE SENSOR
UPPER INJECTRS
THROTTLE BODY
LOWER INJECTRS
Ignition key in the “ON” position
SAFETY SWITCH
KEY SWITCH STARTER
Start activated
NEUTRAL
SERVICE FUSE
CLUTCH
MAIN RELAY
INJECTOR FUSE
FULE PUMP,
COIL, ECU FUSE

Side stand out SWITCH SWITCH
INJECTORS RELAY
FUEL PUMP - COILS -
BATTERY
Gear NOT engaged
Clutch pulled in
Engine is starting
FUEL TANK
- 17 -
Electrical system
TILT SENSOR
PLUG-TOP
COILS
PRESSURE SENSOR
UPPER INJECTRS
THROTTLE BODY
LOWER INJECTRS
E
Electrical system
STARTER MOTOR REMOVAL

• Remove the fuel tank (see chapter C “Bodywork”).
• Drain off the engine coolant, completely emptying
the cylinder passageways via the two screws situat-
ed on the front part of the cylinders.
• Remove the coils from the frame support.
• Remove the blow-by cover.
• Disconnect the cable of the pick-up.
• Disconnect the alternator connector.
• Remove the coolant liquid pump by disconnecting
the rubber union from the conduit that brings the
coolant liquid to the cylinders. Remove the conduit
of the cylinder cooling system.
• Disconnect the cable of the starter motor.
• Remove the two fixing screws of the starter motor.
• Remove the starter motor by extracting it as indi-
cated in the figure.
E
STARTER MOTOR CHECK

If a fault has been diagnosed in the starter motor, it is
necessary to proceed as follows with the check:
• Connect a tester between earth and the starter
motor terminal.
• Check that there is continuity between the positive
pole and the engine earth. If there is no continuity,
substitute the starter motor.
STARTER MOTOR ASSEMBLY

Assemble the starter motor in the reverse order of
removal. Pay attention to the following points:
Substitute the O-ring with a new one to avoid

oil leakage and the ingress of humidity.
• Apply grease to the oil seal lip.

• Apply a small quantity of MOLYKOTE to the rotor
shaft.
• Apply a small quantity of LOCTITE 243 to the bolts
of the starter motor.
- 18 -
Electrical system
STARTER RELAY CHECK

• Remove the seat as described in chapter C
Superstructures.
• Disconnect the relay from the support plate.
• Disconnect the start-up relay connector.
• Disconnect the cables from the negative pole of the

battery to avoid short circuits during assembly.
- 19 -
Electrical system
• Disconnect the cables of the starter motor and the

positive cable of the battery from the relay.
Apply 12 volts to the terminals (1) and (2) of the relay

and check the continuity between terminals B-M.
Do not apply the battery voltage to the starter

relay for more than five seconds to avoid
overheating and therefore damaging the
winding.
• Using a multi-tester, check that the winding is on

open circuit or if a resistance is present. The wind-
ing is in good condition if the value of the resistance
revealed is as indicated.
Multi-tester dial indication: Ω

Starter relay resistance
Standard: 3 – 6 Ω
TILT SENSOR
The fall sensor (1) acts on the engine control unit, inter-
rupting power when a vehicle tilt of more than 60° is 1
detected.
- 20 -
Electrical system
GEARCHANGE POSITION SWITCH

The connector (1) of the gear position sensor is loca- 1
ted on the left beneath the tank.
Disconnect the connector of the gear position switch
and check the resistance value, using a multitester, in
the six gears as well as the idle position, as shown in
the attached table.
When the connector of the gearchange posi-

tion switch is connected and disconnected,
be sure to turn the ignition switch to the
“OFF” position to avoid damaging the elec-
tronic parts.
SIDE STAND SWITCH
The connector for the lateral stand switch is mounted

on a support under the pinion wheel transmission
casing on the left side of the motorcycle.
• Remove the left fairing.

• Disconnect the connector of the side stand switch.
- 21 -
Electrical system
Utilising a multi-tester, check the continuity as indica-

ted in the table.
Green Brown Black

ON (Raised)
OFF (Lowered)
After the tests described above, whenever it is neces-

sary to replace the switch, proceed as indicated in
chapter B Maintenance.
FUSES
The fuses are situated on the left side of the motorcy-
cle.
Lift the rubber cover.
Replace the burnt fuse with the provided tweezers and

then close the cover back up.
To identify the position and function of fuses, consult
information contained in the manual and in the wiring
diagram.
- 22 -
Electrical system
The charge fuse is situated under the seat, in the posi-

tion indicated on the starter relay.
To accede to this component it is necessary to remove

the following parts: Spare fuse
• The driver’s seat;
• Remove the plastic covers on both fuses.
• Substitute the left fuse with the pare one as shown Recharge fuse
in the figure.
• Fit a new 40A fuse in the spare fuse holder as soon
as possible.
SPARK PLUGS
Remove the components of the motorcycle to remove
the spark plugs as described in chapter B “Mainte-
nance”.
Remove the spark plugs utilising the appropriate

16mm hexagonal spark plug spanner.
- 23 -
Electrical system
Check the resistance between the electrode and the

screw cap of the spark plug as shown in the figure.
Permitted resistance: 4.5 ÷ 5.5 K
Carry out the test on all the spark plugs.
Do not use non-resistive spark plugs..
MAIN RELAY
The main relay is situated on the left side and it is iden-

tified by the “M” letter.
The first thing to check is the isolation between the ter-

minals (2) and (4) with a tester.
Apply 12V to the terminals (1) and (3) and check the
continuity between terminals (4) and (2). If there is no
continuity, substitute the relay with a new one.
- 24 -
Electrical system
ENGINE PICK-UP
The engine pick-up is situated on the left side of the
motorcycle. To check this component it is necessary to
identify the relative connector positioned as shown in
the figure, inside the frame on the left side of the motor-
cycle.
After having disconnected the pick-up connector, mea-

sure the resistance between the two points identified by
a (+) and a (-) that are indicated on the connector.
Pick-up resistance value: ~ 680 – 700 Ω
- 25 -
Electrical system
TIMING WHEEL GAP

0.7
To guarantee the correct functioning of the pick-up it is 0.6 ÷
necessary to measure the gap between the pick-up
and the timing wheel by utilising a feeler gauge as
Gap width: 0.6 – 0.7 mm
To carry out this check it is necessary to remove the

cover of the timing wheel by consulting the Workshop
Engine Manual.
RUN OFF SAFETY SWITCH

Remove the right fairing side panel as described in
chapter C “Bodywork”.
Remove the relative connector to the right hand control

group as indicated in the figure.
- 26 -
Electrical system
Remove the connector holding device.
With the switch in the “RUN” position, check the conti-

nuity between pins (5) and (2).
INSTRUMENTATION
If faults are found in the instrumentation, it is necessary
1
to check the main wiring and the various components
assisted by the same instrumentation. To carry out the
various checks after having removed the fairing side
panels and the nose fairing as described in chapter C
“Bodywork”, it is necessary to remove the rubber cap
(1) and then the connector situated behind the instru-
mentation.
- 27 -
Electrical system
Consult the diagram below to identify the contacts of

the various components:
16 pin AMP 174975-2
1 Supply 9 ID warning led

2 Gnd 10 Oil pressure
3 + CAN 11 Ignition key
4 - CAN 12 Serial Tx
5 13 Serial Rx
6 High beam 14 Immobilizer
7 Fuel warning led 15 Immobilizer
8 Hazard out 16
OIL PRESSURE SENSOR

To check the good functioning of this component with
the engine switched off, it is necessary to find the con-
tinuity between the contact of the sensor and the earth
of the motorcycle as shown in the figure.
With the engine switched on, the contact must be inter-
rupted.
FUEL LEVEL WARNING LIGHT CHECK SWITCH
After having checked the breakdown of the fuel reser-

ve warning light, check that there is continuity between
terminal 4 of the tank flange and terminal 7 of the dash-
board.
- 28 -
Electrical system
Having ascertained the good condition of the fuses in

question, proceed as follows:
With the fuel tank removed from the motorcycle and
empty of fuel, connect a small circuit composed of 12V
battery and a light bulb of 12V – 1.7W to the connector
of the fuel level indicator as shown in the diagram.
If the switch is in a good condition, the light bulb should
light up after several seconds.
Pour some fuel into the fuel tank and confirm that the
light bulb switches off after having poured more fuel
into the tank than the maximum required for the reser-
ve.
WATER SENSOR
Verify sensor operation by measuring resistance
between the pin by means of a tester.
TEMP. °C RESIST. kΩ TEMP. °C RESIST. kΩ

- 40 100,950 + 40 1,598
- 30 53,100 + 50 1,150
- 20 29,121 + 60 0,746
- 10 16,599 + 70 0,565
0 9,750 + 80 0,377
+ 10 5,970 + 90 0,275
+ 20 3,747 + 100 0,204
+ 25 3,000 + 110 0,153
+ 30 2,547 + 125 0,102
KEY SWITCH
Whenever the dashboard, with the switch on the ON
position, is not powered, first check the conditions of
the fuse located on the start-up remote switch under
the seat and, if this should be in good condition, check
the conditions of the fuse located in position 1 on the
fuse box.
Check these two conditions; if the defect remains,

check continuity between pins 3 and 4 of the key block
connector.
- 29 -
Electrical system
STARTER RELAY ACTIVATION

• With the engine cut-off switch in the RUN position, press
and hold down the starter button and check if 12V is sup-
plied between relay switch wires B/Y and O/Y.
• If that is not the case, check if voltage is present
between the B/Y wire and ground
• If there is no voltage input , check the condition of
fuse E5 after which check the right hand control as
follows:
1) Disconnect the connector of the right hand con-
trol.
2) With the engine cut-off switch in the RUN posi-
tion, check for continuity between pins (2) and (5),
and then check for continuity between contacts (1)
and (3) while pressing the starter button.
3) If the right-hand control is in good working order,
E the problem is due to a malfunction in the engine
control unit and its connections.
TURN INDICATORS
If the blinker warning lights do not work, continuity
must be checked on the cable R-B between terminal 7
of the switch connector and terminal 9 of the dash-
board connector.
R.P.M. SENSOR
Engine rev information on the dashboard arrives by
means of a CAN line; therefore, if this information is not
displayed and the message CAN ERROR appears on
the dashboard, the problem can be attributed to the
dashboard.
- 30 -
Electrical system
SPEED SENSOR
Whenever the speed is not indicated on the dashboard

and the message SPEED SENSOR appears, proceed
as follows:
• Check the conditions of the fuse in position 1 on the

fuse box.
If the fuse in question is in good condition, proceed

with the check of the speed sensor as follows:
Keeping the sensor connected to the system and with
the key in the ON position, using a tester, check that
when the sensor is positioned in front of one of the nuts
of the brake disk, between terminal 3 and terminal 2 of
the connector, the voltage is close to zero, whilst when
it is not placed in front of one of the nuts, the voltage is
close to that of the battery.
LOW BEAM HEADLIGHT

In the event that the dipping beam does not work,
check the conditions of fuse 3 on the fuse box. If this
fuse is ok, check the conditions of the relay situated on
the left side of the motorcycle, with the label "B".
If this is also ok, check continuity of the R/W cable

which goes from relay "B" to the engine control unit at
terminal 31.
- 31 -
Electrical system
HIGH BEAM HEADLIGHT

In the event that the driving beam does not work, check
the conditions of fuse 2.
If the fuse is ok, check the continuity of the left handle-

bar control connector between positions 1 and 10 with
the driving beam function selected.
If this is also ok, the problem can be attributed to the

headlight unit.
- 32 -
Electrical system
After having checked the bulbs of the headlight, the rel-

ative fuses and the controls as described herewith,
proceed with checks of the relays mounted on the left
side of the motorcycle.
TURN INDICATORS
In the event that turn indicators do not work, check the
conditions of fuse 1 on the fuse box.
If the fuse is ok, check the continuity between terminals

6-7 and 6-5 respectively for left and right indicators on
the left control.
Stop and rear light

In the event that tail lights and brake lights do not work,
check the conditions of fuse 7 for the brake light and 1
for tail lights.
If these are ok, check the continuity of terminals 2 and

8 on the right control.
- 33 -
Electrical system
LICENCE PLATE LIGHT

If the number plate light bulbs do not function, check
the condition of fuse 1 in the fuse box; if these are ok,
replace the bulb.
• Extract the light bulb holder.
• Extract the light bulb.

• Insert the new light bulb.
• Reinsert the light bulb holder.
COOLING FAN SYSTEM
If there is a fault in the functioning of the cooling fan,

proceed with the following check:
• Check the condition of fuse 5;
• If the fuse is in good condition, check the cooling fan
relay mounted on the left side of the motorcycle
markedwith the letter “F”.
- 34 -
Electrical system
If the relay is in good condition but is not energised

aboard the vehicle, disconnect the connector on the
temperature sensor. Make a bridge between the two
contacts as shown in the figure.
With the key in the ON position, after just a few
seconds the fans should start rotating.
If this does not happen, check the continuity of the
system.
If this condition is also met, the problem lies with the
temperature sensor.
HORN
A fault in the horn system should be checked at various

points:
3
• Check the condition of fuse 1 in the fuse box.
• If the fuse is in good condition, disconnect the con-
nector of the left control and check the continuity
between contact 3-4 of the control with the horn but-
ton pressed as in the following page under
“Switches”.
• Check the continuity of the winding of the horn.
- 35 -
Electrical system
SWITCHES
Check the continuity of each switch with a tester. If there is any anomaly, substitute the respective switch unit with
a new one.
R.H. switch
L.H. switch
- 36 -
Electrical system
POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS
LIST OF FASTENING CLAMPS FOR F4 1000 ELECTRICAL SYSTEM CABLES

ELENCO FASCETTE PER FISSAGGIO CAVI IMPIANTO ELETTRICO F4 1000
Code Codice Qty. Qt. Length
Lunghezza Name
Denominazione
800092248
80009224811 11 L=L 82= mm
82 mm Rubber
Fascetta clampL L8282
in gomma
80009224713
800092247 13 L=L 62= mm
62 mm Fascetta in gomma
Rubber clampL L6262
8000537245
800053724 5 L = L39= mm
Rubber clampL L3939
8000926681
800092668 1 L = L25= mm
Rubber clampL L2525
8000567832
800056783 2 L = 142 mmmm
L = 142 FascettaPlastic
in plastica
clampperfor
cavi
cables
8000B44251
8000B4425 1 - - Fascetta
Clamp
For
Per correct
eseguirepositioning
il correttoof posizionamento
the electrical wiring
del
on the motorcycle, first insert the
cablaggio elettrico sulla motocicletta, main cable
connector
inserire on the injection control
preliminarmente il unit as
connettore E
START
shown in fig. 01.
principale del cablaggio sulla centralina
iniezione come mostrato in fig. 01.
Before fastening
Prima di fissare the in
injection
sede control unit in
la centralina
its housing,posizionare
iniezione, position theilPierburg valve
tubo della tube
valvola
as shown in Fig. 02.
Pierburg come mostrato in Fig. 02. Fig. 01
N.B.:Note: Be careful
Prestare attenzione
al to correctly
corretto pass
passaggio
thetubo
del Pierburg valve
valvola tube
Pierburg
Fig. 02
- 37 -
Electrical system
Insert 1 protective clamp (Code 8000B4230) on the throttle body clamps present on the right
Inserire N° 1 fascetta di protezione (Cod. 8000B423 0) sulle fascette del corpo farfallato
side of the motorcycle (see Fig. 03).
presenti sul lato dx della moto (vedi Fig. 03).
Protective
Fascetta clamp
di protezione
Code 8000B4230
Cod. 8000B4230
Fig. 03
E
Note:
N.B.: Be careful
Prestare attenzione
to correctly position the
al corretto posizionamento
node and ethe
del nodo delTPS
cavo cable
TPS
For the position of the clamps for fastening electri-

Persystem
cal il posizionamento
F4 1000 cables,dellerefer
fascette
to therelative
layout al
fissaggio dei cavi dell’impianto
shown below (see figs. 04-28). elettrico F4 1000,
riferirsi alle disposizioni mostrate nelle figure
seguenti (vedi figg. 04–28).
Code
Cod. 800092247
– L= 62
Code
Cod. 800092248 Code
Cod. 800092247
– L= 82 – L= 62
Code
Cod. 800053724
– L= 39
Fig. 04
- 38 -
Electrical system
Prestare attenzione
to correctly
al corretto pass
passaggio
cables
dei cavi
Code
Cod. 800092247 – L= 62
Code
Cod. 800092248 – L= 82
Fig. 05
Prestare attenzione
al to correctly
corretto pass
passaggio
cables
dei cavi
- 39 -
Electrical system
Code
Cod. 800092248 Code
Cod. 800092248
– L= 82 – L= 82
Code
Cod. 800092248
– L= 82
Fig. 06 Note:
N.B.: Be carefulattenzione
Prestare to ensure
correct assembly
alla corretta phasing
fasatura di
of the cable lug
montaggio del capocorda
Prestare attenzione
al to correctly
corretto pass
passaggio
cables and
dei cavi the tubo
e del blow-by hose
blow-by
- 40 -
Electrical system
Fig. 07 Code
Cod. 800092247
– L= 62
Fig. 08
Note:
N.B.: Position nodo
Posizione the
branching node on
di diramazione sulthe
right side
lato dx of
delthe frame
telaio
Note the correct

Prestare passage
attenzione of vacuum
al corretto gaugedei
passaggio tubes
tubi on
perboth the left and
il vacuometro siaright
sul sides
lato sxofche
thesul
motorcycle (see figs. 09-10).
lato dx della motocicletta (vedi figg. 09-10).
Fig. 09 Fig. 10
- 41 -
Electrical system
--Position 1 adhesive
Posizionare N° 1 protection
protezionecode 8000B4924
adesiva cod. on the front4right
8000B492 sul side
tuboframe
ant. tube, firstlato dx
telaio
applying the upper edge as shown in Fig.11.
applicandone inizialmente il bordo superiore come mostrato in Fig. 11.
Protection
Protezione
(Code. 8000B4924)
(Cod. 8000B4924)
Fig. 11
--Wrap the adhesive
Avvolgere protection
la protezione around
adesiva the frame
intorno al tubotube ande complete
telaio application
completarne taking care
l’applicazione avendoto
stretch
cura diitdistenderla
evenly to avoid air bubblesallo
uniformemente (see Fig. di
scopo 12).
evitare la formazione di bolle (vedi Fig. 12).
Fig. 12
--Apply 1 adhesive
Applicare protection code
N° 1 protezione 8000B4924
adesiva on the front
cod. 8000B4924 sulleft sideant.
tubo frame tubelato
telaio in the
sx same
in modo
way as described above for the right side tube.
analogo a quanto sopra descritto per il tubo lato dx.
- 42 -
Electrical system
Screw cap Code

