Maintenance

SECTION
Revision 0
B

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 Maintenance

SUMMARY
TECHNICAL INFORMATION....................................................................................................................PAGE 3
TECHNICAL DATA ..................................................................................................................................PAGE 3
B COMPONENTS IN CARBON FIBRE (F4 BRUTALE ORO) ....................................................................PAGE 6
MAGNESIUM COMPONENTS (F4 BRUTALE ORO) ..............................................................................PAGE 7
PERIODICAL MAINTENANCE SCHEDULE ............................................................................................PAGE 9
MAINTENANCE AND TUNING OPERATIONS ........................................................................................PAGE 11
ENGINE OIL AND OIL FILTER.................................................................................................................PAGE 11
ENGINE COOLANT ..................................................................................................................................PAGE 19
ELECTRIC COOLING FAN.......................................................................................................................PAGE 21
VALVE MECHANISM ADJUSTMENT ......................................................................................................PAGE 22
SPARK PLUGS .........................................................................................................................................PAGE 33
FUEL FILTERS..........................................................................................................................................PAGE 34
FUEL PUMP ASSEMBLY .........................................................................................................................PAGE 44
FUEL UNION TUBES ...............................................................................................................................PAGE 47
FUEL TUBES ASSEMBLY .......................................................................................................................PAGE 47
THROTTLE BODY ADJUSTMENT AND TUNING ..................................................................................PAGE 50
AIR FILTER ...............................................................................................................................................PAGE 57
BRAKES AND CLUTCH ...........................................................................................................................PAGE 60
BRAKE/CLUTCH/GEARCHANGE COMMANDS CHECK............................................................................PAGE 63
BRAKE PADS ...........................................................................................................................................PAGE 65
ACCELERATOR CONTROL.....................................................................................................................PAGE 65
LOCKS .....................................................................................................................................................PAGE 67
STEERING ................................................................................................................................................PAGE 69
TRANSMISSION CHAIN............................................................................................................................PAGE 69
TYRES ......................................................................................................................................................PAGE 72
FRONT WHEEL BEARINGS ....................................................................................................................PAGE 72
WHEELS ...................................................................................................................................................PAGE 73
REAR WHEEL HUB..................................................................................................................................PAGE 74
OSCILLATING ARM BEARINGS .............................................................................................................PAGE 74
REAR SHOCK ABSORBER .....................................................................................................................PAGE 74
SIDE STAND .............................................................................................................................................PAGE 75
FRONT FORK ...........................................................................................................................................PAGE 76
SCREWS AND NUTS ...............................................................................................................................PAGE 76
TUBE BAND FASTENERS.......................................................................................................................PAGE 76
ELECTRICAL SYSTEM .............................................................................................................................PAGE 77
BATTERY...................................................................................................................................................PAGE 77
INSTRUMENTS AND WARNING LIGHTS ...............................................................................................PAGE 80
LIGHTS......................................................................................................................................................PAGE 85
FRONT HEADLAMP.................................................................................................................................PAGE 92

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 Maintenance

TECHNICAL INFORMATION

2020 760

805

135

1410

TECHNICAL DATA
Description BRUTALE ORO BRUTALE S
CHARACTERISTICS
Wheelbase (mm) (*) 1410 1410
Total length (mm) (*) 2020 2020
Maximum width (mm) 760 760
Seat height (mm) (*) 805 805
Ground clearance (mm) (*) 135 135
Trail (mm) (*) 101.5 101.5
Dry weight (kg) 179 185
Fuel tank capacity (litres) (**) 19 19
Fuel reserve (litres) (**) 4 4
Sump oil quantity (kg) 3.5 3.5
ENGINE
Type 4 Stroke four cylinder, 16 valves
Bore (mm) 73.8 73.8
Stroke (mm) 43.8 43.8
Displacement (cm3) 749.4 749.4
Compression ratio 12 : 1 12 : 1
Starter system Electrical
Cooling Liquid with oil cooler
Engine casing and covers Die-cast
Cylinder head and cylinders Chill-cast
Valves Bi-metal/mono-metal

* : I The data declared are not binding. They are susceptible to variations due to riding conditions.
** : I 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.

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 Maintenance

TECHNICAL DATA
Description BRUTALE ORO BRUTALE S
TIMING
Type D.O.H.C. radial valves
LUBRICATION