Cappuccio
(Code
per vite
800094896)
(Cod. 800094896)
Code
Cod. 800092247
– L= 62
Cod. 800092248
– L= 82 Fig. 13
Note:
N.B.: be
prestare
careful to al
attenzione correctly
corretto
pass cables
passaggio dei cavi
Code
Cod. 8000B4425 Note:
N.B.: Be careful
Prestare to
attenzione
correctly position
al corretto Code
Cod. 800053724
cables dei cavi
posizionamento – L= 39
Fig. 14 Fig. 15
- 43 -
Electrical system
Fig. 16 Code
Cod. 800092247
– L= 62
Note:
N.B.: Be careful
Prestare
to attenzione
correctly pass
al
correttocables
passaggio
Note:
N.B.:Be careful
Prestare dei cavi
to correctly
attenzionepass
al
cables
corretto passaggio Code
Cod. 800053724
dei cavi – L= 39
Code
Cod. 800053724 Note: Be careful
N.B.: Prestareof the
– L= 39 burr on thealla
attenzione engine
bava
casing
sul carter motore
Note: BePrestare
N.B.: careful of
the burr on
attenzione the
alla oil
bava
sulla guarnizione
pan gasket
coppa olio
Note: BePrestare
N.B.: careful to
correctly pass
attenzione al
cables
corretto passaggio
Fig. 17 Fig. 18 dei cavi
- 44 -
Electrical system
Code
Cod. 800092668 Fig. 19 Fig. 20
– L= 25
Code 800056783
Cod. 800056783
(plastic)
(plastica)
Code
Cod. 800092247
– L= 62
3-way rear
Connettore
headlight AMP
AMP 3 vie
Fig. 22 fanale post.
connector
Code 800056783 Rear indicator

Cod. 800056783 Frecce post.+
(plastic)
Fig. 21 (plastica)
Fig. 23 Number plate
+ Luce targalight
- 45 -
Electrical system
Note: BePrestare
N.B.: careful to
correctly
attenzione al pass
corretto
Code
Cod. 800092248 cables
passaggio dei cavi
– L= 82
Code
Cod. 800092247
– L= 62
Note: Position the

N.B.: Posizionare il
Code
Cod. 800092247 wiring
nodo del node at the
cablaggio
Fig. 24 – L= 62 beginning
all’inizio
weld
di
of the
del cordone
bead
saldatura
Protection
Guaina di
sheat
Fig. 25 Code
Cod. 800092247
– L= 62
protezione
(Cod. 8000B4963)
Code
Cod. 800092247
– L= 62
Wiring protection
Protezione cablaggio Note:
N.B.:Slip off la
Sfilare the
Code
Cod. 8000B4776
8000B4776 wiring sheath
guaina cablaggiountil
(Assemble
(Montare conwith itfino
reaches the nella
a portarla posi-
LOCTITE 5900)
Loctite 5900) Fig. 26 tion indicated
posizione indicata
- 46 -
Electrical system
Note:
N.B.:Be careful
Prestare
to correctly
attenzionepass
al
cables
corretto passaggio
dei cavi
Fig. 27
Note:
N.B.:Be careful
Prestare
to correctly
attenzionepass
al
cables
corretto passaggio
dei cavi
Fig. 28
- 47 -
Electrical system
- 48 -
Suspension and wheels
SECTION
Revision 0
F
-1-
SUMMARY
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

FRONT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 10
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 25
REAR SUSPENSION AND SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 37
REAR WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 59
MOTORCYCLE SET-UP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 75
WHEELS - CHECK AND BALANCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 78
-2-
FRONT WHEEL
G
F
A
E
B
D
C
B
A
A B C D E F G
N·m 20 ÷ 22 40 ÷ 44
Torque
pressure Kg·m
ft·lb
Operation
Description F4 1000
FRONT WHEEL
FRONT TYRE
Dimensions 120/70-ZR 17 (58W)
DUNLOP - Sport Max Qualifier RR
Front tyre pressure At a speed lower than 300 km/h At a speed higher than 300 km/h
PIRELLI 2.3 bar (33 psi) 2.5 bar (36 psi)
DUNLOP 2.3 bar (33 psi) 2.5 bar (36 psi)
-3-
FRONT WHEEL REMOVAL
Special tool N. 800092642
Front brake caliper removal

F Unscrew the two fixing screws of both front calipers
and remove the calipers.
Protect the disassembled calipers with pro-

tective material thereby avoiding possible
damage to the wheel rim.
Lift the motorcycle up at the front end.

Mount the special tool that is supplied with a pin on the
lower part of the steering base as shown in the figure.
Lift the motorcycle up.
Special tool No. 800095807 and No. 800095808
-4-
Remove the screw on both front wheel/fork attach-

ments.
During this operation, it is necessary to

support the wheel.
Open the terminals (1) and remove the wheel with its
spindle.
Front wheel bearing check

With the wheel spindle still mounted to the wheel, F
rotate the wheel to check that the bearings are not pit-
ted and rotate with a smooth action. Check also for
axial (A) and/or radial (B) movement. If either condition
is verified, substitute the bearings.
Front wheel bearing substitution

Remove the wheel spindle utilising the special tool as
Special tool N. 8000B4412
-5-
Utilise the special tool to extract the bearings. To

assemble the tool, it is necessary to remove the screw
(1) and extract the wheel spindle (2). Remove the nut 1
(3) and then the flange (4). 2
3
Before substituting the bearings as indicated
above it is advisable to remove the brake
discs as indicated in chapter H “Brakes” to
avoid damaging them. 4
Special tool N. 8000B4416
Introduce the extractor until the internal ring of the

F bearing is hooked up. Introduce the wheel spindle and
screw and and block them by means of two 14 mm
wrenches.
Mount the flange, spacer ring and nut utilising a 14 mm

spanner and a 27 mm spanner and extract the bearing
as shown in the figure.
NOTE Operate in the same way on both bearings.
-6-
Check that the ends of the aluminium spacer and the

seats of the bearings on the wheels are not scored or
marked.
Reassembly – front wheel bearings

Before proceeding with the reassembly, accurately F
clean the bearing seats in the wheel hub.
Lubricate the outer ring of both bearings with special
grease.
Mount the bearing on the specific tool and insert it in
the rim housing.
Recommended product: Agip Grease 30
Special tool No. 8000B4421
Mount the bearing and a spacer on the specific tool.
-7-
Insert it on the opposite part, keeping the rim in a verti-

cal position.
Insert the guide spacer and utilising a press, squeeze

F down the bearings.
Proceed as illustrated in the figure.
Attention: the wheel bearings should be

mounted with little interference but should
the action of the press be blocked in any way,
release the press.
Having completed the assembly, check that the alu-

minium spacer does not have axial play.
Assemble the wheel spindle and carry out again the
rolling check by rotating the wheel.
-8-
Wheel spindle check

Place the wheel spindle on two v-prisms on a flat sur-
face.
Utilising a dial gauge, check that the eccen-

tricity in the central part does not exceed
0.05 mm.
Wheel assembly
F
If the front tyre is substituted, before assem-
bling the wheel it is necessary to balance the
wheel following the indications in page 77.
After having carried out the check on the parts of the

front wheel, accurately clean the wheel spindle and
assemble it from right to left. Tighten the screw ring of
the wheel spindle to the torque prescribed utilising the
special tool. Ensure that when the wheel is mounted
into place, the screw ring of the wheel spindle must be
on the left side of the motorcycle.
Apply grease only to the first threads.

38÷40 N•m
Fit the wheel-spindle assembly on the front suspension

pins without pressing axially on the fork legs. 20÷22 N•m
Tighten the two screws to the torque pressure pre-

scribed.
Mount the two brake calipers as described in chapter H
“Brakes”.
During the operation, support the front

wheel so as to prevent the screws from
sticking.
-9-
FRONT FORK N
A H
L G
F
B
H
A
E
D
C
D
E
A B C D E F G H I L M N
N·m 40 20 ÷ 22 20 8 ÷ 10 8 ÷ 9 16 ÷ 18 22 ÷ 24
Torque
pressure Kg·m
ft·lb
Operation
Description F4 1000
FRONT SUSPENSION
Type “Upside down” telescopic hydraulic fork with external and separated
adjustment of rebound and compression damping and of spring preload
Ø stems (mm) 50
Telescopic movement (mm) 120
- 10 -
FRONT FORK OVERHAUL
Before removing and overhauling the front suspension

components, it is advisable to remove the lower fairing,
the left and right fairings, the front cowl, the air ducts,
the front mudguard, the spoiler, the left and right wire
harness covers and the side panels as described in
detail in the chapter “Fairings”.
Support the motorcycle by the rear stand with special

tool.
Special tool No. 800092642
Remove the front wheel as described in the chapter

"FRONT WHEEL" for the vehicle model. 2 F
Remove the fixing screw (1) of the holding clamp (2) of
1
the brake line and remove the clamp.
Repeat operations for the opposite side.
Remove the left clip-on handlebar by unscrewing the

screws shown in the figure. Protect the clip-on handle-
bar with protective material.
Utilise the same procedure for the right clip-on handle-
bar.
The protection of the clip-on handlebars is

necessary to stop scratching painted parts of
the motorcycle.
- 11 -
Stem removal
Slacken the screw (1) of the steering head and the
three screws (2) of the steering base.
During this phase, support the stem.
Slide out the stem, supporting it with both hands and
operating with caution so as not to drop it.
Proceed with the same operation for both stems.
1
Fork tube exploding

F Place the fork leg in a vice, taking care to protect its
surface against possible damage.
Loosen fork plug (1).
- 12 -
Completely unscrew the plug and lower the sheath as

shown in the figure. Perform this operation while hold-
ing the leg in a vertical position.
Unscrew the plug. Using the spanner, adjust the spring

preload while locking the nut on the damping piston F
rod.
Remove spring compression spacer (1) with the relat-

ed thrust washer.
- 13 -
Remove the spring together with the spacer.
Remove the inside rebound adjusting rod.

F
Turn the stem upside down and completely pour out
the oil into a suitable container.
Recover the oil in an appropriate container.

Do not dispose of the used oil in the environ-
ment.
Remove the central lower screw that fixes the damping

piston. Keep the sealing washer underneath. 40 N•m
When refitting, tighten at 40 N•m.
- 14 -
Pull out the damping piston.

Take care not to reverse the pumping elements on the
fork while fitting it back in, and configure as follows:
- Brake-pressing pumping element: fit on left fork.
- Brake-releasing pumping element: fit on right fork.
Lower dust cap (1), taking care not to damage the seat
on the sheath. F
Remove the retaining ring (1) with a screwdriver, tak-

ing care to not scratch the stem.
- 15 -
Extract the fork leg with repeated jerks at the end of its
travel.
Fork assembly check

F Check that the sleeve does not have marks on the
external part that could have repercussions inside the
assembly. Ensure that the inside is completely smooth,
without any scratches.
If necessary, substitute with a new part.
Check for marks or scratches on all surfaces of the

stem and check the condition of the chroming.
Measure the length of the spring and compare

with the following values:
- F4 1000: 260 mm
Manually widen the upper bush and extract it.

Remove the lower bush, the washer, the oil seal, the
stop ring and the anti-dust seal (see figure).
- 16 -
Assembly oil seal and anti-dust seal

After having carefully checked all components, substi-
tute those damaged and/or deteriorated.
Grease the lips of the new anti-dust seal (1) and the
new oil seal (2) with the appropriate grease.
Apply a "sleeve" of nylon to the upper part of the stem
(see figure), to protect the oil seal (2) and the anti-dust
seal (1) from any sharp edges on the lips of the stem
during assembly.
Recommended grease: MOLYKOTE 55M
Visually check for scratches and marks on the pump

rod and check that it slides smoothly inside the pump F
unit without chamfering.
Substitute if necessary.
Assemble the stem into the sleeve, placing the ferrules

into their seats with the respective washers. Utilise the
special tool
Using the same technique, assemble the oil seal and
its stop ring and then manually assemble the anti-dust
seal.
Special tool No. 8000A1039
- 17 -
Fit the inner rod and the spring spacer in their hous-
ings.
While holding the sheath in an upright position, pour in

F the following oil quantities:
- F4 1000: 720 cc(*)

Repeatedly move the damping piston rod up and down

until the it slides smoothly.
Oil type used: SAE 7,5
Check that the oil is at level "X" with reference to the

upper sheath rim, measured when the sheath is com-
pletely compressed.
- F4 1000 (**): X = 70 mm
(**): N.B.: Measured with the pumping rod at the

end of its stroke and the spring spacer in.
- 18 -
Manually turn the counternut in to the end of the

threaded portion.
The counternut is characterized by a special

fitting direction. Ensure that the two span-
ner resting surfaces are facing up (see fol-
lowing figure).
Fit in the spring.
Fit the spanner to damping piston nut (1), pressing

down slightly on the spring. F
Position spring pressing spacer (1) with the related

washer.
Reassemble the complete cap with a new O-ring.
- 19 -
Tighten the plug with the prescribed torque.

20 N•m
Fork leg plug tightening torque: 20 N•m
Insert and screw in the complete cap (1) on the fork sli-
F der.
Fitting the fork legs

Reassemble the stem taking care to pass the electrical
wiring and the clutch tube inside the stem (between the
stem and the steering head).
To ensure proper positioning of the rods, refer to the
figure at right, taking care to observe fitting dimension
"X":
- F4 1000: X = 212 mm
- 20 -
Screw in and tighten the three screws (1) at the base

of the steering.
Carry out this assembly correctly. A casual or

inexact assembly could compromise the sta-
bility and steering of the motorcycle.
Fit the right-hand leg following a similar procedure.
Tighten the three screws (1) at the base of the steer-

ing. Effectuate the operation several times until the 8÷9 N•m F
torque wrench does not turn the screw any more.
This operation must be carried for both stems.
1
Ensure that the steering head is sitting perfectly in its

seat. Tighten the two screws (2) of the steering 16÷18 N•m 22÷24 N•m
head/stems to the prescribed torque pressure and suc-
cessively tighten the central screw (3).
3
Torque pressure steering head (2):
16 ÷ 18 N·m
Torque pressure central screw (3):
22 ÷ 24 N·m
This check is necessary for the correct 2

positioning of the stems even if the steering
head has not been removed. This check
guarantees the standard set-up of the
motorcycle.
- 21 -
Assembly clip-on handlebars

Position the electrical wiring as shown in the figure.
Ensure that the Seeger retaining ring (1) of the clamp
pin is in good condition and in position.
Assemble the clip-on handlebar slotting the clamp pin

F into position on the steering head (see figure).
Tighten the screws (1) to the prescribed torque pres-

sure. After having carried out the assembly of the right
clip-on handlebar, check that the accelerator handgrip
rotates freely and smoothly.
8÷10 N•m
- 22 -
Replace the brake line holding clamps.
Mount the front wheel and brake callipers according to

procedures contained in the previous pages. F
Front suspension adjustment

After properly fitting the fork assembly, adjust the front
suspension so as to ensure optimum vehicle geometry.
FRONT FORK
Substitute oil ¨ every 24000 kilometres
The front fork is vitally important for the handling and

stability of the motorcycle. It is therefore necessary to
substitute the fork oil at the prescribed intervals.
Quantity oil:
- F4 1000: 720 cc (*)

- 23 -
Oil type used: SAE 7,5 Rebound damper

To substitute the fork oil and to do a complete over-
haul of the forks, carry out the described operations
in the previous pages.
Front suspension adjustment

Refer to values contained in the table to adjust front Spring preload
Spring preload
suspension.
NOTE Adjustments contained in the table must

be carried out from initial reference posi-
tions:
Compression damper
- Spring preload: Turn counter-clockwise

F to end stroke.
- Extended brake: Turn clockwise to end
stroke, then turn counter-clockwise
until you hear the first click.
Spring preload
Rebound damper
- Compressed brake: Turn clockwise to

end stroke, then turn counter-clockwise
until you hear the first click.
Type of set-up
F4 1000
On road On race track
Spring preload 2 turns 5 turns
Rebound damping 16 clicks 4 clicks Compression damper
Compression damping 14 clicks 2 clicks
- 24 -
STEERING ASSEMBLY
D
F
B
A B C D E F G H I
N·m 120 ÷ 125 16 ÷ 18 8 ÷ 10 4÷6 22 ÷ 24 22 ÷ 24 8 ÷ 10
Torque Kg·m
pressure
ft·lb
270
Operation
- 25 -
STEERING ASSEMBLY OVERHAUL
Lift the motorcycle and rest it on the special tool.
Steering head removal

F After having removed the two fixing screws (1) of the
steering shock absorber on the frame, loosen the three
fixing screws (2) of the steering head.
Remove the ignition key switch cable clamp.

2
- 26 -
Then remove the steering head complete with shock

absorber and ignition key switch.
Protect the steering head with padded material and

rest it over the dashboard. F
Steering base removal

Preliminary operations:
- Disconnect the connectors (1) of the acoustic war-
ning signal;
- Remove the two fixing screws (2) of the acoustic
warning signal support plate and remove the unit;
- Disassemble the holding clamp on the brake line
(see page 11);
2
1
- 27 -
- Disassemble the handlebars and rest them on the

front support, after having protected them with pad-
ded material.
Using the specific tool, loosen the ring nut of the stee-
F ring spindle, supporting the base of the steering head
with a hand.
Remove the screw ring previously slackened and

remove the steering base complete with the pin.
- 28 -
Remove the anti-dust seal, the internal bearing ring

and the ball bearing ring.
Disassembly of the frame head steering sleeve

Utilising the special tool, remove the steering screw F
ring.
Attention: During this operation press the

centre of the tool with the palm of the hand.
Remove the adjustment screw (1) of the frame head

steering sleeve, sustaining the frame head steering
sleeve at the lower part.
Remove the sleeve (2).