B Type
IGNITION – FUEL FEED SYSTEM
Wet sump

Type Weber-Marelli ignition/injection 1.6 M integrated system

Inductive charge electronic ignition, Multipoint electronic injection
Spark plugs (alternatively) NGK CR9 EB Champion G59c NGK CR9 EB Champion G59c
Spark gap (mm) 0.7 ÷ 0.8 0.6 ÷ 0.7 0.7 ÷ 0.8 0.6 ÷ 0.7
CLUTCH
Type Wet multi-plate
PRIMARY TRANSMISSION
N° teeth - engine crankshaft gear Z = 47 Z = 47
N° teeth - clutch gear Z = 81 Z = 81
Transmission ratio 1.72 1.72
SECONDARY TRANSMISSION
N° teeth – pinion wheel Z = 14 Z = 14
N° teeth – crown wheel Z = 41 Z = 41
Transmission ratio 2.93 2.93
GEAR CHANGE
Type Extractable six speed, with gearing always inserted
Gear ratios (total ratios)
1st 2.92 (14.71) 2.92 (14.71)
2nd 2.21 (11.14) 2.21 (11.14)
3rd 1.78 (8.97) 1.78 (8.97)
4th 1.50 (7.56) 1.50 (7.56)
5th 1.32 (6.65) 1.32 (6.65)
6th 1.21 (6.10) 1.21 (6.10)
FRAME
Type Tubular framework in wire-drawn steel tubes 25 CrMo (TIG welding)
Fork fulcrum plates Magnesium alloy Aluminium alloy
FRONT SUSPENSION
Hydraulic telescopic forks with the stems positioned upside down, equipped with
Type
a system of external adjustment for extension, compression and spring preload
Ø stems (mm) 50 with titanium nitride treatment 50
Telescopic movement (mm) 128 128
REAR SUSPENSION
Progressive, single-steering damper adjustable in extension, in compression
Type
(high/low speed), and in spring-preloading
Mono-arm fork Magnesium alloy Aluminium alloy
Wheel travel (mm) 120 120
FRONT BRAKE
Type Floating double disk with the braking area in steel
Ø Discs (mm) 310 310
Disc flanges Aluminium Steel
Pincers (Ø pistons mm) 6 pistons (Ø 22.65; Ø 25.4; Ø 30.23)
REAR BRAKE
Type Disc type in steel
Ø Discs (mm) 210 210
Pincers (Ø pistons mm) 4 pistons (Ø 25.4)
FRONT WHEEL
Material Magnesium alloy Aluminium alloy
Dimensions 3.50” x 17” 3.50” x 17”
REAR WHEEL
Material Magnesium alloy Aluminium alloy
Dimensions 6.00” x 17” 6.00” x 17”
TYRES
Front 120/65-ZR 17 (56 W)
Rear 190/50-ZR 17 (73 W) o 180/55-ZR 17 (73 W)
Brand and type PIRELLI - Dragon Evo MTR 21 Corsa (Ant.)
PIRELLI - Dragon Evo MTR 22 Corsa (Post.)
DUNLOP - Sport Max D 207 PIRELLI - Diablo Corsa
Race Replica MICHELIN - Pilot Sport
MICHELIN - Pilot Power
DUNLOP - Sport Max D 207 Race Replica
Tyre pressures (*)
Front 2.3 bar (33 psi) 2.3 bar (33 psi)
Rear 2.3 bar (33 psi) 2.3 bar (33 psi)

* : In the event of different make tyres being used as opposed to those advised, refer to the pressure values marked on the side of the tyre by the manufacturer.

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 Maintenance

TECHNICAL DATA
Description BRUTALE ORO BRUTALE S
ELECTRICAL SYSTEM
Voltage 12V 12V
Front dipped beam light bulb 12V 55W 12V 55W
Front main beam light bulb 12V 60W 12V 60W
Front sidelight bulb 12V 5W 12V 5W
Rear light bulb 12V 5W 12V 5W
Rear stop light bulb 12V 21W 12V 21W
Direction indicators 12V 10W 12V 10W
Battery 12V - 9Ah 12V - 9Ah
Alternator 650W a 5000 r.p.m. 650W a 5000 r.p.m.
BODYWORK
Tank Thermo-plastic material Thermo-plastic material
Air filter compartment conveyors Carbon fibre Thermo-plastic material
Tank side panel Carbon fibre Thermo-plastic material
Tail unit rear side panel Carbon fibre Thermo-plastic material
Tail unit Carbon fibre Thermo-plastic material
Instrumentation protection Carbon fibre Thermo-plastic material
Ignition switch cover Carbon fibre Thermo-plastic material
Exhaust tube protection Carbon fibre Thermo-plastic material
Chain guard Carbon fibre Thermo-plastic material
Oil cooler protection Carbon fibre Thermo-plastic material
Number plate carrier Thermo-plastic material Thermo-plastic material
Rear-view mirrors Thermo-plastic material Thermo-plastic material
Protezione tubo scarico Aluminium Aluminium

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 Maintenance

★ COMPONENTS IN CARBON FIBRE (F4 BRUTALE ORO)

1 - Right air filter compartment side panel 8 - Ignition switch cover
2 - Left air filter compartment side panel 9 - Tail unit
B 3 - Right tank side panel 10 - Front mudguard
4 - Left tank side panel 11 - Top chain protection
5 - Right cylinder cover 12 - Lower chain protection
6 - Left cylinder cover 13 - Oil cooler protection
7 - Instrument panel protection

2 4 9

10

9 3 5 8
13 6 12 11
7

10

13

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 Maintenance

★ MAGNESIUM COMPONENTS (F4 BRUTALE ORO)

1 - Steering base
2 - Frame side plate
3 - Front wheel rim
4 - Rear wheel rim
B
5 - Mono-arm fork

2 5
1

2 3

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 Maintenance

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 Manutenzione
Maintenance

PERIODICAL MAINTENANCE SCHEDULE

The following table shows the recommended intervals for the interventions of periodical maintenance. Periodical
maintenance is necessary to keep the motorcycle in an optimum condition. The intervals are expressed in kilome-
tres.
For motorcycles used in particularly severe conditions, maintenance operations must be B
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.
★ The information marked with this symbol refers only to the F4 BRUTALE model
series ORO.
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
● ● ● ● ● ● ●
Engine oil Substitution
At least once a year

Substitution ● ● ● ● ● ● ●
Engine oil filter (Utilise only originali MV
Agusta oil filters) At every substitution of engine oil

Check level and top-up ● ● ● ● ● ● ● ●

Engine coolant
Substitution At least every two years

Cooling system Check for leakages ● ● ● ● ● ● ● ●

Electric fan Check functioning ● ● ● ● ● ● ● ●

Valves Check / adjustment ● ● ● ●

Check ● ● ●
Timing chain
Substitution ●

Check / Substitution ● ● ●

Pattino
Mobile mobile distribuzione
timing chain guide ●
Substitution
At least every substitution of the timing chain

Timing chain tensioner Check / Substitution ● ● ●

Check / Substitution ● ● ● ●
Spark plugs
Substitution ● ● ●

Fuel filter Check / Substitution ● ● ●

Throttle body Check and adjust ● ● ● ● ● ● ●

Air filter Check / Substitution ● ● ● ● ● ●

Check level ● ● ● ● ● ● ●

Brake freni
Fluido and clutch fluid
e frizione ●
Substitution
At least every two years

Check functioning ● ● ● ● ● ● ● ●

Brakes and clutch Check circuit ● ● ● ● ● ● ● ●

Cleaning of contact lever / ● ● ● ● ● ● ● ●
pump piston area
Brake pads Check / Substitution ● ● ● ● ● ● ●
( front and rear )
Check for defects and ● ● ● ● ● ● ●
leakages
Fuel tubes
Substitution At least every three years

Check functioning ● ● ● ● ● ● ● ●
Accelerator control
Check/adjust play ● ● ● ● ● ● ● ●

Starter control Check functioning ● ● ● ● ● ● ● ●

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 Manutenzione
Maintenance

Programmed maintenance schedule

0 1000 6000 12000 18000 24000 30000 36000
Frequenza Km (mi)
Km (mi) covered (600) (3800) (7500) (11200) (14900) (18600) (22400)

Service
Tagliando Pre- A B C D E F G
delivery
Description Operation

B Transmission and flexible controls Check / Adjust ● ● ● ● ● ● ● ●

Check / Adjust ● ● ● ● ● ● ● ●

Transmission chain Lubricate ● ● ● ●

Substitution ★ ★● ★ ★● ★ ★●
Check ● ● ● ●

Pinion wheel/stop washer ★ ★● ★ ★● ★ ★●

Substitution
At least at each substitution of the transmission chain

Check ● ● ● ●

Crown wheel ★ ★● ★ ★● ★ ★●
Substitution
At least at each substitution of the transmission chain

Crown wheel tension regulator Check ★ ★● ★ ★● ★ ★●

Steering head flange ring Check / Adjust ● ● ● ●

Check / Adjust ● ● ● ●
Steering bearings
Lubricate ●

Check for pressure ● ● ● ● ● ● ● ●

Tyres
Check for wear ● ● ● ● ● ● ●

● ● ● ● ● ● ●
Wheel rims Visual check
Every tyre substitution

● ● ● ● ●
Check
Front wheel bearings
Every tyre substitution

Substitution ●

Visual check for knocks ★ ★ ★ ★ ★ ★ ★

Parts in magnesium
and scratches ★ At least every six months
Side stand Check functioning ● ● ● ● ● ● ● ●

Side Check functioning ● ● ● ● ● ● ● ●

stand switch Cleaning of contact lever
● ● ● ● ● ● ● ●
area with side stand
lubricate roller
Check / bearings and ● ●
Rear wheel hub guides
lubricate roller
Substitution / bearings and ●
guide
Rear fork bearings Check / lubricate ●

Rear fork chain guide Check / substitution ● ● ● ● ● ● ●

Chain guide frame plate Check / substitution ● ● ● ● ● ● ●

Rear shock absorber Check / Adjust ● ● ● ●

Front fork oil Substitution ●

Battery connections Check and clean ● ● ● ● ● ● ●

Electrical system Check functioning ● ● ● ● ● ● ● ●

Instrument Check functioning ● ● ● ● ● ● ● ●

Lights/visual signals Check functioning ● ● ● ● ● ● ● ●

Horn Check functioning ● ● ● ● ● ● ● ●

Check functioning ● ● ● ● ● ● ● ●
Front headlight
Adjust At every variation of the riding set-up of the motorcycle

IIgnition switch Check functioning ● ● ● ● ● ● ● ●

Locks Check functioning ● ● ● ● ● ● ● ●

Torque settings – nuts and bolt Check / tightness ● ● ● ● ● ● ● ●

Tube band fasteners Check / tightness ● ● ● ● ● ● ● ●

General lubrication ● ● ● ● ● ● ● ●

General check ● ● ● ● ● ● ● ●

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 Maintenance

Table of lubricants and fluids

Description Recommended product Specification
Engine oil AGIP RACING 4T 10W/60 (*) SAE 10W/60 - API SJ
Ethylene-glycol
Engine coolant AGIP ECO - PERMANENT diluited with 40%

Brake and clutch fluid AGIP BRAKE FLUID DOT4

distilled water
DOT4
B
Chain lubrication oil MOTUL CHAIN LUBE PLUS –

* : 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 that
conform or exceed the following norms:

– Conforming to API SJ
Engine oil
– Conforming to ACEA A3 SAE 10 W-60
– Conforming to JASO MA
API SJ
– Grade SAE 20 W-50 o 10 W-60 ACEA A3
JASO MA
The above specifications indicated are marked either on their
N.B. own or together with others on the container of the lubricating
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:
n Place the motorcycle on the rear stand.

The substitution of the engine oil must

N.B. be done with a hot engine as opposed to
the oil-check that is done with a cold
engine.
Place a container underneath the engine to collect the
1
used oil.
Remove the oil discharge plug (1).

Recover the oil in an appropriate container.

Do not scatter the drainage oil into the envi-
ronment.

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 Maintenance

Remove the oil filler plug (1) on the right side of the
motorcycle so that it facilitates the discharge of the
used oil.
Wait until the lubrication system is completely empty of
B used engine oil.

Substitution of the oil filter

In order to proceed to replace the oil filter you should
remove the exhaust manifolds of the cylinders 3 and 4.