1
- 29 -
Reassembly of the frame head steering sleeve

Clean the parts accurately so that a visual check can
be made of the tube and the seats.
There should not be marks or lines in the bearing
seats. If so, substitute the parts as necessary.
Lightly grease the contact area of the frame head

F steering sleeve (see figure) and the threaded part with
Agip Grease 30.
Accurately clean the bearing seats on the frame head
steering sleeve.
Recommended grease Agip Grease 30
Reassemble the frame head steering sleeve aligning

the slot on the frame head steering sleeve with the
threaded hole on the frame head (see figure).
When the slotted hole is aligned with the hole, turn in
head tube adjusting screw (1).
Tighten screw (1) with the prescribed torque.
1
- 30 -
Screw ring assembly

After having accurately cleaned the screw ring and the
seats of the steering head on the frame, grease the
screw ring and screw it in manually onto the relative
seat.
Grease only the first threads and the conical

section of the ring nut.
Utilising the special tool, tighten the screw ring (1) to

the prescribed torque pressure. 120÷125 N•m F
During this tightening operation, press down with force

onto the head of the special tool.
Steering base assembly

Accurately clean all the parts and check the general
condition.
Before reassembly, grease the ball bearing ring and
place it onto the steering pin.
- 31 -
Fit the lower triple clamp to the frame.

Fit the upper ball bearing race after greasing it.
Fit the bearing inner race, the dust seal and the upper
clamping collar.
Steering pin tightening

F Screw down, without tightening, the screw ring of the
steering pin.
2
This operation must be done manually.
Ensure that the steering base is turned as far as pos-
sible to the right.
Utilising the special tool, tighten the screw ring (1) by
rotating it 10° (see figure, calculable as one-third dis-
tance between the two holes of the steering head
screw ring (2).
Ignition key switch tightening

To disassemble and replace the ignition key switch, it
is best to completely remove the motorcycle steering
head.
Remove "immobilizer" connector clamp.
Disconnect the "immobilizer" connector.
- 32 -
Open the plastic clamp (1) on the right side of the

headlight support frame and remove the wiring.
Extract the ignition block connector (2) from the faste-

ning plate and disconnect it. F
Remove the wiring from the left part of the motorcycle.
- 33 -
Remove the complete steering head from the motorcy-

cle.
Remove the 2 key switch fixing screws and extract

F them.
When reassembling, apply the following

tightening torque: 22 ÷ 24 N·m
Steering shock absorber connecting rod removal

Remove the locknut of the screw (1) that connects the
connecting rod to the steering head.
Remove the screw (2) that connects the connecting
rod to the steering head.
1
- 34 -
Remove the screw (3) that connects the connecting

rod to the steering shock absorber.
Check that the connecting rod is in good condition and
that play is not present on the two bearings. 2
If play is found, substitute the worn parts with new
ones.
Connecting rod reassembly

Be careful to correctly position washers when reas- F
sembling.
Apply Loctite 270 on the screw (1) that fixes the con-
necting rod to the steering head. Tighten the screw (1)
to the prescribed torque pressure.
Threadlocking product used: Loctite 270
1
8÷10 N•m
Use strong 270 Loctite thread-brakes on the screws (3)

that fix the linkage to the steering shock absorber.
Tighten the screw to the prescribed torque pressure.
3
Threadlocking product used: Loctite 270
8÷10 N•m
- 35 -
Steering head assembly

Position the steering head in its housing according to
the inverse order of disassembly operations.
Tighten the central fixing screw (1) of the steering

F head.
22÷24 N•m
Tighten the two front fixing screws (2) of the steering

head.
1
16÷18 N•m 2
Block the steering shock absorber in position by tigh-

tening the two fixing screws to the frame.
8÷10 N•m
- 36 -
REAR SUSPENSION AND SWINGARM
C D
A B C D E
N·m 40 ÷ 44 40 ÷ 44 40 ÷ 44 45 ÷ 50 70 ÷ 75
Torque Kg·m
pressure
ft·lb
243
Operation
Description F4 1000
REAR SUSPENSION
Type Progressive, single shock absorber with rebound-compression
(high speed/low speed) damping and spring preload adjustment
Swingarm Aluminium alloy
Wheel travel (mm) 120
During the disassembly and check of the rear suspension assembly, it is advisable to disassemble the under-
engine fairing, fairing side panels, tail unit and fuel tank as described in chapter C "Bodywork".
- 37 -
Rear shock absorber disassembly

Remove the seats, side panels, tank and rear panels
as described in Chapter C "Fairings".
Lift up the rear part of the motorcycle (with the specific

lifter) high enough to take the load off the shock
absorber.
Slacken the upper screw (1) of the shock absorber.

F
Remove the lower screw (2) of the shock absorber.
- 38 -
Remove the previously loosened upper screw.
Remove nut (3) from the central rocker pin.

F
Remove the pin (4) of the compensator assembly (5).
- 39 -
Lift the rocker and extract at the same time as the com-
plete shock absorber.
Rear shock absorber test

F Check that the lower and upper bolt holes do not have
axial (A) and radial (B) play.
- 40 -
Check the length of the rear shock absorber spring.

Standard spring adjustment (A):
- F4 1000: A = 170,5 mm
Check the functioning of the adjusters.
The shock absorber contains high-pressure
gas. Do not touch the valve of the shock
absorber tank. Do not try to disassemble the
shock absorber.
Spring preload and rebound and (high/low speed)
compression damping for the rear shock absorber:
Type of set-up
F4 1000
On road On race track A
Rebound damping 16 clicks 7 clicks
Compression damping (high speed) 0 clicks 6 clicks
Compression damping (low speed) 18 clicks 7 clicks
NOTE Adjustments contained in the table must be Compression damping hydraulic

carried out from initial reference positions. device (high speed) F
These positions must be determined by
means of the following procedures:
- Extended brake: Turn clockwise to end
stroke, then turn counter-clockwise until
you hear the first click.
- Compressed brake (High speed): Turn
clockwise to end stroke, then turn counter-
clockwise until you hear the first click. Compression damping hydraulic
- Compressed brake (low speed): Turn device (low speed)
clockwise to end stroke, then turn counter-

clockwise until you hear the first click.
Rebound damping
NOTE The following operations can be also car- hydraulic device
ried out with the rear shock absorber

assembled to the motorcycle.
For further tests on the ball joints of rear
shock absorber attachments, it is neces-
sary to follow disassembly phases descri-
bed in this chapter.
- 41 -
Compensator assembly removal

Remove the special screw (1) that fixes the compen-
sator assembly of the rear suspension to the mono-
arm fork. Extract the complete compensator assembly.
1
Compensator assembly overhaul

1
F Remove the anti-dust seal (1).
Check the condition of the roller bearings and if it is
necessary to substitute them, utilise an extractor as
Check for eventual axial play of the bolt holes of the

connecting rod (2). Substitute if worn.
- 42 -
Rear shock absorber support plate removal

Remove the three screw (1) indicated in the figure and 1
remove the support plate (2).
When reassembling, it is necessary to apply special

product to the three screws and lightly screw them in. F
Tighten the central screw first and then the other two to
the prescribed torque pressure.
Special product: Loctite 243
40÷44 N•m
Compensator Assembly
Replace the rocker unit components in the sequence
Pay attention to position both plastic spacers on the left
- 43 -
After having cleaned and greased the seat of the spe-

cial screw situated on the mono-arm fork.
Screw in the screw without tightening it.
Recommended grease: Agip Grease 30
Rear shock absorber assembly

F Accurately clean all parts. Grease the screws with Agip
Grease 30 before reassembly.
Insert the shock absorber from above and lightly screw
in the lower screw of the shock absorber.
Centralise the compensator assembly and replace the
pin. Screw on the nut of the pin without tightening it.
Insert the shock absorber into the compensator
assembly and lightly screw in the screw.
Lower the motorcycle to the ground, remove

the lift and safety straps.
This operation is necessary to recover the
play between the shock absorber/compen-
sator assembly/mono-arm fork.
Tighten up the whole assembly:

Tighten the screws of the connecting rod (1). 40÷44 N•m
Tighten the lower and upper screw of the shock absorber
(2).
Tighten the screw of the compensator assembly (3). 1
Grease only the screw thread.
3
Connecting rod torque pressure 40 ÷ 44 N·m 2
Shock absorber torque pressure 40 ÷ 44 N·m 45÷50 N•m
Compensator assembly torque pressure 45 ÷ 50 40÷44 N•m
N·m
- 44 -
SWINGARM REMOVAL AND OVERHAUL

Remove the shock absorber and the con-rod of the
rear suspension as described in the previous pages.
Rear wheel removal

Remove the rubber and the safety spring clip (1) and
unscrew the screw ring of the wheel.
Attention! The screw ring has a left-handed

thread.
Footrest removal
Unscrew the two screws (1) of both footrest supports F
and remove them.
1
Right passenger footrest removal

Remove the right passenger footrest by unscrewing
the two relative screws.
- 45 -
Lower chain guard removal

Remove the three socket head screws (1) of the lower 1
chain guard.
Remove the lower chain guard, taking care to recover
the internal bushes.
Exhaust protection removal

F Remove the three screws (1) that fix the protection
onto the exhaust group.
Silencers Removal
Remove the closing wiring cover on the heat guard,
levering with a screwdriver.
- 46 -
Extract the wiring and disconnect the three rear head-

light connectors.
Remove the fixing screw (1) of the exhaust valve plate.

F
Loosen the lock nuts (2) of the valve opening and clo-
sing adjusters.
- 47 -
Remove the valve safety plate (1).
Disconnect the valve opening and closing adjuster

F cables.
Loosen the screws (2) from the exhaust connection

clamp.
2
- 48 -
To facilitate silencer dismantling operations, remove

the rear fixing screw from the central protection.
Move the rear end outward.
Supporting the silencer unit in its rear part, remove the

two exhaust support side screws (1) (see figure). F
Lower the rear part of the silencer unit by removing the

heat guard wiring.
- 49 -
Remove the silencer unit from the exhausts.
Upper chain guard removal

F Remove the screw complete with ferrule.
Extract the chain guard by pulling it out from the back
part of the wheel (see figure) so that it is freed from its
position on the swingarm.
CHAIN REMOVAL
Cut the chain utilising the special tool. 2
Special tool no. 8000B1439.
Unscrew bolt (1) so that the tip is retracted into the hex
nut.
NOTE This tool coud be applied in any point of

the lower section of the chain.
1
- 50 -
Unscrew shoulder bolt (2) until you can insert the chain
into the special tool. Position the chain breaker (1) so 2
that the ends of the chain pin can fit into the holes of
the hex nut and bolt (2).
Thread with the fingers the shoulder bolt (2) to put in

phase the chain with the tool. 1
Screw the bolt (1) until the pin is out of the chain plate
on the wheel side. F
1
How to fit the chain back in

Pick the new connecting link from the package.
The connecting link is supplied lubricated
with a special product that guarantees long
life. Absolutely avoid wiping away the lubri-
cant from the pin surfaces, as this would
seriously reduce the connecting links opera-
tional life.
This is particularly important for O-Ring
chains, as they cannot be re-lubricated.
Never reuse an old rivet link or old outer

plate previously disassembled from the
chain.
- 51 -
Check that the fork of the new connecting link fork has
an O-Ring installed on each pin.
Insert the new connecting link fork from the wheel side,
avoiding any contact with the pins in order not to remo-
ve the lubricant.
Place the other two O-Rings on the extended ends of

the bushings.
Rotate the rear wheel so that the rivet link is positioned

F on the lower strand of the chain where there is more
room to work.
Closing the rivet link

Closing the link utilising the special tool.
2
Put the assembling tool on the chain, placing the cen-

tering pin between the chain rollers, in order to fit with
the rivet link.
Thread the bolt (1) with the fingers in until the outer
plate is placed on the rivet link fork pins. 1
With a wrench fully thread in the bolt (1) until the pin
ends reach the bottom the slots in the link plate carrier
(2). Avoid to force too much. This places the outer plate
at the correct position on the fork.
Slowly unscrew the bolt (1) and remove the tool from 1
the chain.
- 52 -
Riveting
Use the professional rivet tool.
Pull the plate (4) to open the positioning rods (3), insert
the chain into the tool in correspondance of the first pin
to rivet an release the plate (4). The chain should be
correctly inserted into the tool and kept in place by rods
(3).
Slide punch (5) to contact the head of the pin to be rive-

ted. F
Using a hammer, give a sharp blow to punch (5) to 4
deform the head of the pin.
Rotate punch (5) approx. 90° and repeat operation. 5
Release the chain by retracting plate to open the posi-

tioning rods and continue the operation cycle on the
second pin to be riveted.
Check for smooth flexing of the link and that the O-

Rings are correctly positioned and not damaged or cut.
When the riveting is over, check if the diameter of the

head of both pins is between the following range:
- Pin head diameter after riveting:

d = Ø 5.60 - 5.80 mm
If the diameter is out of the specified range repeat the

riveting operation.
- 53 -
Removing the rear brake caliper

Loosen the two screws (1) and remove brake caliper (2).
Speed sensor cable disassembly

F Remove the speed sensor cable holding clamp (3).
Disconnect the speed sensor cable connector.
- 54 -
Swingarm pin removal
Before removing the swingarm pin, loosen the suspen-

sion rocker pin and the two engine pins.
Remove the screw (1) on the left side of the vehicle.

Remove the washer and push out the pin manually.
Support the swingarm so that it does not drop to the
ground.
Upper chain guide removal

Remove the two screws (1) and the relative plates. F
Lift up the front part of the chain guide to remove it
from the swingarm (see figure).
1
Repeat the operation on the rear part, where the screw

seat is situated in the swingarm.
- 55 -
Slide out in a forward position as shown in the figure.

When reassembling, proceed in the reverse order of
removal ensuring the correct positioning of the front
reference peg.
.
Bearings overhaul
F If it is necessary to substitute the bearings of the swin-
garm because of excessive play, operate as follows:
Remove the right and left spacer.
Remove the Seeger retaining ring on the right side of
the swingarm.
Remove the anti-dust seal on the left side.
Utilising the special tool, remove the two roller bearing
units.
Special tool N. 800092860 LEFT SIDE
Mount the tool so that both roller bearings are

removed.
Utilising the special tool press on both ball bearings

and extract them.
Operate in the same way for the bearings on the left
side.
Special tool N. 800092860 RIGHT SIDE
- 56 -
Extract the spacer from the right side.
Check the condition of both bearing seats and the seat

of the spacer.
If the spacer is in good condition, reinsert it onto the
fork from the right side.
Fitting the bearings and the roller cases on the rear

swingarm. F
Take two new roller cases (Part No. 800084936) and
two new ball bearings (Part No. 800084938).
Preassemble the 2 roller cases (Part No. 800084936)

on specific tool Part No. 800092866 (see figure).
Fit the assembly to the left side of the swingarm.
Assembly the inner bearing spacer (Part No.

800084872) and the two ball bearings (Part No.
800084938) on the tool Part No. 800092866 on the
right side of the swingarm (see figure).
Complete the assembly by fitting the two bushings

relating to the tool Part No. 800092866 on the right
side of the swingarm.
Special tool no. 800092866
- 57 -
Utilising a press fit the bearings and the roller bearing

units (see figure).
- 58 -
REAR WHEEL HUB
I
O
E M
B
A
A B C D E F G H I L M N O
N·m 30÷35 20÷22 45÷50 200÷220 28÷32 220÷240 140 25 8 5÷7 18 18÷20
Torque
pressure Kg·m
ft·lb
Operation 243 270 243 243 270
Description F4 1000
REAR WHEEL
REAR TYRE
Dimensions 190/55-ZR 17 (75W)
Rear tyre At a speed lower than 300km/h At a speed higher than 300km/h
pressure: PIRELLI 2.3 bar (33 psi) 2.9 bar (42 psi)
DUNLOP 2.3 bar (33 psi) 2.9 bar (42 psi)
- 59 -
Before checking and overhauling the rear wheel hub

assembly it is necessary to carry out the following pre-
liminary operations:
Remove the rear wheel by removing the polygonal nut.
Utilise the following tools:
• Torque wrench 55 mm polygonal spanner
The polygonal fixing nut of the rear wheel

has a left hand thread. To effectuate the
removal it is therefore necessary to turn the
torque wrench in a clockwise direction as
After having effectuated the rear wheel removal, sup-

F port the motorcycle with a lift as shown in the figure.
Remove the rear stand.
Remove the safety ring (1) of the crown flange-fixing

nut.
- 60 -
Slacken the nut of the flange by rotating it in an anti-

clockwise direction as shown in the figure. Utilise the
following tools:
• Torque wrench
• 55 mm polygonal spanner
Slacken the fixings (1) of the wheel hub.

F
Remove the screw complete with bushing.