Release the two side clamps of the oil cooler.

Unscrew the lower fixing screws of the oil cooler pro-

tection on the lower basis of the water radiator.
Remove the oil cooler protection.

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 Maintenance

Slightly move the coolers towards the front area of the

motorcycle, then unscrew the nut on the fixing flange of 20÷22 N•m
the exhaust manifilds of the cylinder group.

During this operation pay attention to the B

exhaust pipes in order to avoid from scor-
ching.

Release the union spring between compensator and

manifolds of cylinders 3 and 4.

Remove the manifold of cylinders 3 and 4.

N.B. In order to facilitate the reassembly of the

manifolds you should place the fixing flan-
ge on the manifolds before these
manifolds are pleced on the engine.
Insert the flange in the manifolds and then
turn it.
Place the flange-manifolds assembly on
the fixing stud, then tighten the check nut
to the torque wrench shown.

Torque wrench of exhaust manifold check

nut: 20÷22 Nm

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 Maintenance

Loosen the safety clamp and remove it.

Unscrew the oil filter by an appropriate wrench.

In the event of a filter branded TOYO ROKI use the

wrench for oil filter:

TOYO ROKI
FACOM D. 139 tool
Part code 8000A4317

In the event of a filter branded Champion use the wren-

ch for oil filter:

Champion
Part code N° 800099010

Clean accurately any oily parts.

Using a clean cloth to clean accurately the area and

the filter face.

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 Maintenance

Take out the oil filter from the new engine oil filter kit.

- Toyo Roki oil filter kit: Part code 8000A3702

- Champion oil filter kit: Part code 8000A1428
B
Only use original components of MV Agusta.

If you use an oil filter Toyo Roki (Part code

8000A3702), you should the following preliminary ope-
ration.

Take out the gasket from the engine oil filter kit of new
equipment and insert on the filter as shown in the figu-
re on the left.

Only use a new gasket.

Slide the gasket up to bring in contact with the oil filter

back ring (see figure on the right).

Lubricate the gasket on the filter with engine oil.

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 Maintenance

Insert the filter in its seat.

Turn the filter manually until the gasket is into slight

contact with the machined surface.
B

Tighten the filter using the appropriate tool and a tor-

que wrench.

- TOYO ROKI oil filter:

FACOM D. 139 tool
Part code 8000A4317
Oil filter torque wrench:
24 N·m

- Champion oil filter:

Tool code 800099010 TOYO ROKI:
Oil filter torque wrench: 24 N•m
15 N·m
Champion:
15 N•m

After having tightened the filter, take out the clamp for
engine oil filter and its screw from the new oil filter kit.

Only use a new clamp.

Insert the clamp and slide it until it brings in contact

with the oil filter back ring.

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 Maintenance

Place the clamp lock at a range of 2 mm from the

screwhead on the supporting plate of oil cooler pipes.

2 mm
Turn the clamp screw up to bring in contact with the fil-
ter without tightening.

Mark the screw position drawing a line by a felt-tip both

on the screw and on the clamp.

Make the last tightening of the screw getting it perform

2 turns and 1/4 further the position marked previously.

Once completed the assembly, ensure that the clamp

lock of the engine oil filter is at a range between 1 and
1.5 mm from the screwhead on the supporting plate of
oil cooler pipes. Check any leakages from oil filter.

Mark the position of the definite tightening of the screw

using a felt pen, both on the filter and the band faste- -1÷1,5 mm
ner. Trace a reference mark also on the band fastener
and the relative screw, with the object of eventually
checking any slackening of the screw.

Do not use the oil filter as a point of grip or

contact.

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 Maintenance

On the oil discharge plug there is a magnet to attract

any metal residues that could form in the engine during
rotation.
Before proceeding with the reassembly of the plug,
B check that the cleaning has been done thoroughly and
also the condition of the gasket seal.
Screw in the oil discharge plug and tighten it to the spe-
cified torque.

Torque pressure – oil discharge plug: 35

N·m

35 N•m

Pour approximately 3 litres of engine oil ( in according

to the type specified in table on page 11 in this chap-
ter) into the oil filler hole of the engine.
Close the filler hole using the appropriate cap.
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
“MAX” mark shown on the engine casing. Do not sur-
pass this limit.
Check any oil leakages.
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
emptying a little oil out of the engine.

Oil tubes

During normal maintenance procedures check the cor-

rect assembly of components and check for blow-bys
or oil leaks from the engine parts.
In particular:

– Blow-bys at the base of the engine.

– Oil filter support
– Oil pump-engine cylinder head delivery tubing.

When oil leaks are identified, even small

ones, proceed with the overhaul of compo-
nents as described in the F4 workshop engi-
ne manual (Code 8000 A1592).

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 Maintenance

ENGINE COOLANT
Check/top-up level ➝ At the pre-delivery, at
the first 1000 kilome-
tres and then every
6000 kilometres B
Keeping the motorcycle in a vertical position, check
that the level of engine coolant is between the «MIN»
mark found on the expansion tank (1) and the lower
part of the frame tube, that you can see from the ope-
ning on the frame protection panel on the left side of
the motorcycle.

If the level is under the minimum line, proceed with top-

ping-up as follows:

• Remove the two fixing screws (2) of the ignition

switch cover (3). 2
• Extract the cover.

With the engine cold, top up the level using the filler
hole (4) of the expansion tank.

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.