Extract the chain guard by pulling it out from the back
part of the wheel (see figure) so that it is freed from its
position on the swingarm.
- 61 -
With the special spanner mounted on the extension

tube, pull forward the eccentric adjuster and release
the chain from the crown wheel.
Special tool:
Eccentric adjuster spanner N. 800092854
Spanner extension N. 800092855
When adjusting the tension of the chain it is

necessary to carry out the motorcycle
set up adjustment. See “Motorcycle set up
adjustment” in this chapter.
Remove the wheel spindle nut (2) previously slacke-

2
F ned and the spacer ring (4) underneath.
Remove the rear sprocket unit (3) and the spacer ring
(5) underneath.
- 62 -
Remove the rubber clamp (1) around the rear brake

pipe.
Slacken the two screws (6) and remove the brake cali-
per (7). F
Disassembly of the wheel pin

Remove the wheel spindle complete with the brake
disc, extracting it from the right side of the motorcycle
- 63 -
Brake caliper support flange removal

Remove the Seeger retaining ring (1), the spacer ring
(2), the flange (3) and the spacer ring underneath.
3
Wheel hub disassembly

F Extract the wheel hub from the left side of the fork.
Carefully wash all parts.
Check the condition of the roller bearing and the ball
bearing.
If there is excessive play (even only one of the bea-
rings) or chamferings during rotation, substitute the
wheel hub, complete with bearings with a new unit.
If only one bearing is worn, substitute the

complete unit. Never substitute one bearing
only.
For normal maintenance, remove the three internal

spacers (wheel spindle seat), wash the roller bearing
units, dry them and grease them.
Check the condition of the ball bearings.
The grease used must have the following

characteristics:
– Lithium soap grease with a mineral oil base
– Consistency NLGI: 2
– Dripping point: 181° C
– Viscosity at 37.8°C: 140 cSt
– Temperature field: from -25°C to +120°C
- 64 -
Caliper holder pin

30÷35 N•m
NOTE Unscrew the caliper holder pin only if it is
damaged.
When reassembling apply the prescribed type of

Loctite and tighten to the prescribed torque pressure.
Recommended thread-locking fluid: Loctite

243
Caliper holder pin torque pressure:

30 ÷ 35 N•m
Wheel spindle unit check

Check the condition of the wheel drive engagement F
splines.
If it is worn, substitute as follows.
After heating with a heat gun, remove the four fixing

screws (1) of the brake disk flange sealed with Loctite
270. Remove the flange.

270
- 65 -
Check the extra-smooth parts of the wheel spindle for

wear (A).
A A
Utilising a press with an adequate punch for both the

F removal and assembly of the pins of the wheel drive
engagement.
When assembling, apply force on the crown of the peg
not on the point. (see figure).
Assemble the brake disc carrier plate by tightening the
screws to the prescribed torque pressure and then
apply Loctite 270.

270
Brake disc carrier plate screw torque pres-

sure: 20 ÷ 22 Nm
20÷22 N•m
Crown wheel assembly check

Remove the driving flange by pushing the central ring
(1) outwards.
- 66 -
Evaluate the wear condition of the crown wheel. If it is

badly worn, effectuate a substitution with a new part
proceeding as described.
Extract the 5 spring drives (2) from the gear flange sup-
port (3) and assess its condition.
If the spring drives are worn, replace with new ones.
2 3
Check that the coupling bushes of the gear flange sup-

port (1) and the driving flange (2) do not show any
1
F
signs of excessive or uneven wear.
If the bushes are excessively worn, replace the entire

set of flanges. 2
- 67 -
Remove the 5 nuts (3) to free the crown (1) from the
crown flange (2). 1
2
Replace the crown.
Remount the new crown on the crown flange, making

sure the pins (4) enter the holes.
Check that the coupling bushes of the gear flange sup-

F port (1) and the driving flange (2) do not show any signs
of excessive or uneven wear.
Bushes coupling area (1):

Grease AGIP GR SM 1
Bushes coupling area (2):
Grease AGIP GREASE 30
Do not apply grease to the threads of the pins.
Reassembly wheel hub

Lightly grease the wheel hub.
Introduce the hub to the swingarm from the left side of
the motorcycle and push it in.
Screw in the two screws on the swingarm without tigh-
tening.
- 68 -
To assemble the brake caliper-carrying flange, carry

out the following operations:
Grease the O-rings and insert them into their respecti-

ve seats on the flange.
Assemble the rear spacer ring in contact with the hub,
then the brake caliper-carrying flange (1), the second
spacer ring and the Seeger retaining ring (1).
It is important to ensure that the Seeger retaining ring
is inserted around the whole circumference of the seat.
Grease the roller bearing.

Introduce the first bush, the spacer and then the F
second bush.
The grease used must have the following

characteristics:
– Lithium soap grease with a mineral oil base
– Consistency NLGI: 2
– Dripping point: 181° C
– Viscosity at 37.8°C: 140 cSt
– Temperature field: from -25°C to +120°C
Reassembly rear wheel pin

Grease the wheel pin and introduce it carefully into the
hub.
- 69 -
Reassemble the brake caliper (1) and tighten the fixing

screws (2) at the specified torque. 18 N•m
Special product: Loctite 243 2
Torque pressure: 18 N•m
Reinsert the rubber clamp (1) around the rear brake

F pipe.
Insert the spacer with neck illustrated in the figure onto

the wheel pin.
Insert the crown wheel assembly, the second spacer
ring and the wheel pin fixing nut. 2
Reassemble the chain as described at pages 51÷53 of

this chapter.
- 70 -
Tighten the 5 nuts to block the silentblocks as shown

in the figure. 25 N•m
Tightening torque: 25 N·m
Apply grease only on the threaded part
Reposition the nut of the flange (1) with the relative

washer (2) without tightening. 1 F
Using the special spanner, bring the eccentric back

into position by rotating in an anti-clockwise direction to
tighten the chain.
Special tool:
Spanner for eccentric hub N. 800092854
Extension for spanner N. 800092855
Whenever the chain is tightened, it is neces-

sary to adjust the stability of the vehicle -
see "Adjusting vehicle stability" in this
chapter.
- 71 -
Tighten the wheel pin fixing nut by rotating it clockwise

as shown in the figure, by using the following tools:
• Torque wrench
• 55 mm polygonal socket wrench
1
Slip flange nut coupling torque:
200-220 Nm
Assemble the retaining ri ng (1).
Reassemble the lower chain pad, the upper chain 200÷220 N•m
guard and the central exhaust manifolds respectively.
Rear wheel assembly

F
In the case of substitution of the rear tyre it
will be necessary to effectuate the balancing
of the wheel before assembling it. Follow the
instructions indicated in page 73.
Insert 1st gear. Reassemble the rear wheel.

Tighten the wheel axis nut to the prescribed torque
pressure.
Rear wheel RH nut torque pressure:

220 ÷ 240 N•m

1
Insert the retaining ring (1).
- 72 -
Remove the screw (1) of the clutch control cylinder and

the three screws (2) of the pinion wheel cover.
1
2
Remove the cover being careful to not extract the clut-

ch control rod (it must remain inserted in the engine) F
and be careful to not lose the two centralising bushes
indicated in the figure.
Straighten the metal tongue with a flat-head drift and

hammer.
Unscrew the pinion wheel retaining nut.
Now cut and remove the chain as described on pages

50-51.
- 73 -
Using the specially designed spanner, remove nut (1)

and washer (2).
Remove the pinion and replace it with a new pinion.
For reassembly, insert the pinion to end stroke.

F Take a new washer, assemble it with the nut and tight-
en to the prescribed torque pressure utilising Loctite
thread-locking fluid.
Hammer the new washer down onto the two opposite
faces of the hexagon.
Torque pressure: 140 N·m
Recommended thread-locking fluid: Loctite 243
Remove the chain as described on pages 51-53. 140 N•m
Reassemble the pinion wheel cover after having clea-

ned the support base.
Screw in the four screws lightly and proceed with the 25 N•m
tightening, screwing down respectively on the three 8 N•m
screws M8 (1) and on the screw M6 (2).
1
Torque pressure (M8 Screws): 25 N•m 2
Torque pressure (M6 Screws): 8 N•m
- 74 -
MOTORCYCLE SET-UP ADJUSTMENT
WARNING: The following adjustments must

be made when the fuel tank is full.
Insert the setting-up arm (1) of the rear suspension

(special tool) in its appropriate seats as shown in the
figure.
Special tool no. 8000B4413

1
Raise the rear part of the motorcycle until the full

extension of the rear shock absorber is reached. F
Contemporaneously measure the distance X1 between
the upper extremity of the rear stand and the point on
the setting-up arm shown in the figure.
NOTE Two persons must carry out this opera-

tion.
Check that dimension X1 is equal to:

218 mm ( reference dimension).
X1
Should X1 be different from the reference dimension,

loosen rear suspension half linkage fixing counternuts
(2). 2
- 75 -
Using an Allen key, change the centre distance

between the two half linkages by turning adjuster (3).
Repeat these operations until X1 is equal to the refer-

ence dimension.
Manually and firmly tighten the two tightening lock nuts

F of the half supports until you hit the adjuster bar.
2
Press down the saddle to compress the rear shock

absorber, then allow the vehicle to spring back to its
rest position.
- 76 -
Measure the distance X2 between the upper end of the

stand tube and the point on the setting rod indicated by
an arrow (see figure).
Calculate static settling Δ using the following formula:
Δ = X1 – X2
The static settling value should be:
X2
Δ = 23 mm
If static settling Δ differs from the above value, perform
the following adjustments on the shock absorber
spring.
Turn the adjustment ring nut of the spring preload using

a 75 mm Allen spanner in one direction or the other Turn anticlockwise Turn clockwise F
depending on the calculated static failure value Δ.
Δ < 23 mm: Turn anticlockwise

Δ > 23 mm: Turn clockwise
After having completed the adjustment of the motorcy-

cle set-up, it is necessary to adjust the tension of the
chain.
Check also the orientation of the front headlight and if
necessary effectuate the necessary adjustments.
Both these operations are described in chapter B
“Maintenance”.
- 77 -
WHEEL BALANCE CHECK

If the tyres are substituted, it is necessary to effectua-
te the following operations balancing and checking the
wheels.
Front wheel balancing

Mount the wheel onto an adequate support similar to
that shown in the figure, utilising a ground pin of 35
mm diameter. Check the wheel. Utilising a dial gauge,
check the following tolerances:
Ovalization and maximum eccentricity

must not exceed 0.5 mm.
Flatness must not exceed 0.5 mm.
When effectuating balancing on certain

F makes of tyres, it is necessary to refer to the
yellow mark (1) present on the side of the tyre
as shown in the figure. It indicates the lighte-
st point of balancing and must be situated
close to the tyre valve when the tyre is moun-
ted onto the wheel rim.
Rear wheel balancing
Before mounting the rear wheel on the appropriate

tool, insert the balancing tool into the central hole of
the wheel.
Special tool N. 800092865
- 78 -
Insert the polygonal nut of the balancing tool from the

opposite side and screw it onto the threaded part of the
tool so that the tool can be fixed to the wheel.
Mount the wheel onto an adequate support similar to

that shown in the figure, utilising the special tool cod. F
8000A1953. Check the wheel utilising a micrometer
gauge and check the following tolerances:
Ovalization and maximum eccentricity

must not exceed 0,5 mm.
Special tool N. 8000A1953
Place the dial gauge as shown in the figure, and check

the flatness.
Flatness must not exceed: 0.5 mm.
- 79 -
When effectuating balancing on certain

makes of tyres, it is necessary to refer to the
yellow mark (1) present on the side of the tyre
as shown in the figure. It indicates the lighte-
st point of balancing and must be situated
close to the tyre valve when the tyre is moun-
ted onto the wheel rim.
- 80 -
Frame
SECTION
Revision 1
G
-1-
Frame
SUMMARY
BATTERY CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 3

REMOVAL OF SAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 5
SIDE STAND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 7
FOOTREST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 8
SILENCERS AND EXHAUST GROUP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 8
EXHAUST TUBES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 12
SIDE EXHAUST PROTECTION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 15
FRAME REMOVAL PRELIMINARY OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 16
THROTTLE BODY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 17
PLUG-TOP COIL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 22
FRAME DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 30
FRAME CHECKS AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 32
STEERING SLEEVE HOUSING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 35
FRAME ASSEMBLY ON THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 36
PRELIMINARY WIRING POSITIONING OPERATIONS ON THE ENGINE . . . . . . . . . . . . . . . . . . . . .PAG. 38
REAR FRAME DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 41
FRAME PLATE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 42
REAR FRAME UNIT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 47
ENGINE DISASSEMBLY FROM THE FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 48
G ENGINE ASSEMBLY ON THE FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAG. 59
-2-
Frame
BATTERY CABLES
It is a good rule to disconnect the battery
cables before removing components from the
motorcycle.
After having removed the tail unit and the tank as

described in chapter C "Superstructures," remove the
fixing screws of the seat/tank support on both sides
and remove the bracket.
Remove the screw (2) indicated in the figure.

Disconnect the negative pole of the battery.
When removing the battery, it is necessary to

remove the negative pole cable first and then
the positive pole cable. When reassembling, G
proceed in the reverse order.
2
Disconnect the positive pole of the battery.
-3-
Frame
Remove the battery from its compartment.
If the power cables need to be removed, remove the

battery, then, as described before, remove the fixing
between the grounding wire and the engine.
-4-
Frame
SAS VALVE DISASSEMBLY
This operation is only necessary if the engine should

need to be removed from the frame. 1
Disconnect the SAS valve connector (1).
Remove the clamps and the tubes from the blade cov-
ers.
Remove the valve (2), pulling it from the support out-

ward from the right side with the aid of a screwdriver.
-5-
Frame
Remove the SAS valve support fixing screws (3) and

disassemble the support.
If the SAS valve tubes must be removed, when

reassembling be careful to correctly phase the clamps
to prevent interference with their supports (see figure).
-6-
Frame
SIDE STAND REMOVAL
If the side stand needs to be replaced, use the follow-

ing procedure:
Place the motorcycle on the rear stand (special tool).
1
Remove the side fairings and the underfairing as

described in the chapter "Superstructures."
Disconnect the electrical connector of the safety
switch.
Remove the side stand safety switch by unscrewing
two screws (1) indicated in the figure.
5÷7 N•m
Release the two springs.

Remove the nut located behind the stand mount. 3
Remove the screw (2).
If the stand plate needs to be removed, remove the

three fixing screws (3). G
For reassembly, proceed in the reverse order of
removal.
Apply the recommended thread-locking liquid to the
three plate fixing screws.
Tighten to the prescribed torque pressure.
2
Tightening torque for the stand plate screws (3):
23 ÷ 25 N·m
25 N•m
Recommended thread-locking liquid:
Loctite 243
Tightening torque for the stand nut (2): 25 N·m
Side stand (1) switch screw tightening torque: 3

5 ÷ 7 N·m
Recommended thread-locking liquid:

Loctite 243
The springs must be removed with a special-

ly designed tool.
Before reattaching the springs, ensure that
the stand can swing freely (with no friction or 2
sticking).
23÷25 N•m
-7-
Frame
FOOTREST REMOVAL
Unscrew the two screws (1) of both footrest supports
and remove them.
EXHAUST SILENCERS DISASSEMBLY

Remove the closing wiring cover on the heat guard,
levering with a screwdriver.
Extract the wiring and disconnect the three rear head-

light connectors.
-8-
Frame
Remove the fixing screw (1) of the exhaust valve plate.
Loosen the lock nuts (2) of the valve opening and clos-
ing adjusters.
Remove the valve safety plate (1).
-9-
Frame
Disconnect the valve opening and closing adjuster

cables.
Loosen the screws (2) from the exhaust connection

clamp.
2
To facilitate silencer dismantling operations, remove

the rear fixing screw from the central protection.
Move the rear end outward.
- 10 -
Frame
Supporting the silencer unit in its rear part, remove the

two exhaust support side screws (1) (see figure).
Lower the rear part of the silencer unit by removing the

heat guard wiring.
Remove the silencer unit from the exhausts.
- 11 -
Frame
EXHAUST TUBE REMOVAL

NOTE: This operation is not necessary for disas-
sembly of the engine or frame. Proceed as descri-
bed below for exhaust manifold replacement.
Slide off the Lambda probe connector (1) and lift.
Remove the central protection by unscrewing the two

screws (2).
- 12 -
Frame
Unscrew the two screws (3), one per part, and remove
the front protection.
3
Unscrew the two nuts (4) relative to the manifold tube

couple.
4
Remove the nuts and fixing flanges (5).
- 13 -
Frame
Unhook the oil radiator from the rear support pin on the
engine to then facilitate removing the manifold.
Unscrew the rear support screw (6), holding up the

manifold centrally.
Remove the manifold as indicated in the figure.
- 14 -
Frame
Disassemble the ring seals (3) on the head.
Apply sufficiently adequate wadding to the exhaust

ports to stop the entry of dirt and dust into the cylin-
ders.
If the engine has to be removed from the frame, it will

be necessary to remove the chain as described in
chapter F “Suspension and wheels”.
Side exhaust protection disassembly

Remove the three screws (1) supporting the exhaust
protection.
- 15 -
Frame
FRAME REMOVAL PRELIMINARY OPERATIONS

Support the motorcycle with the aid of the following
kickstands:
- Code 800092642: Rear kickstand
- Code 800095807: Front kickstand
- Code 8000B4303: Engine support
Remove the following components in order:

- Front mudguard
- Front brake callipers
- Front wheel
- Central air manifold
G as described in chapters F - "Suspension and Wheels"
and C "Superstructures."
- 16 -
Frame
THROTTLE BODY REMOVAL

Remove the electrical connectors on the injectors (1) 2
and on the potentiometer (2). 1
Remove the phase sensor fixing screw (3).
3 G
Remove the frame vacuum gauge sockets (4) on both

sides of the vehicle and recover with adhesive tape.
- 17 -
Frame
Loosen to end stroke the screws (5) of the two pairs of

clamps on the suction manifolds as shown in the figure.
Loosen the upper gas control cable fixing nut (6).
G 6
Disconnect upper cable from the support.
- 18 -
Frame
Loosen the lower gas control cable fixing lock nut (7).
Remove the complete throttle body unit.
Fully loosen the lower gas control fixing nut and

remove from the throttle body.
- 19 -
Frame
Remove the clamp from the left suction manifold, move

the phase sensor cable and the potentiometer cable to
the side and fasten them to the frame with adhesive
tape.
Protect suction ducts with adhesive tape to prevent dirt

intrusion inside the cylinders.
Fully tighten the lower gas control fixing nut when

reassembling the throttle body.
- 20 -
Frame
Check the proper passage of the connectors and tube


- Steering head
- Acoustic warning signal
- Right/left handlebars
- Right/left front forks
- Steering sleeve G
as described in chapter F - "Suspension and Wheels."
- 21 -
Frame
PLUG-TOP COIL DISASSEMBLY

Remove the wiring fixing clamp on the right side of the
frame.
Disconnect the secondary air valve connector.
Remove the coil fixing bracket screws.
- 22 -
Frame
Unhook the injection control unit and disconnect the

coil cable connectors.
Remove the coils pulling them upward.
Turn coils on the outer side of the motorcycle before

removing them.
- 23 -
Frame
Disconnect the two exhaust valve control cables from

the actuator and remove them from the lower right part.
Remove the two control unit fixing screws, sliding them

toward the rear part and resting them on the engine.
Wind the positive and negative electrical battery cables

and position them on the engine.
- 24 -
Frame
Remove the engine rev sensor wiring clamp and dis-

connect the connector.
Remove the three Lambda probe wiring clamps.
Disconnect the Lambda probe connector.