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 Maintenance

Engine coolant substitution

Substitution → Every two years

Before proceeding the emptying of the system,

2
B Perform the following operations in advance:

• Remove the ignition switch cover (see “Engine

coolant level check”);
• Place a container under the engine to collect the
used coolant; 1
• Open the expansion tank cap;
• Remove the coolant discharge screw (1) situa-
ted on the coolant pump (2), thereby letting the
coolant flow out.

8 N•m

Wait for the engine coolant to completely flow out.

Collect the engine coolant in an appropriate
container. Do not scatter the engine coolant
into the environment.
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 N·m
Fill the cooling system with the appropriate liquid
described in table (see page 11 of this chapter) until
the level is between the «MIN» mark found on the
expansion tank and the lower part of the frame tube
(see figure below).
Close the cap.
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. Wait
some minutes for the engine to cool down.
Carefully check for leaks, blow-bys, dama-
ged tubing, etc. If there are leaks or damage
in the cooling system, proceed with the
overhaul as described in the chapter
“Cooling system”.
Check once again the level of the coolant inside the
expansion tank (3).
It should be between the «MIN» mark found on the
expansion tank and the lower part of the frame tube, as 3
shown in the figure.
f the level is inferior to the «MIN» mark, top up the coo-
lant level by pouring new coolant into the filler hole.

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 Maintenance

Complete the assembly of the motorcycle.

ELECTRIC COOLING FAN

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 fan, switch on the engine and heat it up.

The electric fan should come into operation when the

instrument panel shows a system temperature of about
100 °C. If the electric cooling fan does not switch on,
carry out the checks on the various components as
described in chapter L “Cooling system”.

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 Maintenance

VALVE MECHANISM ADJUSTMENT

Check and adjust → at 1000 kilometres and
every 12000 kilometres

B Remove in order the following components to carry out

the measuring of the play between the camshaft and
the valve cups:

• Passenger seat
• Rider seat
• Left tank side panel
• Right tank side panel
• Ignition switch cover
• Fuel tank
• Air filter compartment
• Throttle body

N.B.: For all removal operations, including the relative

attention notes, please refer to the specific sections 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 the left.

Before proceeding with the various maintenance ope-

rations, it is advisable to thoroughly wash and clean
the motorcycle.
Place the motorcycle (now without the components
listed 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.

- 22 -
 Maintenance

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. B

Apply adhesive tape also on the oil breather tube (A)

and on the terminals of the accelerator control (B).

B
A

Pull out the connectors of the coils.

In order to perform this operation, release the secon-
dary lock (yellow tongue) pulling out from its seat, then
press the black tongue and release the connector.

- 23 -
 Maintenance

Unscrew the earth bonding on the engine head cover

and release the coil harness from the frame removing
the two clamps, and extract it on the right side.

Unscrew the fixing screws of the coil plates, and remo-

ve them.
Pull out the coils from their seat.

Screw and remove the eight fixing bolts of the cylinder

head cover.

- 24 -
 Maintenance

Operating as shown in the figure, slightly lift up the

cylinder head cover.

To carry out this operation, use only the work surfaces

indicated. B
Take care to not ruin or deteriorate the motorcycle
parts in the proximity of the work area.

Proceed with the removal of the cylinder head cover.

To facilitate this operation, it is advisable to move the

rubber engine coolant filling tube situated on the left
side of the motorcycle.

Complete the removal of the cylinder head cover by sli-

ding it towards the rear part of the motorcycle.

Remove the head cover gasket.

- 25 -
 Maintenance

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.

Rotate the camshaft by turning the central nut in an

anti-clockwise direction to bring piston N° 1 of the engi-
ne to the Top Dead Centre position (T.D.C.) when the
piston is at its uppermost part of the compression
stroke.

- 26 -
 Maintenance

Check the timing of the engine by ensuring that the

incision stamped on tooth (A) of the timing wheel is in
line with the “tooth” (B) that is present on the engine B
casing.
B
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
casing. Also the marks present on the toothed wheels
of the camshaft must be aligned together when the
timing wheel is in this position.

Utilising a feeler gauge of the type shown in the figure,

measure the play between the camshaft and the valve
cups.

- 27 -
 Maintenance

Continue measuring the play as illustrated in the figu-

re.

The correct measuring of the play is a funda-

B mental operation for the correct functioning
of the engine.

- 28 -
 Maintenance

Carry out the measuring of the play of the following val-

ves:

Cylinders 1 and 2 intake valves (number° 1,2,3,4)

Cylinders 1 and 3 exhaust valve (number 11,12,15,16). B

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

INDUCTION 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

CYLINDER 1 CYLINDER 2 CYLINDER 3 CYLINDER 4

EXHAUST Valve n° 16 Valve n° 15 Valve n° 14 Valve n° 13 Valve n° 12 Valve n° 11 Valve n° 10 Valve n° 9

Valve play

Pad thickness

Values measured after having replaced adjusting pins:

CYLINDER 1 CYLINDER 2 CYLINDER 3 CYLINDER 4

INDUCTION 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

CYLINDER 1 CYLINDER 2 CYLINDER 3 CYLINDER 4

EXHAUST Valve n° 16 Valve n° 15 Valve n° 14 Valve n° 13 Valve n° 12 Valve n° 11 Valve n° 10 Valve n° 9

Valve play

Pad thickness

- 29 -
 Maintenance

The progressive numeration of each valve is illustrated EXHAUST

SCARICO
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 5 6 7 8

ASPIRAZIONE
INDUCTION

To facilitate the operation, it is possible to note befo-

rehand 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 pre-

viously 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.

- 30 -
 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 fol-

lowing 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.

- 31 -
 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 workshop engine manual
(Code 8000A1592).
If the values are correct, reassemble in reverse order
to disassembly. Consult the F4 workshop engine
manual (Code 8000A1592) for the specific torque
pressures and the necessary products.
Before proceed to reassemble the engine head cover, it is
recommended to clean accurately the residues of dope
along the seal form on the head and use a new gasket.

- 32 -
 Maintenance

Timing chain, mobile timing chain guide and timing

chain tensioner

Timing chain and mobile timing chain guide:

Check → First 1000 kilometres and B
then every 12000 kilome-
tres
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 descri-
bed in the overhaul section of the F4 workshop engine
manual (Part code 8000A1592).

SPARK PLUGS
Check/substitute ➝ First 1000 kilometres, at
6000 kilometres and then
every 12000 kilometres
Substitute ➝ Every 12000 kilometres

The following components must be removed to accede

to the spark plugs:

• Passenger seat
• Rider seat
• Fianchetto laterale sx
• Right side panel
• Fuel tank
• Air filter compartment

Proceed to pull out 4 coils as described above.

Remove the spark plugs utilising the appropriate 16
mm hexagonal spark plug spanner.

Heat Grade
Check the heat grade of the spark plugs.

Spark plug gap

Measure the gap between the electrodes of the spark
plug with a feeler gauge. Adjust this gap in compliance
with the values written in the table below.

Spark plugs (alternatively) electrode distance “A” (mm)

NGK CR9 EB 0.7 ÷ 0.8

Champion G59c 0.6 ÷ 0.7

- 33 -
 Maintenance

Electrode condition
Check the electrodes for wear or burning. If they are extre- 12 N•m
mely used or burnt, substitute the spark plugs. Also sub-
stitute the spark plugs in the case of breakage of the cera-
B mic 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 com-
pletely screwed in by hand, tighten to the specified torque
pressure.

Spark plugs torque pressure: 12 N·m

FUEL FILTERS
Check and substitute → Every 12000 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:

• Passenger seat
• Rider seat
• Ignition commutator cover
• The side panels
• Fuel tank

N.B.: In order to perform the above-mentioned opera-

tions, refer to the chapter C “Superstructures”.

Carry out the following operation.

Drain completely the fuel tank using a booster pump as

shown in the figure.

- 34 -
 Maintenance

Petrol flange assembly removal

1
Close the tank filler cap.
Invert the tank and remove nine fixing screws (1) for
1
fixing the flange to the tank. B

1 1
Remove the flange assembly (2) from its seat.

To pull out the flange (2) use three M6 screws (1) remo-
ved previously.
Insert the screws (1) into the respective threaded holes.
1
Screw in sequence until the flange is extracted.

2
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.

Specified pincers: CLIC R 205

Part code 800095850

- 35 -
 Maintenance

Extract the complete flange assembly (1).

Remove the sealing O-rings (1) of the flange (2) and

clean them accurately.
Check they are undamaged.
If damaged, replace them with new rings.

1
2

Disconnect the electric connectors of the fuel pump (1).

- 36 -
 Maintenance

Remove the fuel probe by using a tube spanner on the

fixing nut of the probe.

Remove the closing screw (1) of the conduit indicated

in the figure so that the remaining fuel flows out of the
conduit.

Remove the two CLIC R 96135 fasteners (1), placed

on top of the fuel filter.

- 37 -
 Maintenance

Operate as indicated in the preceding figure and remo-

ve the CLIC R 96135 fastener (1).

Remove the fuel filter (1).

Extract the fuel pump (1) from its seat.

- 38 -
 Maintenance

Disassemble the fuel filter (1) on the pump and blow in

compressed air from inner to outer as shown in the
figure.

1 B

Clean the seat of the fuel pump and the fuel bowl.
Remove any residue and ensure that there are no sha-
vings that have originated from mechanical work.

Degrease the threaded hole and the screw (1) with the
appropriate solvent as shown in the figure.
Clean and dry by blowing with compressed air.

Apply LOCTITE 542 thread-locking fluid.

Reassemble the screws and tighten to the specified

torque.

Specified product LOCTITE 542

Torque pressure: 10 N·m

1

10 N•m

- 39 -
 Maintenance

Using fine abrasive paper clean the first threading “cre-

sts”of the fuel probe seat as shown in the figure.

This operation is necessary to not compromise the

B good condition of the gasket during the assembly
phase of the probe.

Place the fuel filter on the pump in according to the

timing shown in the figure.

Operate with care so that the net filter is not

damaged.

Assemble the CLIC R 96 135 fastener (1) –green

colour – onto the tube as shown in the figure.

- 40 -
 Maintenance

Insert a new fuel filter (1) within the pipe verifying its
right placement (the arrow, marked on the exterior of
the body must be oriented as shown in the figure).
If necessary, utilise alcohol to facilitate the assembly.
Tighten the CLIC R 96 135 fastener (2) – green colour B
– utilising the CLIC 205 pincers.
1

Insert the connection pipe of fuel filter / pump using

alcohol in order to facilitate the assembly.

Assemble the CLIC R 96 135 fastener (1) – green

colour – using the CLIC 205 pincers.

Insert the pump into its seat.

- 41 -
 Maintenance

Insert the pipe on the fuel pump.

Facilitate the insertion using alcohol.

Assemble the CLIC R 96 135 fastener (1) – green

B colour – using the CLIC 205 pincers.

Assemble the fuel probe (1) on the die-cast flange.

When reassembling, substitute the gasket (2) with a 2 1
new one and lubricate it with silicone grease.
Apply a light layer of silicone grease also on the threa-
ded seat of the probe.

Tighten the probe so that the output position of the

electrical wiring is in correspondence with the centre
line of the writing “FRONT” between the two arrows.