Remove the Lambda probe wiring from the upper side
of the motorcycle.
- 25 -
Frame
Disconnect the speed sensor and the rear stop con-

nector.
Disconnect the water temperature sensor connector.
Disconnect the alternator connector.
- 26 -
Frame
Disconnect the gear sensor connector.
Disconnect side stand switch connector.
Disconnect the oil pressure sensor connector.
- 27 -
Frame
Slip the wiring of the two connectors that you just dis-
connected behind the water pump tube and wind them
on the frame hook present on the left side of the motor-
cycle.
Unscrew the two battery holder fixing screws on the

right side of the motorcycle.
Remove the five clamps indicated in the figure.
- 28 -
Frame
Disconnect the rear headlight connector.
Disconnect the start-up remote switch.
Slightly lower the battery holder from the right side and
remove the rear frame electrical wiring.
- 29 -
Frame
Wind the wiring and fasten it on the control unit fixing

clamp.
FRAME DISASSEMBLY
Unscrew and remove the right lower rear fixing nut
from the frame. Remove the spindle from the left side
of the frame.
Unscrew and remove the upper rear fixing screws from

both sides of the frame.
- 30 -
Frame
Unscrew and remove the engine fixing screw from the

left side of the frame.
Loosen the engine fixing screw from the right side of

the frame without removing it.
Remove the bushes from the rear right and left frame
fixing points with the aid of a special tool.
- 31 -
Frame
Holding up the front part of the frame, remove the

engine fixing screw from the right side of the frame.
Remove the frame from the engine, taking care not to

damage the electrical wiring.
FRAME CHECKS AND INSPECTION

Carefully clean the coupling bevel housing from the
steering sleeve.
- 32 -
Frame
Check that no surfaces have any bumps or dents.
Check that none of the area highlighted in the figure is

deformed (as a result of any accidents).
Check that there are no dents or evident breakage on

frame tubes.
Replace frame if any damage is detected.
In this case, remove the following components: G

- Exhaust valve actuator / Fuse box / Support
- Injection control unit / Support
- Dashboard / Front headlight support
- Clamps / Electrical wiring
- 33 -
Frame
- 34 -
Frame
Steering sleeve housing check

Check the diameter and for any ovalisation on the
steering sleeve bevel housing, at 3 mm from the upper
and lower edge as shown in the drawing here to the
side.
Measure ovalisation in different points as shown in the

diagram.
- 35 -
Frame
FRAME ASSEMBLY ON THE VEHICLE

If frame replacement should be necessary, you can
recover components from the old frame, in particular
the fairing attachment plates and threaded caps.
These components can be assembled on the new
frame after having carried out a careful inspection.
Contact MV AGUSTA spare parts service for approval

punching and decals on the new frame.
Carefully clean the frame-engine head and frame- rear

suspension plates coupling planes.
- 36 -
Frame
Before proceeding with frame reassembly, replace the

previously removed electrical wiring and components.
- 37 -
Frame
See Chapt. E - Electrical System regarding the posi-

tioning and passage of cables, clamps and wiring.
Preliminary wiring positioning operations on the

engine
To facilitate reassembly, before repositioning the frame

on the vehicle, perform the following cable and tubing
G positioning checks.
- Make sure that alternator and gear sensor connectors

are in position (A).
1 2 C
3 4
- Make sure that the coil cables are positioned between
the suction manifolds (1-2) and (3-4). H
- Make sure the solenoid valve suction tubes (B) and F

the phase sensor (C) are fitted behind the suction
hoses. A B
- Make sure the rev sensor cable (D) is wound togeth- G

er with battery and ground cables (E).
D
- Make sure there are three rubber caps on the engine,
two on the cylinder flute (F) and one on the blow-by
cover (G). E
- Check the proper passage of the TSS closing tube

(H).
- 38 -
Frame
Carry out the sequence of operations of assembly in

reverse order to removal for the correct assembly of
the frame to the motorcycle.
Tighten the various fixings to the torque pressure
shown in the following diagram.
PART. DESIGN NO. DESCRIPTION DIM. TORQUE PRESSURE

N·m Kgm
1 8000B3004 Front engine mounting screw M12x1,25 55/60 5,5/6,0
2 8000B3561 Upper engine mounting screw M12x1,25 55/60 5,5/6,0

G
3 8000B2756 Lower engine mounting screw M12x1,25 55/60 5,5/6,0
4 8000B2750 Plate – frame screw M12x1,25 55/60 5,5/6,0
5 8000B2751 Front fork pin screw M15x1,25 70/75 7,0/7,5
6 8000B2755 Rear suspension compensator screw M10x1,25 45/50 4,5/5,0
7 8D00B2690 Plate – lower sub-frame fixing screw M8x1,25 24/28 2,4/2,8
8 8D00B2690 Plate – lower sub-frame fixing screw M8x1,25 24/28 2,4/2,8
The tightening of the engine mounting screws and the

plates 1 2 3 4 5 6 is effectuated with the motor-
cycle resting on its wheels and the engine hanging
from the frame.
The tightening of the rear sub-frame screws 7 8 is

carried out by letting the sub-frame drop into position
by its own weight.
Utilise AGIP GREASE 30 for the screws.
- 39 -
Frame
- 40 -
Frame
REAR FRAME DISASSEMBLY

Remove the rubber caps from the upper fixing screws
on the rear frame.
Remove the four frame fixing screws.

Hold the frame up before removing the last screw.
Remove the rear frame from the vehicle.
- 41 -
Frame
FRAME PLATE REMOVAL

Cut the chain as described in chapter F "Suspension
and Wheels."
Remove the exhaust manifold support screw from the
right side of the motorcycle.
Disconnect the rear brake pump connector.
Remove the rear brake pump fixing screws.
- 42 -
Frame
Remove the rear brake pump and wind it with protec-

tive material.
Remove the gear control pedal.
Remove the rear wheel fixing nut and disassemble the

wheel.
- 43 -
Frame
Position an adequate support under the rear part of the

motorcycle.
Loosen the fork spindle pivot nut from the right side of
the motorcycle.
Partially slide the fork spindle pivot off from the left side
of the motorcycle.
- 44 -
Frame
Remove the plate-rear suspension unit from the

engine, moving it from the rear part of the motorcycle.
Remove the rear brake fluid tank.
Remove the rocker spindle fixing nut.
- 45 -
Frame
Remove the fork pivot spindle fixing nut.
Remove the rocker spindle from the left side of the

motorcycle.
Remove the right frame plate.
- 46 -
Frame
Remove the fork pivot spindle from the left side of the
motorcycle.
Remove the left frame plate.
REAR FRAME UNIT ASSEMBLY

To assemble the rear sub-frame unit to the motorcycle,
proceed in the reverse order of removal. Tighten the
four fixing screws (1), two on each side, to the pre-
scribed torque pressure.

(See page 39).
1
24÷28 N•m
- 47 -
Frame
ENGINE DISASSEMBLY FROM THE FRAME

Support the motorcycle with the aid of the following
kickstands:
- Code 800092642: Rear kickstand
- Code 800095807: Front kickstand
- Code 8000B4303: Engine support

- Throttle body (page 17)
- Secondary air valve (page 5)
- Water radiator (chapt. L "Cooling system")
- Exhaust silencers (page 8)
- Exhaust manifolds (page 12)
Remove the suction hose clamps, loosened in the

throttle body disassembly procedure (on both sides).
Disconnect the clamps and remove the suction tube fro

the solenoid valve.
- 48 -
Frame
Disconnect the two exhaust valve control cables from

the actuator and remove them from the lower right part.
Remove the two control unit fixing screws, sliding them

toward the rear part and resting them on the engine.
Disconnect the coil cable connectors and remove them

- 49 -
Frame
Temporarily reposition the control unit on the frame,

partially screwing in one screw.
Remove the previously removed battery cable clamp

and wind the cables themselves on the engine.
Remove the wiring holding clamp on the right side and

disconnect the rev sensor connector.
- 50 -
Frame
Disconnect the Lambda probe connector.
Disconnect the complete rear brake pump, removing

the two screws.
Insert the rear brake pump in a protection cap, fixing it

with an elastic on the frame.
- 51 -
Frame
Remove the screw and remove the gear pedal.
Remove the four clutch cover fixing screws.
Remove the cover holding the clutch control rod on the

engine.
- 52 -
Frame
Protect the cover with a nylon cap and remove the two
wiring holding clamps.
Rest the cover on the handlebar.
Break the chain as described in chapt. F "Suspension

and Wheels" and remove the chain from the pinion.
- 53 -
Frame
Disconnect the kickstand connector and the oil pres-

sure connector.
Move wiring upward, winding it on the frame.
Disconnect the gear sensor connector and the alterna-

tor cable connector.
- 54 -
Frame
Disconnect the water temperature sensor connector.
Loosen the fork spindle tightening screw, turning it

once.
Loosen the rocker spindle nut from the rear suspen-

sion.
- 55 -
Frame
Remove the lower engine spindle nut.
Extract the lower engine fixing spindle from the left side
of the motorcycle.
Remove the upper engine spindle nut.
- 56 -
Frame
Extract the upper engine fixing spindle from the left

Remove the front engine support screws (one per

side).
With a special tool, extract the bushes (one per side) of

approximately 15 cm in order to free the engine.
- 57 -
Frame
Push the engine forward by hand approximately 3 cm.
Lower the rear engine support screw in order to turn

the engine downward.
Lift the front part of the motorcycle by means of the rel-

ative front kickstand crank.
- 58 -
Frame
Use the crank to free the engine.
ENGINE ASSEMBLY ON THE FRAME

To facilitate reassembly, before repositioning the
engine on the vehicle, perform the following cable and
tubing positioning checks.
- Make sure that alternator and gear sensor connectors G

are in position (A).
- Make sure that the coil cables are positioned between C

1 2 3 4
the suction manifolds (1-2) and (3-4).
- Make sure the solenoid valve suction tubes (B) and H

the phase sensor (C) are fitted behind the suction
hoses. F
- Make sure the rev sensor cable (D) is wound togeth- A B

er with battery and ground cables (E).
G
- Make sure there are three rubber caps on the engine,
D
two on the cylinder flute (F) and one on the blow-by
cover (G).
- Check the proper passage of the TSS closing tube E

(H).
- 59 -
Frame
Reposition the engine under the motorcycle.

Lower the front part of the motorcycle by means of the
relative front kickstand crank.
Use the crank to align it for front engine fastening.
This operation must be performed several times in

order to prevent damage to the frame with the head-
cylinder fixing screw.
G
Insert the two front engine support screws (one per

part) and screw in for only 2/3 of a turn.
- 60 -
Frame
Fully lower the front kickstand.
Lift the rear engine support screw in order to turn the

engine upward and realign with fixing holes.
Insert the lower engine fixing spindle.
- 61 -
Frame
Rest the two front support screws (one per part).
With a special tool, bring the engine centring bushes in

position.
Insert the upper engine support spindle.
Make sure the wiring on the right side follows the direc-
tion of the frame tubes.
Perform all other remaining operations in the reverse

order of disassembly, lubricating the various fasteners
and tightening them to the torques detailed on page
39.
- 62 -
Brakes
SECTION
Revision 0
H
-1-
Brakes
SUMMARY
FRONT BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

FRONT BRAKE PADS SUBSTITUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 4
SUBSTITUTION AND BLEEDING OF THE FRONT BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 6
FRONT BRAKE CALIPERS SUBSTITUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 10
FRONT BRAKE PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 10
REPLACING THE BRAKE FLUID TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 11
REPLACING THE FRONT BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 13
CLUTCH LEVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 13
FRONT BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 14
FRONT BRAKE DISC REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 15
REAR BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 17
REAR BRAKE PADS SUBSTITUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 18
SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 20
REAR BRAKE CALIPERS SUBSTITUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 22
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 24
REAR BRAKE DISC REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 24
-2-
Brakes
FRONT BRAKE SYSTEM
D E
H
G
A B C D E F G H
N·m 2 8 8÷10 40 ÷ 42 23 ÷ 26 16 ÷ 18 8 ÷ 10 23 ÷ 25
Torque Kg·m
pressure
ft·lb
243
Operation
Description F4 1000
FRONT BRAKE
Type Dual floating disc with steel braking band
Ø discs (mm) 320
Disc flanges Aluminium
Calipers (Ø pistons mm) Radial-type, single-piece with 4 pistons Ø 34
Front disc thickness (mm) 5
Min. pad thickness (mm) 1
It is advisable to remove the parts of the bodywork as described in the chapter "Bodywork" that could obstruct
normal operations, before proceeding with the overhaul of the front brake system.
-3-
Brakes
FRONT BRAKE PADS SUBSTITUTION

To replace the front brake pads, remove the front brake
caliper, as detailed in the “Suspensions and Wheels”
section.
Widen the pads with a screwdriver so that the pistons

are pushed back into their seats (as shown in the fig-
ure).
The movement towards the outside of the

brake pads makes the pistons go back into
their seats, with the consequent increase in
the level of the brake fluid in the brake fluid
chamber.
Move either pad to the centre of the opening and pull it

out of the caliper. Repeat on the other pad.
Every 6000 kilometres, check the wear of the pads.

The thickness of the friction material must not be less
than 1 mm. If the pads are excessively worn, substitute
them.
Brake disc
Brake pads
-4-
Brakes
Before fitting the pads back in, make sure the plate
rests against its stop. If it does not, push it down, as
shown in the Figure.
Fit either pad through the midst of the front back caliper
opening, then push it towards its pistons. Do the same
with the other pad.
Fit the caliper back in but do not tighten the screws.
Operate the front brake lever to position the pistons

(pushing against the pads).
While pulling the front brake lever, tighten the caliper

screws to the right torque.
Torque pressure calipers: 40÷42 N·m
40÷42 N•m
-5-
Brakes
SUBSTITUTION AND BLEEDING OF THE FRONT

BRAKE FLUID
Place the motorcycle on a horizontal surface with the
steering in a straight line.
It is advisable to remove the nose fairing when carry-
ing out this operation.
Remove the two screws of the front brake fluid cham-
ber cover.
Brake fluid has a strong corrosive power.

Be careful to not spill the fluid on surround-
ing parts.
If the fluid is spilt clean immediately with
industrial alcohol and dry with compressed
air.
Remove the protection cap of the bleed valve of the

front right caliper.
Put in the steering key, then fit a rubber tube on to the
dump screw (on top of the brake calliper).
Put the other end of the rubber tube in a suitable con-
tainer.
Pull the brake lever without releasing it.

Slacken the bleed valve and empty the brake system.
Tighten again the bleeding screw, before releasing the

brake lever.
-6-
Brakes
Fill the system by pulling the front brake lever 3-4 times
(see figure).
Repeat the above operations until the fluid reaches the
minimum level in the reservoir. Top up with fresh fluid
and carry on with the operation until fluid of a different
colour (fresh) flows out.
The quantity of brake fluid necessary for this operation
is approximately 250 cc.
NOTE Repeat this operation on both pincers.
Recommended brake fluid: AGIP Brake

Fluid DOT 4
Utilise only the prescribed brake fluid from
sealed containers. NEVER use old or used
brake fluid.
Tighten the bleed screw, remove the rubber tube, care-

fully clean the screw with alcohol, blow it dry and put the
protective cap back on.
Bleed screw tightening torque: 8 Nm
Slowly squeeze the brake lever to bring the pads in

contact with the disc and also checking that there is no
sponginess in the action of the lever. Air bubbles
should not rise in the chamber.
If the bleeding has been done correctly, the movement
of the lever is short and without any elastic effect.
Repeat the bleeding operation if there is still spongi-

ness at the lever.
-7-
Brakes
Pour new brake fluid into the chamber until it reaches

the maximum level.

Fluid DOT 4
Utilise only the prescribed brake fluid from

sealed containers. NEVER use old or used
brake fluid.
Top-up the level of the fluid until it reaches the maxi-

mum mark
Carefully clean around the edge of the brake fluid

chamber utilising a clean cloth.
Imperfect cleaning of this component could

cause the loss of small quantities of brake
fluid whilst riding.
-8-
Brakes
Accurately clean the three elements of the brake fluid

chamber cap with alcohol and dry with compressed air.
Place the cap on the brake fluid chamber and tighten

the two lateral fixing screws.
-9-
Brakes
FRONT BRAKE CALIPERS SUBSTITUTION
• Slightly move the front brake lever towards the right

handgrip and hold it in position with a strap to limit
the outflow of brake fluid during subsequent opera-
tions.
• Taking care to not spill any remains of the brake fluid
that may remain inside the brake tubing, remove the
union as indicated in the figure.
Brake liquid can corrode painted surfaces. Clean
immediately any spilt brake liquid using industri-
al alcohol and drying with compressed air. .
• Remove the two caliper fixing screws indicated in

the figure.
• Remove the brake caliper.
NOTE The removal operation is identical for both
calipers.
To fit the front brake calipers, follow these steps:
• Insert the caliper fixing screws and turn them it until
they make contact.
Only grease the first threads of the brake
caliper fixing screw.
H • Refit the caliper connection after replacing the sea-

ling washers.
Torque pressure caliper union: 23÷26 N·m
• Fill the system with brake fluid.

• Bleed the system as described on page 6.
23÷26 N•m 40÷42 N•m
• Keep the brake lever pulled back with a strap and
tighten the brake caliper fixing screws.
Torque pressure calipers screws: 40÷42 N·m
FRONT BRAKE PUMP REMOVAL

Remove the cap from the front brake fluid reservoir
and drain the reservoir with a syringe.
Remove the union indicated in the figure.
Brake fluid is extremely corrosive.

Avoid contact with the eyes, skin and nose.
Wash abundantly with water and call a doc-
tor if accidental contact occurs.
During the following operations, avoid con-

tact with painted surfaces.
- 10 -
Brakes
Remove the connectors of the electrical system.
Remove the fixing screw that fixes the pump to the

handlebar.
Open the clamp.
Push down to remove the pump from the reference pin.
REPLACING THE BRAKE FLUID RESERVOIR

Loosen fixing screw (1) and then remove the brake
fluid reservoir.
- 11 -
Brakes
Thoroughly clean housing (1).

2
Fit O-ring (2) into its groove.
NOTE Use a new O-ring.

1
Place reservoir (1) in its housing (2).

3 1
Insert rubber separator (3).
2
H
Put a thread-brake of the recommended type on the

first few threads of the locking screw (1).
Specific product: Loctite 243
Insert the fixing screw (1) into the corresponding

threaded hole and tighten the screw to the prescribed
torque pressure.
Torque pressure: 2 N•m
NOTE When refitting the float chamber, use a new

fixing screw.
1
NOTE To substitute the reservoir of the clutch pump,
operate exactly in the same way as the front 2 N•m
brake pump.
- 12 -
Brakes
REPLACING THE FRONT BRAKE SWITCH
To replace the front brake switch, remove the screw

After having carried out the overhaul of the

front brake pump assembly, carefully wash
and bleed the front brake system as previ-
ously described in this chapter.
CLUTCH LEVER REMOVAL

Remove the nut shown in the figure.
Unscrew the pin.

Remove the clutch lever.
- 13 -
Brakes
When reassembling, be careful to insert the

pin of the pump piston into the seat situated
on the lever (see figure).
Grease the pin:
For the reassembly of the lever tighten the pin.

Tighten the nut while holding the pin in place with a flat
blade screwdriver.
Torque pressure: 8 - 10 N·m
NOTE To remove the brake lever, follow the proce-

dure used for the clutch lever.
8÷10 N•m
FRONT BRAKE DISCS

Check the thickness of the front discs utilising a
micrometer gauge and measure three points at least
with 120° between them as shown in the figure.
Use a micrometer gauge for this check.
- Minimum allowable thickness: 4.5 mm
This operation just be carried out on both front discs.
If the measurements are below the mini-

mum, substitute the component with a new
one.
- 14 -
Brakes
FRONT BRAKE DISC REMOVAL

Take down the front wheel as described in chapter F
"Suspensions and Wheels".
Using two special spanners (see chapter F "Suspen-
sions and Wheels"), remove the front wheel spindle.
Special tool 800092872
Place the wheel in a horizontal position and remove

the five screws of each disc proceeding in a star-like
mode for the removal.
Visually check the discs for lines or score marks.
Place the brake disc on a level surface with the milled

side face down and utilising a micrometer gauge check
that the maximum oscillation of the disc reached dur-
ing a rotation of 360° does not exceed 0.3 mm.
Utilise a micrometer gauge for this check
If the measurements are below the mini-

mum, substitute the component with a new
one.
This operation must be carried out on both front discs.
- 15 -
Brakes
Front disc assembly

Thoroughly clean the contact surfaces of the discs and
the wheel.
Accurately grease all relative surfaces of the disc
before reassembling.
The following operation is to be carried out on all mod-

els.
Apply thread-locking fluid to the five fixing screws of

the disc.

H 243
Screw in the screws lightly, proceeding in a star-like

mode. 23÷25 N•m
Continuing in a star-like mode, tighten the screws to
the prescribed torque pressures.
Torque pressures: 23-25 N·m

Be careful to reassemble the discs in the original posi-
tions (it is advisable to mark them by applying an adhe-
sive label).
This operation is important so that a good

contact between the brake discs and the rel-
ative pads.
Proceed by reassembling the parts in the reverse order
of removal. Consult chapter F “Suspension and
wheels” for further information.
- 16 -
Brakes
REAR BRAKE SYSTEM
F
D
E H
C
A B C D E F G H
N·m 220 ÷ 240 15 ÷ 20 16 ÷ 18 8 ÷ 10 18 18 ÷ 20 16 ÷ 18
Torque
pressure Kg·m
ft·lb
243 270
Operation
Description F4 1000
REAR BRAKE
Type Single steel disc
Ø discs (mm) 210
Caliper (Ø pistons mm) With 4 pistons Ø 25.4
Rear disc thickness (mm) 6
Min. pads thickness (mm) 1
- 17 -
Brakes
REAR BRAKE PADS SUBSTITUTION

Remove the safety retainer and unscrew the rear ring
nut by turning it clockwise (see figure).
Remove the wheel.
Utilising circlip pincers as shown in the figure, widen

the pads so that the pistons are pushed back into their
seats.
The outward movement of the brake pads

provocates the retraction of the pistons in their
relative seats, with a consequent increase in
the level of the brake fluid in the brake fluid
chamber.
H
Unscrew the spindle as shown in the figure.
- 18 -
Brakes
Remove the pad support pin (1) and the relative spring
(2).
Remove the pad (3) by letting it drop down. 3
Carry out the check every 6000 kilometres.
Brake disc
H
Brake pads
Check the condition of the rear braking system and its

components.
Refit as described for the front braking system.
- 19 -
Brakes
Tighten the pin to the prescribed torque pressure.
15÷20 N•m
SUBSTITUTION AND BLEEDING OF THE REAR

BRAKE FLUID
1
The operation described herewith must be

carried out with the engine cold because of
the nearness of the exhaust tubes that could
cause grave burns.
It is necessary to remove the seats, rear fairings and

H fuel tank before performing these operations (see
chapter C "Superstructures").
Open the cover of the rear brake fluid reservoir by
removing the two screws (1).
Be careful to not spill the fluid from the

reservoir during these operations.
Brake fluid is extremely corrosive.
Avoid contract with the eyes, skin and nose.
Wash abundantly with water if contact is
accidentally made and consult a doctor.
During the successive operations, avoid
spilling the fluid onto painted surfaces.
Fill the braking system by operating the rear brake

lever.
- 20 -
Brakes
Connect a rubber tube to the bleed valve, empty the

system in an appropriate container by slackening the
bleed valve as shown in the figure
Tighten the bleed valve.

Fill the rear brake fluid reservoir until the fluid reaches
the maximum level.

Fluid DOT 4
Utilise exclusively the prescribed brake

fluid. Use only new brake fluid from sealed H
containers. NEVER utilise old or used brake
fluid.
Carefully clean around the edge of the brake fluid tank

using a clean cloth.
Before closing the fluid reservoir, check the condition

of the components.
Carry out bleeding also on the front brakes (see the
paragraph in this chapter).
- 21 -
Brakes
REAR BRAKE CALIPER SUBSTITUTION

To facilitate the operation, remove the brake pads as
described previously.
Empty the rear brake system as previously described
in the paragraph “SUBSTITUTION AND BLEEDING
OF THE REAR BRAKE FLUID”.
Remove the tubing by unscrewing the union indicated
in the figure.
Pay attention to the fluid left in the caliper and the tube.
Remove the two screws indicated in the figure.

Substitute the caliper. 18 N•m
For reassembly, tighten the two screws to the pre-
scribed torque pressure.
Recommended threadlocking product:

Loctite 243

H
Assemble the union tightening to the prescribed

torque.
16÷18 N•m
Torque pressure: 16-18 N·m
NOTE Substitute the gaskets with new ones.
Proceed with the filling and bleeding of the rear brake

system (see page 20).
- 22 -
Brakes
Rear brake pump removal

Carry out the emptying of the brake system as previ-
ously described.
Remove the clip with the pump control fork pin by turn-
ing the pin and pulling it out (see figure).
Unscrew connection (1) as shown in the figure so as to

disengage the pump from the brake line.
1
Unscrew the two fixing screws (2) of the brake pump to H

its relative support.
Remove the Lambda probe connector support plate.
Remove the pump.
Remove and disconnect the the Lambda probe con-

nector.
Remove clamp and disconnect the tube.
- 23 -
Brakes
After having carried out a check on all components and

substituted those used, damaged or defective proceed 16÷18 N•m
with the assembly by following the procedure in
reverse order of removal.
NOTE Substitute the gaskets of the pump/caliper

hoses.
Tighten the fixings to the prescribed torque pressure.
8÷10 N•m
Torque pressure pump union: 16÷18 N·m
Torque pressure brake pump/support: 8÷10

N·m
Conclude the operations by filling the system with
brake fluid and successively bleeding the system (see
page 20).
REAR BRAKE DISC
Check the thickness of the rear brake disc.

Substitute the disc if the measurements are less than
the minimum value allowed. Effectuate the substitution
as hereby described.
- Minimum thickness allowed: 5,7 mm

H
REAR BRAKE DISC REMOVAL

Before proceeding with the removal of the rear brake
disc, it is necessary to carry out certain operations
described previously in this chapter:
Remove the rear wheel.
Remove the rear brake disc from its support.
Remove the four nuts fastening the disc to the flange.
Remove the four nuts previously freed by extracting

them from the rear part of the motorcycle and rotating
the disc to facilitate the removal of the nuts.
- 24 -
Brakes
Check the planarity of the rear brake disc by utilising a

micrometer gauge and placing the disc on a level work
surface. Utilise the same procedure adopted for the
front wheel discs.
The planarity value must not exceed 0.3 mm.
Utilise a micrometer gauge with support to

carry out this check.
Check the thickness of the rear brake disc by utilising

a micrometer gauge and measuring at least at three
points with 120° between them.
The minimum thickness of the disc must not be less

than 5.7 mm.
Utilise a micrometer gauge for this check.

H
Before fitting the rear brake disc, check the condition of

the four pins. 18÷20 N•m
Replace the four special nuts with new ones.
Proceed with tightening of the nuts.
Turn in the nuts until they make contact,

then tighten them in a crosswise pattern.
Loctite 270
Torque pressure: 18-20 N·m.
Conclude the reassembly operations of the various

components by following the procedures previously
described in the chapter.
- 25 -
Brakes
- 26 -
Cooling system
SECTION
Revision 0
L
-1-
Cooling system
SUMMARY
COMPLETE COOLING SYSTEM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

COOLING SYSTEM LEAKAGE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 4
WATER RADIATOR CAP CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 4
ENGINE COOLANT EXTRACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 5
WATER RADIATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 5
WATER RADIATOR COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 10
WATER RADIATOR COMPONENT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 15
THERMOSTATIC VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 17
THERMOSTATIC VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 19
WATER RADIATOR VEHICLE UNIT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 20
OIL RADIATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 21
OIL RADIATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 25
FILLING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 26
MOTOR OIL SYSTEM FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 27
SYSTEM FUNCTION VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 28
-2-
Cooling system
COMPLETE COOLING SYSTEM ASSEMBLY
Before proceeding with the disposal or overhaul of any component relative to the cooling system, carry out cer-
tain preliminary operations:
1) Let the engine cool down.
2) Remove the side fairings, the underfairing, the fairings push rod, the headlight fairing, the suction duct covers
and suction ducts as described in the chapter "Superstructures."
-3-
Cooling system
COOLING SYSTEM LEAKAGE CHECK
Before removing the radiator and discharging the

engine coolant, check that the cooling system does not
have leakages.
Remove the water radiator cap and connect the tester
(of the type shown in the diagram) to the filler hole.
Do not open the radiator cap whilst the

engine is hot.
Apply a pressure of approximately 120 kPa (1.2

kg/cm2) and check that the system maintains the pres-
sure for at least 10 seconds.
If the pressure diminishes within ten seconds means

that there is a leak in the system.
If so, check the entire system and substitute the defec-

tive/damaged parts.
When removing the tester from the filler

hole, wrap a cloth around the filler hole to
avoid spurts of engine coolant.
Do not exceed the recommended pressure

to avoid damaging the radiator.
L
WATER RADIATOR CAP CHECK

Check the release pressure of the radiator cap by util-
ising the appropriate tester as follows:
Apply the cap to the tester as indicated and slowly cre-
ate a pressure by activating the tester.
Make sure that the increase in pressure is interrupted
at 110±15 kPa (1.1±0.15 kg/cm2) and check that with
the tester held steady, the pressure is maintained for at
least ten seconds. Substitute the cap if the pressure is
not maintained for ten seconds.
Radiator cap release pressure: 110±15 kPa (1.1±0.15

kg/cm2).
-4-
Cooling system
ENGINE COOLANT EXTRACTION
Remove the water radiator cap. 2

Open the cap of the expansion tank.
Empty the cooling system of the coolant as follows:
• Place under the engine a container to collect the dis-

charged coolant.
• Remove the discharge screw (1) situated on the
water pump (2)
• Make sure the coolant flows into the container. 1
Wait until all the engine coolant has dripped out of the
cooling system.
RADIATOR DISASSEMBLY
After having emptied the cooling system, proceed as

follows to remove the radiator:
Disconnect the connectors (1) of the radiator electric 1

fans of the right side of the motorcycle.
-5-
Cooling system
Disconnect the tension regulator connector from the

left side of the motorcycle and remove the holding
clamp.
Disconnect the three clic holding clamps of the radiator

tubes.
Special tool: CLIC 205 pincers
Disconnect the tubes.
-6-
Cooling system
Remove the upper and lower fixing screws of the radia-

tor from the left side.
Remove the upper central radiator fixing screw.
Holding the upper radiator (water), push the lower

radiator (oil) toward the right to remove the connector
pin.
-7-
Cooling system
Lower the left side radiator and push it toward the right
to remove the upper support pin.
Extract the radiator from the left side, turning it as

If necessary, to carry out overhauling of the lower

water union tube, remove the two clic clamps at the
end of the radiator filling tube on the left side of the
motorcycle.
-8-
Cooling system
Remove the tube.
Before carrying out this operation, position a collection

container under the engine to collect any residual
liquid.
NOTE Carry out the said operations with care.

Pour the remaining coolant inside the
radiator into an appropriate container.
Do not dispose of engine coolant in the envi-

ronment. Collect in an appropriate container
and dispose of it according the norms in
force.
With the aid of a screwdriver, unhook and remove the

holding clamps of the lower water union tube, both
from the right side and from the left side of the motorcy-
cle.
Remove the tube from the supports and check vibra-

tion damper conditions.
-9-
Cooling system
WATER RADIATOR COMPONENT DISASSEMBLY
Expansion tank removal

Unscrew the expansion tank cap.
Empty the tank in an appropriate container.
Disconnect the clic holding clamp of the water radiator

recovery tube and remove the tube.
- 10 -
Cooling system
Remove the two radiator tray screws and remove the

tray itself.
Check for any tube faults.
Tension regulator disassembly

Remove the two tension regulator support fixing
screws and remove the regulator.
Electric fan disassembly

Remove the central cable holding clamp.
- 11 -
Cooling system
Remove the two rigid clamps cutting them with clip-

pers.
Disconnect the two electric fan cable connectors.
Remove the 6 fan rack fixing screws (3 per side) and

remove racks.
- 12 -
Cooling system
Radiator fastening component disassembly.

Remove the four threaded clips.
Release the closing cap clic clamp and remove

everything.
- 13 -
Cooling system
Unscrew and remove the radiator anchoring pin.
Remove the left upper support bracket spacer.
Remove the upper support bracket vibration dampers.
- 14 -
Cooling system
RADIATOR GROUP ASSEMBLY

Before reassembling, check the correct rotation of the
fans, the condition of all components and all connec-
tions.
Radiator check and clean
The dirt and extraneous material embedded in the radi-

ators must be removed.
It is recommended to use compressed air for the clean-

ing of the radiator.
Bent fins can be straightened by utilising a small

screwdriver.
Cooling fan motor check

To check the efficiency of the fan motors it is necessary Electric fan
to connect them as indicated in the figure, utilising a Motorino
motor
elettroventola Ammeter
Amperometro
voltmeter and ampmeter.
During the check, the fans must be fed by 12V and this
test can be carried out on a work surface (connecting A
a 12V–9Ah battery) or on board the motorcycle.
The voltmeter is to check that the battery feeds the
motor at 12V. When the fan turns at maximum speed
the ampmeter should indicate not more than 5 ampere. Battery
Batteria V Voltmeter
Voltmetro
If the motor does not turn, substitute the fan motor unit
with a new one.
NOTE To carry out the above-indicated test it is

L
not necessary to remove the fan motors
from the engine.
Position the electric fans on the upper radiator.

Position electric fan wiring as indicated in the figure.
- 15 -
Cooling system
Tighten the 6 screws (3 per fan) to the prescribed tigh-

tening torque.
Replace the previously removed components following

the disassembly procedures inversely.
5÷6 N•m
Recovery tank fixing screws:

8 N•m

Loctite 243
Radiator connection pin:
- 16 -
Cooling system
The assembly of the new radiator group has been

completed.
At the end of the assembly operation, the radiator
group should look like the group indicated in the figure.
The radiator group can be mounted onto the motorcy-

cle.
THERMOSTAT REMOVAL
Unhook the tube clic clamps of the thermostatic valve

and remove the tubes.
Remove the three fixing screws (1) of the thermostat
cover.
Remove the cover of the thermostat (1).