- 42 -
 Maintenance

Reconnect the electrical connectors.

It is advisable to clean and degrease the contacts with
the correct solvent.
Curl the electrical cable (1) into a circle at least twice to
1
contain it in the space. B
Place the tube (2) so that it is almost into contact with
the fuel pump.
2

Complete the assembly of the flange group (1) inser-

ting the sealing O-Rings (2) in their seat. Before
assembling verify that components are undamaged
and lubricate them applying silicone grease.
It is recommended to apply a layer of silicone grease
on the seat of the die-cast flange.

The use of worn O-Rings can cause any fuel

leakage from the tank motorcycle, and fire
risk for the motorcycle as a consequence.

Carry out a check on the flange assembly.

Check the correct execution of all the operations car-
ried out and described.

- 43 -
 Maintenance

FUEL PUMP ASSEMBLY

- 44 -
 Maintenance

N. Code Q.ty Note BRUTALE ORO BRUTALE S I FRAME I I ENGINE I

1 8A0094275 1 • •
2 800090927 1 • •
3 800021480 1 • •
4 80A090925 1 • •
B
5 800090925 1 • •
6 800090939 2 • •
7 8000A1400 1 • •
8 800090919 1 • •
9 800090920 1 • •
10 800093410 1 • •
11 800093411 1 • •
12 800090921 1 • •
13 800098305 1 • •
14 8M0092249 2 • •
15 8S0092249 2 • •
16 8E0087431 1 • •
17 8H0087431 1 • •
18 800088585 1 • •
19 800090929 1 • •
20 800093323 1 • •
21 800093324 1 • •
22 800090930 1 • •
23 800098304 1 • •

- 45 -
 Maintenance

Fuel flange unit assembly

Before starting the assembly of the flange to the fuel

tank, check the condition of the two small overflow
B 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.

Position the flange unit (1) inside the fuel tank.

Check that the two small overflow tubes (2) remain out-
side of the fuel tank.

Specific pliers: CLIC R 205 1

Part code 800095850

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 pin-
cers.

1 2

- 46 -
 Maintenance

Insert the flange unit inside the tank and tighten the
nine fixing screws. 6 ÷ 6,5 N•m

Torque wrench of fuel pump flange fixing

screws: 6 ÷ 6,5 N·m B
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
• Tank side panel
• Ignition switch cover
• Rider seat
• Passenger seat

FUEL UNION TUBES

Check for leaks ➝ First 1000 kilometres and then
every 6000 kilometres

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 TUBES 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:

• Passenger seat
• Rider seat
• Tank side panel
• Ignition switch cover
• Fuel tank
Insert the fuel tubes onto the unions of the throttle
body.
UTILISE ONLY NEW PARTS.

- 47 -
 Maintenance

The fuel tube with the white CPC union is

assembled on the right side of the butterfly
body.

B The fuel tube with the black CPC union is

assembled on the left side of the butterfly
body.

Follow the indication shown in the figure.

Orientate the CPC unions as shown in the figure.

During the check, distend the tubes to eliminate

flexions and deformation of the same.

- 48 -
 Maintenance

Ensure that the tubes are correctly fitted onto the metal
unions of the butterfly body and check that the rubber
tubes do not cover the curved section of the metal
union.
B
Position the “head” of the fastener as shown in the figu-
re.

Fix the fuel tubes to the unions of the butterfly body by

utilising the CLIC R 96 135 (green colour) fasteners.

Utilise the CLIC 205 pincers to secure them.

Specified pincers: CLIC R 205

Part code 800095850

Connect the pipes using the appropriate clamp that

can be opened.

Ensure that the two tubes are of equal length and posi-
tion the fasteners so that they are exactly aligned with
the frame tube (see the figure).
Conclude the operation by reassembling the compo-
nents in reverse order of disassembly.

- 49 -
 Maintenance

THROTTLE BODY ADJUSTMENT AND TUNING

(Tickover check, CO synchronisation and check)

Check and adjust ➝ First 1000 kilometres and

B then every 6000 kilome-
tres

The throttle body adjusting should be performed star-

ting the engine of the motorcycle, therefore you should
use a flue gas exhauster in order to not saturate the
environment with burnt gas.

The following described operations are fundamental

for the correct functioning and the maximum perfor-
mance of the engine.

When carrying out operations on throttle bodies, it is

advisable to remove certain parts of the bodywork
such as:
• Passenger seat
• Rider seat
• Tank side panels
• Ignition switch cover
• Fuel tank
Attention: before adjusting the throttle body verify
accurately:
- the absence of any cracks or damages on the pipes
to check the depression;
- the absence of gas leakages from drain pipes joint;
- that the fuel pipe unions are not buckled and crushed.

You should provide the motorcycle with tank placed on

an auxiliary support. Therefore you should connect the
hydraulic extensions of the fuel pipes and the electrical
extension for feeding fuel pump.

- 50 -
 Maintenance

Verify the parameters of the injection-ignition system

by the MDST diagnosis software.

Connect the tool cable of the MDST diagnosis with the

“Diagnostics” tap on the right side of the motorcycle
near the expansion tank of the coolant.

Start the MDST diagnosis software and go to the

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

- 51 -
 Maintenance

Check the throttle angle when the throttle is completely

closed.
The nominal throttle opening angle is 1.7°.
Huntings between 1.5° and 1.7° are allowed only if the
B engine is started.
Huntings between 1.7° and 1.9° and between 1.3° and
1.5° are not allowed.

If necessary adjust the throttle opening using only the

appropriate screw on the throttle opening pulley.
It is recommended not modify the throttle potentiome-
ter position because the throttle has been set during
the production to the optimal value.