Remove the thermostat (2).
- 17 -
Cooling system
Check
Check to see if the thermostat pad is damaged.
Check the functioning of the thermostat as follows:
• Suspend the thermostat by a piece of string threaded

through the flange as indicated in the figure.
• Immerse the thermostat in water contained in a labo-
ratory glass as indicated in the figure. Ensure that the
thermostat is maintained in suspension. Heat the
water with a heat source and observe the increase in
temperature of the thermometer.
• Observe the temperature at the moment of opening of
the thermostat. The temperature at which the thermo-
stat commences to open should be between the indi-
cated values.
Standard
Thermostat opening temperature:
60°C
• Continue to heat the water to increase the tempera-
ture.
• When the temperature of the water reaches the spec-
ified value, the thermostat should be raised up by at
least 7 mm.
Standard
Raising up of the thermostat:
More than 7.0 mm at 90°c.
• If the thermostat does not satisfy only one of the req-
uisites (opening temperature and raising up of the
thermostat), it must be substituted.
L
- 18 -
Cooling system
THERMOSTAT ASSEMBLY
Insert the O-ring (1) in its appropriate seat on the cover

of the thermostat.
1
Check the condition of the O-ring previously utilised.
If the O-ring is not in good condition, substi-

tute it with a new one.
Apply a thin layer of silicone grease.
Recommended grease: Silicone Grease.
Apply grease on the outer flange of the thermostatic

valve on the inlet side of the engine.
Insert the thermostatic valve in its housing on the engi-

ne. 3
During thermostatic valve assembly, ensure that the
notch (2) present on the outer flange of the valve is 2
positioned near the machining (3) on the engine.
- 19 -
Cooling system
Insert the thermostat cover on the engine.
Tighten the three fixing screws (1) to the prescribed

torque pressure.
Replace the tubes on the thermostatic valve and fasten

the relative clic clamps.
L
10 N•m
WATER RADIATOR VEHICLE UNIT ASSEMBLY
Insert the upper right radiator mount into the peg on the
frame (right side).
Reassemble the radiator unit in the opposite order of

disassembly.
- 20 -
Cooling system
OIL RADIATOR DISASSEMBLY
Insert the receptacle under the engine and remove the

oil drain screw.
Proceed with emptying oil present in the engine.
Remove the clamps from both sides of the central

water tube with the aid of a screwdriver.
- 21 -
Cooling system
Remove the screws from the tube holding plate of the

radiator and remove the plate.
Remove the lower oil radiator support bracket.
Move the tube support plate outward to facilitate the

following operations.
- 22 -
Cooling system
Remove the tube unions from the right side of the oil
radiator with the aid of a screwdriver.
Remove the central water tube from the supports on

the oil radiator.
Remove the oil radiator support screw from the left

- 23 -
Cooling system
Lower the oil radiator from the left side and push
toward the right to free it from the support pin.
Remove the oil radiator.
Check the conditions of the component and, if neces-

sary, straighten the folded flaps with a screwdriver.
- 24 -
Cooling system
OIL RADIATOR ASSEMBLY

Before reassembly, check the integrity of the oil tubes
and replace if necessary.
Also check conditions of the oil tube union seal rings
and replace if necessary.
Grease O-rings with silicone grease.
Reassemble previously removed components in the

opposite order of disassembly.
NOTE The radiator group that has just been

assembled should be complete with all
parts as shown in the exploded view in
page 3 of this chapter.
Carry out a final check before proceeding
with successive operations.
For an eventual codification and definition
of the parts, consult the spare parts cata-
logue (Table G08).
- 25 -
Cooling system
FILLING THE COOLING SYSTEM

figure.
Fill the cooling system with a suitable liquid described
in the table (see page B-8) until you reach the level of
the bar of the radiator filler cap. Do this in stages to sta-
bilise the liquid level.
Close the cap and move the motorcycle to a horizontal

position.
Switch on the engine and keep it running until the

water becomes hot enough to automatically switch on
the electric cooling fan. Switch off the engine. Repeat
the operation at least once, then wait some minutes for
the engine to cool down.
Carefully check for leaks, blow-bys, dam-
aged tubing, etc. If there are leaks or damage
in the cooling system, proceed with the over-
haul as described in the chapter “Cooling
system”.
Remove the cap of the upper expansion tank.

Fill the system with the appropriate coolant.
Carefully check that there is no leakage from the cool-
ing system or the exchanger.
The level should be between the «MIN» and «MAX»
mark found on the expansion tank.
If the level is less than the indicated «MIN» line, open
the expansion tank cap and top-up with new coolant.
Max. level
Min. level
- 26 -
Cooling system
MOTOR OIL SYSTEM FILLING
Unscrew filler plug using the 10-mm hexagonal bar

provided fitted to a specially designed spanner (see
figure).
Pour in the required quantity of oil.
Check the level of oil in the appropriate window.
MAX
MIN
Before replacing the filler plug, grease O-ring (1) with

silicone grease, then reinsert it into its seat (see fig- 2 1
ure).
Tighten plug (2) with the prescribed torque.
Torque pressure: 35 N·m 1
35 N•m
- 27 -
Cooling system
SYSTEM FUNCTIONING CHECK
Assemble the following components in order:

• Airbox.
• Fuel tank.
• Rear side panels.
• Fuel tank side panels.
• Airbox side panels.
For the assembly operations, assemble in reverse

order of removal.
Cooling system
Insert the ignition key and start up the vehicle engine.
Keep it running until it warms up and wait until fans
enter into operation at least twice. Switch off the engi-
ne and wait for the temperature to cool down. Then do
a final check of the cooling liquid level and top up if
necessary.
Carefully check that there is no leakage from the cool-

ing system or.
Motor oil system

L Start the engine for some minutes.
After having shut off the engine, wait for at least 10
minutes and check the oil level. Ensure that the ground
is flat and keep the motorcycle standing as much as
possible.
The level must be near the “MAX” reference on the
timing case as much as possible. Do not exceed this
limit.
Check any oil leakages.
Avoid making the engine turn with the oil

level lower than the minimum level; this can
impair the operation of the different parts of
the engine.
If the oil level, after the reset, is upper than
the “MAX” reference, correct it by emptying
the system.
Complete the assembly of the motorcycle.
- 28 -
Special tools
SECTION
Revision 1
M
-1-
Special tools
MAINTENANCE TOOLS
The special tools shown in the following chapter are indispensable for a correct carrying
out of the described maintenance operations.
To order the special tools, refer to the spare parts catalogue.
-2-
Special tools
N. Code Q.ty Note F4 1000 Descrizione Description
1 800095830 2 • Cavalletto Front stand

anteriore
2 800091645 1 • Chiave ghiera Steering bearing
cuscinetti di sterzo pin wrench
3 800092857 1 • Chiave ghiera Steering cam
eccentrico sterzo ring nut wrench
4 800092860 1 • Estrattore cuscinetti Fork bearings
forcellone puller
5 800092861 1 • Boccola estrattore Fork bearing
cuscinetti forcellone puller bushing
6 8000B4416 1 • Estrattore cuscinetti Front wheel
ruota anteriore bearings puller
7 800092642 1 • Cavalletto posteriore Rear stand
8 8000A1953 1 • Perno per albero Pin for centering
di centraggio shaft
9 800092865 1 • Attr. bilanciamento Rear wheel
ruota posteriore balancing tool
10 800095850 1 • Pinza montaggio/ Pliers for clic R
smontaggio clamps assembly/
fascette clic R disassembly
11 800098321 1 • Pinza inclinata Clic R clamp
monta fascette clic R fitting pliers
12 800092866 1 • Attrezzo montaggio Fork pack
pacco forcellone assembly tool
13 8000A1039 1 • Attrezzo parapolvere Dust cover and oil
e paraolio splash guard tool
14 8000B4412 1 • Chiave perno Front wheel
ruota anteriore pin wrench
15 8000B4415 1 • Estrattore boccole Frame-engne-plate
telaio-motore-piastra bushes puller
-3-
Special tools
-4-
Special tools
1 800092867 1 • Attrezzo montaggio Equaliser

pacco bilanciere pack tool
2 8000B4421 1 • Attrezzo cuscinetti Front wheel
ruota anteriore bearings tool
3 8000B1439 1 • Attrezzo taglio Chain cutting tool
catena
4 8000B1456 1 • Attrezzo chiusura Chain joining tool
catena
5 8000B1457 1 • Attrezzo ribaditura Chain riveting tool
catena
6 800095807 1 • Cavalletto anteriore Front stand
7 800095808 1 • Perno cavalletto Front stand pin
anteriore
8 800097887 1 • Attrezzo cuscinetto Steering pin
perno di sterzo bearing tool
9 800097888 1 • Piastra di riscontro Steering base
base di sterzo plate
10 800097889 1 • Estrattore cuscinetto Steering pin
perno di sterzo bearing extractor
11 800097890 1 • Attrezzo montaggio Steering pin
cuscinetto bearing
perno di sterzo assembly tool
12 8000B4413 1 • Asta settaggio Rear suspension
sospens. posteriore setting rod
-5-
Special tools
-6-
Special tools
1 8A0094792 1 • Attrezzo montaggio Gear change

cambio mounting tool
2 800086119 8 • Bussola di Locating bush
riferimento
3 8000A1087 1 • Cuscinetto Bearing
4 800098405 1 • Cuscinetto Bearing
5 800087300 1 • Cuscinetto Bearing
6 8A00A5394 1 1 • Software Diagnostics
diagnostica software
6 8B00A5394 1 2 • Software Diagnostics
diagnostica software
7 8000A3406 1 • Attrezzo misura Piston projection
sporgenza pistoni measuring tool
8 800094797 1 • Lastra sagomata Head cover
copri testa shaped plate
9 8000B4304 1 • Attrezzo bloccaggio Alternator shaft
volano
10 8000B4305 1 • Attrezzo estrattore Rotor puller
volano tool
11 800094798 1 • Attrezzo smontaggio Valve rubber caps
gommini valvola removal tool
12 62N115538 1 • Rosetta elastica Spring washer
13 8C0069056 3 • Vite M8x30 Screw M8x30
14 800094796 1 • Attrezzo montaggio/ Valve assembling/
smontaggio valvole disassembling tool
15 800051521 2 • Vite M4x6 Screw M4x6
16 800095429 1 • Tampone controllo Gauge pad
17 800095581 1 • Punzone montaggio Valve seals
tenute valvola mounting punch
18 8000A2385 1 • Tampone Guide mounting
montaggio guida pad, exhaust
scarico
19 8000B4368 1 • Tampone Guide mounting
montaggio guida pad, inlet
aspirazione
20 800095179 1 • Attrezzo Half-cones
smontaggio disassembling
semiconi tool
21 800095180 1 • Attrezzo Half-cones M
montaggio assembling
semiconi tool
22 8000A2625 1 • Broccia per Broach for
guida valvole valve guide
23 8000A7688 1 • Chiave USB USB key
24 8000A5393 1 • Cavo interfaccia Interface cable
25 8C0093878 1 1 • CD-Rom per Diagnostic
software software
diagnostica CD-Rom
25 8D0093878 1 2 • CD-Rom per Diagnostic
software software
diagnostica CD-Rom
26 8000A7689 1 • Adattatore Serial/USB
USB/Seriale adapter
27 8000A9639 1 3 • Piastra di base Base plate
1 Versione Windows 98 - Windows 98 version - Version Windows 98 - Windows 98 Version - Versión Windows 98
2 Versione Windows Vista - Windows Vista version - Version Windows Vista - Windows Vista Version - Versión Windows Vista
3 Da utilizzare con il part. N° 14 (Cod. 800094796) - To be used with part No. 14 (Code No. 800094796) - Employez avec le piéce No° 14 (Code
N° 800094796) - Mit Teil nr. 14 (Kennziffer Nr. 800094796) verwendet werden - Utilizar con la pieza N° 14 (Cod. N° 800094796).
-7-
Special tools
-8-
Special tools
28 8000B2114 1 1 • Software Power unit

programmazione programming
centralina software
28 8A00B2114 1 2 • Software Power unit
programmazione programming
centralina software
29 8000B2116 1 • Chiave USB USB key
30 8000B2117 1 1 • Cavo seriale Serial cable
30 8A00B2117 1 2 • Cavo seriale Serial cable
31 8000B2118 1 1 • CD-Rom per Power unit
software programming
programmazione software
centralina CD-Rom
31 8000B2118 1 2 • CD-Rom per Power unit
software programming
programmazione software
centralina CD-Rom
32 8A00B2859 1 • Tubo Pipe
D39-d27,2-L74,5 D39-d27.2-L74.5
1 Versione Windows 98 - Windows 98 version - Version Windows 98 - Windows 98 Version - Versión Windows 98
2 Versione Windows Vista - Windows Vista version - Version Windows Vista - Windows Vista Version - Versión Windows Vista
-9-
Special tools
- 10 -
Special tools
1 8000B2051 1 • Attrezzo fissaggio Exhaust screw

vite scarico fixing tool
2 800079015 1 • Attrezzo bloccaggio Clutch blocking tool
frizione
3 8000A2280 1 • Attrezzo chiusura Timing chain
catena distribuzione mounting tool
4 8000A2281 1 • Attrezzo apertura Timing chain
catena distribuzione cutting tool
5 800095318 1 • Tampone per sede Pad for exhaust
valvola scarico valve seat
6 8000B4566 1 • Tampone per sede Pad for intake
valvola aspirazione valve seat
7 8000B4309 1 • Kit guarnizioni Cylinder head
cilindro testa gasket kit
8 8000B4310 1 • Kit guarnizioni Cylinder
cilindro engine block
basamento gasket kit
9 8000B4414 1 • Supporto serbatoio Fuel tank
benzina support
10 8000B4417 1 • Supporto montaggio Engine assembly
motore support
11 8000B4726 1 • Distanziale per dado Spacer for
speciale special nut
12 8A00B4340 1 • Protezione per Guard for fuel tank
supporto serbatoio support
- 11 -
Special tools
- 12 -
Tightening torques
SECTION N N
Revision 1
-1-
Tightening torques
-2-
Tightening torques
-3-
Tightening torques
-4-
Diagnostic
SECTION
Revision 0
O
O
-1-
Diagnostic
ELECTRICAL COMPONENTS
CHARGING SYSTEM
Battery warning light on Alternator broken Replace
Alternator connection defective Check
Battery faulty Replace
Recharge fuse (40A) blown Replace
Recharge fuse connection defective Deoxidize/Repair
Battery connections oxidized Deoxidize/Repair
POWER SUPPLY FOR 12V SERVICES
No function enabled Ignition switch broken Replace
Ignition switch connection defective Deoxidize/Repair
Main relay broken Replace
Main relay connection defective Deoxidize/Repair
ELECTRIC STARTER
Electric starter does not work Start-up engine does not work, Tilt sensor fault Replace
Low battery Recharge
Neutral position sensor broken Replace
Clutch pump switch broken Replace
Starter motor broken Replace
Starter button broken Replace
Right-hand switch unit connection faulty Deoxidize/Repair
Starting relay switch broken Replace
Power cable connections faulty Deoxidize/Repair
Power unit failure Replace
COOLING SYSTEM
Electric fans do not work Fuse 5 blown Replace
Fuse 5 connection faulty Deoxidize/Repair
Fan relay broken Replace
Electric fan broken Deoxidize/Repair
LIGHTS/INDICATORS
Rear tail lights not working Fuse 1 blown Replace
Ignition switch broken Replace
Ignition switch connection faulty Deoxidize/Repair
Device damaged Replace
High beam does not work Fuse 2 blown Replace
Bulb burnt out Replace
Low beam does not work Fuse 3 blown Replace
O Bulb burnt out Replace

Bulb connections faulty Deoxidize/Repair
Ballast control unit damaged Replace
Lights switch broken Replace
Lights switch connection faulty Deoxidize/Repair
Ballast relay broken Replace
Ballast relay connection faulty Deoxidize/Repair
-2-
Diagnostic
Brake light does not work Fuse 1 blown Replace

Front brake lever switch broken Replace
Front brake lever switch connection faulty Deoxidize/Repair
Rear brake lever switch broken Replace
Rear brake lever switch connection faulty Deoxidize/Repair
Brake light stays on Front brake lever switch jammed Replace/Repair
Rear brake lever switch jammed Replace/Repair
Horn does not work Fuse 1 blown Replace
Horn broken Replace
Indicators do not work Fuse 1 blown Replace
Flasher unit broken Replace
Flasher unit connection faulty Deoxidize/Repair
Indicator switch broken Replace
Indicator switch connection faulty Deoxidize/Repair
INSTRUMENT PANEL
Instrument panel does not work Fuse 1 blown Replace
Instrument panel broken Deoxidize/Repair
Instrument panel connection faulty Deoxidize/Repair
CAN line error Instrument panel connection faulty Deoxidize/Repair
Power unit connection faulty Deoxidize/Repair
Power unit failure Replace
Speedometer does not work Speed sensor broken Replace
Speed sensor connection faulty Deoxidize/Repair
Fuse 1 blown Replace
Water temperature gauge does not work Temperature sensor broken Replace
Temperature sensor connection faulty Deoxidize/Repair
Oil warning light does not work Oil pressure sensor broken Replace
Oil pressure sensor connection faulty Deoxidize/Repair
Instrument panel broken Replace
Gear indicator not working Gear position sensor broken Replace
Gear position sensor connection faulty Deoxidize/Repair
Battery warning light does not work Alternator connection defective Deoxidize/Repair
Regulator connection defective Deoxidize/Repair
Side stand warning light does not work Side stand switch broken Replace
Side stand switch connection faulty Deoxidize/Repair
Low fuel warning light does not work Fuel level sensor broken Replace
Fuel level sensor connection faulty Deoxidize/Repair
Indicator warning light does not work

Instrument panel connection faulty
Flasher unit broken
Deoxidize/Repair
Replace
O
Flasher unit connection faulty Deoxidize/Repair
Low beam warning light does not work Instrument panel broken Replace
High beam warning light does not work Instrument panel broken Replace
-3-
Diagnostic
IAW 1.6M IGNITION - INJECTION

Air pressure/temperature sensor indicates malfunction Sensor broken Replace
Sensor connection faulty Deoxidize/Repair
Throttle valve potentiometer indicates malfunction Potentiometer broken Replace

Potentiometer connection faulty Deoxidize/Repair
Engine temperature sensor indicates malfunction Engine temperature sensor broken Replace
Engine temperature sensor connection faulty Deoxidize/Repair
FUEL INJECTION SYSTEM

Injector does not inject fuel Fuse 6 blown Replace
Power relay broken Replace
Power relay connection faulty Deoxidize/Repair
Injector broken Replace
Injector connection faulty Deoxidize/Repair
7BM injection control unit broken Replace
Side stand injector broken Replace
Engine pick-up broken Replace
Pick-up gap / phonic wheel incorrect Repair
Fuel pump broken Replace
IGNITION SYSTEM
No sparks at the plugs Fuse 4 blown Replace
Power relay broken Replace
Power relay connection faulty Deoxidize/Repair
Coils broken Replace
7BM injection control unit broken Replace
Safety switch broken Replace
Spark plug broken Replace
Engine earth connection faulty Repair
Side stand switch broken Replace
Safety control unit fault Sostituire
Engine pick-up broken Replace
Pick-up gap / phonic wheel incorrect Repair
-4-
Diagnostic
FRAME
STEERING
Steering stiff Steering bearings damaged Replace
Steering bearings overtightened Adjust
Steering pin bent Replace
Steering damper action excessive Adjust
Steering damper joints damaged Replace
Tyre pressure low Adjust
Vehicle tends to steer or does not travel on a straight line Fork bent Replace
Frame bent Replace
Swingarm bent Replace
Steering damper joints damaged Replace
Steering bearings damaged Replace
Wheel spindle bent Replace
Swingarm bearings damaged Replace
FRONT WHEEL
Front wheel wobbles/vibrates Wheel rim bent Replace
Wheel unbalanced Balance
Tyre faulty Replace
Tyre unsuitable Replace
Wheel bearings damaged Tighten
Spindle fixing screws loose Tighten
Spindle ring nut loose Tighten
Front wheel hardly turns Wheel bearings damaged Replace
Wheel spindle bent Replace
Brake pad friction on discs excessive (see brakes) Check
Brake discs bent Replace
Wheel spindle ring nut overtightened Use prescribed torque
FRONT SUSPENSION
Front suspension soft Fork oil deteriorated Renew
Spring preload low Adjust
Hydraulic compression damping insufficient Adjust
Fork oil level low Top up
Fork damaged Repair
Front suspension stiff Spring preload excessive Adjust
Hydraulic compression damping excessive Adjust
Swingarm oil level high Adjust
Tyre pressure high Adjust
REAR WHEEL
Rear wheel wobbles/vibrates Wheel rim bent Replace
Wheel unbalanced Balance
Tyre faulty Replace
Tyre unsuitable Replace
Wheel bearings damaged Replace
Locknut loose Tighten
Suspension screws loose Tighten
Suspension bearings damaged Replace
Rear wheel hardly turns Wheel bearings damaged Replace
Wheel hub circlip displaced Check
Brake pad friction on discs excessive Check
Brake disc bent Replace O
Drive chain damaged Replace
REAR SUSPENSION
Rear suspension soft Spring preload excessive Adjust

Hydraulic compression damping (high/low speed) insufficient Adjust
Hydraulic rebound damping insufficient Adjust
Shock absorber damaged Replace
Rear suspension stiff Spring preload excessive Adjust
Hydraulic compression damping (high/low speed) excessive Adjust
Hydraulic rebound damping excessive Adjust
Tyre pressure high Adjust
-5-
Diagnostic
Swingarm bearings damaged Replace

Swingarm rocker bearings damaged Replace
Shock absorber joints damaged Replace
Suspension linkage joints damaged Repair
Swingarm pin bent Replace
BRAKES
Brake lever and pedal soft (“spongy”) Air bubbles in hydraulic circuit Bleed
Leaks in hydraulic circuit Repair
Caliper seals damaged Replace
Pump seals damaged Replace
Caliper pistons do not slide freely Check
Brake fluid level low Top up
Brake discs distorted Replace
Brake lever or pedal stiff Brake lever or pedal bent Replace
Braking action insufficient Disks dirty Clean
Air bubbles in hydraulic circuit Bleed
Leaks in hydraulic circuit Repair
Caliper seals damaged Replace
Pump seals damaged Replace
Brake fluid level low Top up
Brake pads rub against brake disks Brake pad springs damaged Replace
Brake fluid level too high Adjust
Brake pads worn down Replace
EXHAUST SYSTEM
Exhaust noise excessive Exhaust pipe damaged Replace
Exhaust pipe fasteners loose Tighten
Engine performance poor Exhaust pipe damaged Replace
Exhaust pipe fasteners loose Tighten
COOLING SYSTEM
Engine temperature high Coolant level low Top up
Cooling fan faulty Replace
Expansion tank cap faulty Replace
Instrument temperature sensor faulty Replace
Thermostat locked in closed position Replace
Radiator fins bent or obstructed Repair/Clean
Radiator scaly Clean
Water pump damaged Replace
Injection/ignition system faulty Check
Fuel unsuitable Change
Engine cooling circuit faulty Check
Spark plug heat grade unsuitable Replace
Carbon formation in cylinder head/piston Clean
Engine temperature low Thermostat locked in open position Replace
-6-
Analytical index
SECTION
Revision 1
P
-1-
Analytical index
ANALYTICAL INDEX - F4 1000 WORKSHOP MANUAL Transmission chain . . . . . . . . . . . . . . . . . . . . .B-53

Tube band fasteners . . . . . . . . . . . . . . . . . . . .B-60
Section A - General Description Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-56
Glossary and symbols . . . . . . . . . . . . . . . . . . .A-4 Valve mechanism adjustment . . . . . . . . . . . . .B-15
How to consult the manual . . . . . . . . . . . . . . . .A-3 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-75
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
Operative technical specification . . . . . . . . . . .A-9 Section C - Bodywork
Purpose of the manual . . . . . . . . . . . . . . . . . . .A-3 Air intake system . . . . . . . . . . . . . . . . . . . . . . .C-20
Right hand and left hand standards . . . . . . . . .A-5 Fairing assembly . . . . . . . . . . . . . . . . . . . . . . .C-3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-12
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8 Heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-25
Mudguard - Central spoiler -
Section B - Maintenance Radiator protection . . . . . . . . . . . . . . . . . . . . . .C-25
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-40 Tail unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-60
Brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-71 Section D - Air intake injection system
Brakes and clutch . . . . . . . . . . . . . . . . . . . . . . .B-44 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-13
Electric cooling fans . . . . . . . . . . . . . . . . . . . . .B-14 Air intake system technical characteristics . . .D-15
Electrical system . . . . . . . . . . . . . . . . . . . . . . .B-60 Diagnostic system . . . . . . . . . . . . . . . . . . . . . .D-14
Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . .B-11 ECU (Electronic control unit) . . . . . . . . . . . . . .D-9
Engine oil and oil filter . . . . . . . . . . . . . . . . . . .B-8 Engine-control system - Position of the parts . .D-17
Front forks . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-60 Fuel feed system . . . . . . . . . . . . . . . . . . . . . . .D-5
Front headlight . . . . . . . . . . . . . . . . . . . . . . . . .B-90 Fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
Front wheel bearings . . . . . . . . . . . . . . . . . . . .B-56 Fuel pressure regulator . . . . . . . . . . . . . . . . . .D-6
Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-27 Fuel pump check . . . . . . . . . . . . . . . . . . . . . . .D-11
Fuel pump assembly . . . . . . . . . . . . . . . . . . . .B-33 Fuel pump control system . . . . . . . . . . . . . . . .D-7
Fuel union tubes . . . . . . . . . . . . . . . . . . . . . . . .B-36 Injection arrest control . . . . . . . . . . . . . . . . . . .D-4
Fuel tubes assembly . . . . . . . . . . . . . . . . . . . .B-36 Injector check . . . . . . . . . . . . . . . . . . . . . . . . . .D-11
Instruments and warning lights . . . . . . . . . . . .B-61 Injection system technical characteristics . . . .D-3
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-82 Injection system electrical diagram . . . . . . . . .D-18
Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-51 Injection time compensation (Volume) . . . . . . .D-4
Maintenance and tuning operations . . . . . . . . .B-8 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8
Periodical maintenance schedule . . . . . . . . . .B-6 – Atmospheric air temperature/pressure . .D-8
– Throttle body position . . . . . . . . . . . . . . .D-10
Rear shock absorber . . . . . . . . . . . . . . . . . . . .B-58
Technical specifications -
Rear wheel hub . . . . . . . . . . . . . . . . . . . . . . . .B-57
secondary air system . . . . . . . . . . . . . . . . . . .D-16
Screw and nuts . . . . . . . . . . . . . . . . . . . . . . . .B-60
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-59 Section E - Electrical system
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . .B-25 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
P
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-53 – Battery assembly . . . . . . . . . . . . . . . . . . .E-8
Swingarm bearings . . . . . . . . . . . . . . . . . . . . .B-57 – Efficiency check . . . . . . . . . . . . . . . . . . . .E-13
Technical information . . . . . . . . . . . . . . . . . . . .B-3 – Initial charge . . . . . . . . . . . . . . . . . . . . . . .E-11
Throttle control . . . . . . . . . . . . . . . . . . . . . . . . .B-49 – Recharging system . . . . . . . . . . . . . . . . .E-7
Throttles body adjustament and tuning . . . . . . . .B-51 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
-2-
Analytical index
Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3 Rear wheel hub . . . . . . . . . . . . . . . . . . . . . . . .F-59

Electrical diagram . . . . . . . . . . . . . . . . . . . . . .E-5 Steering assembly . . . . . . . . . . . . . . . . . . . . . .F-25
– Parts list . . . . . . . . . . . . . . . . . . . . . . . . . .E-6 Wheels - Check and balancing . . . . . . . . . . . .F-78
Electric fan cooling system . . . . . . . . . . . . . . .E-34
Engine pick-up . . . . . . . . . . . . . . . . . . . . . . . . .E-25 Section G - Frame
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3,22 Assembly frame to the motorcycle . . . . . . . . . .G-36
High beam headlight . . . . . . . . . . . . . . . . . . . .E-32 Battery cables . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-35 Engine removal from frame . . . . . . . . . . . . . . .G-48
Ignition/side stand safety system parts check . .E-20 Exhaust tubes removal . . . . . . . . . . . . . . . . . . .G-8
– Gear switch . . . . . . . . . . . . . . . . . . . . . . .E-21 Footrest removal . . . . . . . . . . . . . . . . . . . . . . .G-8
– Side stand switch . . . . . . . . . . . . . . . . . . .E-21 Frame control reference measurements . . . . .G-34
– Tilt sensor . . . . . . . . . . . . . . . . . . . . . . . .E-20 Frame disassembly . . . . . . . . . . . . . . . . . . . . .G-30
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . .E-27 Frame plate removal . . . . . . . . . . . . . . . . . . . .G-42
– Ignition switch . . . . . . . . . . . . . . . . . . . . .E-29 Frame removal preliminary operations . . . . . .G-16
– Fuel level warning ligth switch check . . . .E-28 – Plug top coils removal . . . . . . . . . . . . . . .G-22
– Oil pressure sensor . . . . . . . . . . . . . . . . .E-28 – Throttle body removal . . . . . . . . . . . . . . . .G-17
– R. P. M indicator . . . . . . . . . . . . . . . . . . . .E-30 Mounting engine on the frame . . . . . . . . . . . . .G-59
– Speed sensor . . . . . . . . . . . . . . . . . . . . . .E-31 Rear frame unit assembly . . . . . . . . . . . . . . . .G-47
– Starter relay check . . . . . . . . . . . . . . . . . .E-30 Rear sub-frame removal . . . . . . . . . . . . . . . . .G-41
– Turn indicators check . . . . . . . . . . . . . . . .E-30 Removing the SAS valve . . . . . . . . . . . . . . . . .G-5
– Water sensor . . . . . . . . . . . . . . . . . . . . . .E-29 Side stand removal . . . . . . . . . . . . . . . . . . . . .G-7
Licence plate light . . . . . . . . . . . . . . . . . . . . . .E-34 Silencers and exhaust group removal . . . . . . .G-12
Low beam headlight . . . . . . . . . . . . . . . . . . . . .E-31
Main relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-24 Section H - Brakes
Positioning of electrical system wire clamps . .E-37 Front brake system . . . . . . . . . . . . . . . . . . . . .H-3
Run-Off safety switch . . . . . . . . . . . . . . . . . . . .E-26 – Clucth lever removal . . . . . . . . . . . . . . . .H-13
Semiconductors parts . . . . . . . . . . . . . . . . . . .E-4 – Front brake calipers substitution . . . . . . .H-10
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . .E-23 – Front brake disc removal . . . . . . . . . . . . .H-15
Starter system . . . . . . . . . . . . . . . . . . . . . . . . .E-14 – Front brake discs . . . . . . . . . . . . . . . . . . .H-14
– Starter motor check . . . . . . . . . . . . . . . . .E-18 – Front brake pads substitution . . . . . . . . .H-4
– Starter relay check . . . . . . . . . . . . . . . . . .E-19 – Front brake pump removal . . . . . . . . . . . .H-10
– Starter motor assembly . . . . . . . . . . . . . .E-18 – Replacing the brake fluid tank . . . . . . . . .H-11
– Starter motor removal . . . . . . . . . . . . . . .E-19 – Replacing the front brake switch . . . . . . .H-13
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-36 – Substitution and bleeding of the front
Rear tail lghts and brake lights . . . . . . . . . . . . .E-33 brake fluid . . . . . . . . . . . . . . . . . . . . . . . .H-6
Timing wheel gap . . . . . . . . . . . . . . . . . . . . . . .E-26 Rear brake system . . . . . . . . . . . . . . . . . . . . . .H-17
Turn indicators . . . . . . . . . . . . . . . . . . . . . . . . .E-33 – Rear brake calipers substitution . . . . . . .H-22
– Rear brake disc . . . . . . . . . . . . . . . . . . . .H-24
Section F - Suspension and wheels – Rear brake disc removal . . . . . . . . . . . . .H-24
P
Front wheel . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3 – Rear brake pads substitution . . . . . . . . . .H-18
Front forks . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-10 – Substitution and bleeding of the rear
Motorcycle set-up adjustment . . . . . . . . . . . . .F-75 brake fluid . . . . . . . . . . . . . . . . . . . . . . . .H-20
Rear suspension and swingarm . . . . . . . . . . . .F-37
-3-
Analytical index
Section L - Cooling system

Complete cooling system assembly . . . . . . . . .L-3
Cooling system leakage check . . . . . . . . . . . . .L-4
Electric fan removal . . . . . . . . . . . . . . . . . . . . .L-11
Engine coolant extraction . . . . . . . . . . . . . . . . .L-5
Expansion tank assembly . . . . . . . . . . . . . . . .L-16
Expansion tank cap check . . . . . . . . . . . . . . . .L-4
Expansion tank removal . . . . . . . . . . . . . . . . . .L-10
Filling the cooling system . . . . . . . . . . . . . . . . .L-26
Radiator group assembly . . . . . . . . . . . . . . . . .L-15
Radiator group assembly to the motorcycle . . .L-20
Radiator removal . . . . . . . . . . . . . . . . . . . . . . .L-5
System functioning check . . . . . . . . . . . . . . . .L-28
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . .L-17
Voltage regulator removal . . . . . . . . . . . . . . . .L-11
Water radiator parts removal . . . . . . . . . . . . . .L-10
Section M - Special tools

Maintenance tools . . . . . . . . . . . . . . . . . . . . . .M-2
Section N - Torque pressure

Frame tightening torques . . . . . . . . . . . . . . . .N-2
Section O - Diagnostic
Electrical components . . . . . . . . . . . . . . . . . . .O-2
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .O-5
Section P - Analytical index

Analytical index - F41000 workshop manual . .P-2
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Cop.M.O.Mototel.F5_GB_Ed.1.fh 20-05-2010 11:02 Pagina 1
C M Y CM MY CY CMY K
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12.-F4 1000 R (2010) WORKSHOP MANUAL (Ingles) 7510036966512279755

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12.-F4 1000 R (2010) WORKSHOP MANUAL (Ingles) 7510036966512279755

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Cop.M.O.Mototel.F5_GB_Ed.1.

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Part no. 8A00B4301 - Edition no. 1

Respect and defend the environment

AIR INTAKE INJECTION SYSTEM .......................................................................... D

ELECTRICAL SYSTEM ............................................................................................ E

SUSPENSION AND WHEELS .................................................................................. F

COOLING SYSTEM .................................................................................................. L

SPECIAL TOOLS ...................................................................................................... M

TORQUE PRESSURES ............................................................................................ N

ANALYTICAL INDEX ................................................................................................ P

HOW TO CONSULT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

HOW TO CONSULT THIS MANUAL A

Display of the operations

PURPOSE OF THE MANUAL

A GLOSSARY AND SYMBOLS

This signifies that the lack Use the recommended coolant.

Utilise a specific tool or equipment for

Tighten to the specified torque. Use the recommended adhesive.

Tolerance or limit of use. Carry out accurate cleaning.

Utilise the tester. Use new components.

Use the recommended oil. Substitute the component.

Use the recommended grease. Do not leave litter about.

Use the recommended brake fluid.

RIGHT HAND AND LEFT HAND STANDARD A

Left side Right side

Nitrogen - rear shock absorber

GENERAL INDEX SUMMARY OF EACH CHAPTER

OPERATIVE TECHNICAL SPECIFICATIONS A

2) Engine registration number

1) Frame registration number

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

TECHNICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

PERIODICAL MAINTENANCE SCHEDULE

We respect and defend the environment.

Check level and top-up G G G G G G G G

Cooling system Check for leakages G G G G G G G G

Electric fans Check functioning G G G G G G G G

Valves Check / adjustment G G G

Mobile timing chain guide G

Timing chain tensioner Check / Substitution G G G

Fuel filter Check / Substitution G G G

Throttle body Check and adjust G G G G G G G

Air filter Check / Substitution G G G G G G

Brake and clutch fluid G

Check for defectsand leakages G G G G G G G

Throttle control Check functioning G G G G G G G G

Choke control Check functioning G G G G G G G G

Programmed maintenance schedule

Drive chain Lubricate G G G G

Front sprocket / stop washer G G G

Rear sprocket spring drive Check / Substitution G G G

Steering head flange ring Check / adjust G G G G

Side stand Check functioning G G G G G G G G

Swingarm bearings Check / lubricate G

Drive chain pads on swingarm Check / substitution G G G G G G G

Drive chain pads on frame plate Check / substitution G G G G G G G

Rear shock absorber Check / adjust G G G G

Front fork oil Substitution G

Battery connections Check and clean G G G G G G G

Electrical system Check functioning G G G G G G G G

Instruments Check functioning G G G G G G G G

Horn Check functioning G G G G G G G G