Remove the sealing caps of the small tubes to check

the vacuum pressure.
The number of the cylinder to which the caps are con-
nected is written on the caps.
The small tubes for checking the vacuum pressure are
situated on the left and right side of the motorcycle.

- 52 -
 Maintenance

Connect the depression pipes with the vacuometer

complying with the match between the pipe and the
cylinder which is connected to.

In order to perform the following operations, you

should provide with the specific tool kit for setting CO.

Specific tool:
Part code 8000A4686

Remove the sealing caps of the CO drives placed on

the exhausts.
Insert and screw the 2 probes registering CO inside the
specific tool kit (code 8000A4686).
Assemble the 2 pipes with their Y union, also supplied
with tool kit, code 8000A4686, on the probes registe-
ring CO.
Connect the Y union with a rubber pipe to the exhaust
gas analyser.

Verify that the ignition switch is set to OFF.

Disassemble the injection-ignition gearcase placed on
the air filter compartment unscrewing the four fixing
nuts.
Reset the earth bonding on the gearcase by using a
nut and a M6 screw (for the correct performance of the
adjusting operations, it is important the gearcase is
earthed).

- 53 -
 Maintenance

Remove the seal plate and then the gearcase sealing

cap.

Operate the by-pass screws in order to return to a

known condition.
Close completely the screws and then open them for 1
turn again.

Start the engine and warm it up. During this phase you
should not accelerate because the high depression
created in the induction lines could pipe the mercury
from vacuometer.
The engine rotation can be supported by using the
starter.
The attainment of the correct thermal speed is given by
the intervention of the cooling fan.

- 54 -
 Maintenance

Balance the depressions in the cylinders: the thermo-

meters should get to the same height (reference level
= 2).
Se all engine parameters are correctly set, the position
of the adjusting screws should be between 1 and 1.5 B
rpms from the fully closed position.

Keeping the depressions aligned, adjust the engine

speed (with fan connected and light on) so it is
between 1100 and 1200 rpms.

Check the CO value using the exhaust gas analyser.

This value must be between 3% and 4%.

If the CO value does not fall into the established

values, operate the trimmer inside the gearcase until
the values fall into the tolerance range.

- 55 -
 Maintenance

The attainment of the correct CO value could involve a

variation of the engine speed at minimum.
In this case you should operate the by-pass screws
again to return the speed to the desired value and then
B repeat the trimmer adjustment.

After having finished the adjustment operations,

perform in the order as follows:
- assemble the rubber plug on the gearcase lower side;
- apply a new seal plate;
- assemble the gearcase on the air filter compartment
restoring the earth bonding;
- disassemble the exhaust gas probes and tighten the
fixing screws;
- restore the sealing caps of drives for checking
depression;
- reassemble tank, tank side panels, ignition switch
cover, rider seat and passenger seat.

After reassembling all parts, carry out a final check to

ensure that everything has been correctly replaced.

- 56 -
 Maintenance

AIR FILTER
Check/substitute Every 6000 kilo-
metres
Certain parts must be removed in sequence before
acceding to the air filter. See chapter C “Bodywork”: B
• Passenger seat
• Rider seat
• Left tank side panel
• Right tank side panel
• Ignition switch cover
• Fuel tank
• Air filter compartment

Remove the sealing rubber gasket (1).

Work on the three “tongues” of the air filter and extract

it from the air filter compartment.

- 57 -
 Maintenance

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
B clean and free from foreign bodies.

Insert the air filter complying with the correct assembly

direction shown in the figure.
Press in the three fixing tongues until a click is heard.

Complete the assembly of the filter into the air filter

compartment sealing the operation opening by the rub-
ber gasket as shown in the figure.

- 58 -
 Maintenance

Before proceeding with the assembly of the air filter

compartment onto the motorcycle, apply silicone grea-
se to the gaskets of the air intake bell chambers.
Proceed with the assembly of the parts listed below
and according to the procedure described in chapter C B
“Bodywork”:
• Air filter compartment
• Fuel tank
• Right tank side panel
• Left tank side panel
• Ignition switch cover
• Rider seat
• Passenger seat

- 59 -
 Maintenance

BRAKES AND CLUTCH

Check the levels of

fluid in the systems➝ At pre-delivery, at first 1000 kilo-
B metres and then every 6000 kilo-
metres

Check for leakages➝ At pre-delivery, at first 1000 kilo-

metres and then every 6000 kilo-
metres

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 that is described as follows must be
carried out for the fluid chambers of both the front and
rear brakes and also the clutch fluid chamber.
Place the motorcycle in a vertical position with the
handlebars 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 is lower than the lower level line, add brake
fluid complying with the specification by the manufac-
turer in according to the following procedure:
- Remove the 2 screws from the fluid tank cover;
- Remove the three elements of the cover.

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.

- 60 -
 Maintenance

In order to access the back brake fluid tank you should

remove the fuel tank as described in the Chapter C
“Super structures”.

Likewise proceed to the front brake fluid tank.

Before completing the operation, clean and wash accu-

rately the 3 components of the chamber cover using
alcohol 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.

Imperfect cleaning of these parts could

cause the discharge of small quantities of
brake fluid during riding. Brake fluid has
strong corrosive properties.

- 61 -
 Maintenance

Check eventual leaks and blow-bys of brake and clut-

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

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.

- 62 -
 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 calibrated
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.

- 63 -
 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

Operate on both the gearchange and rear brake levers 2

in the same way.

6 N•m

(Only for the Brutale ORO model)

Footrest adjustment
On the BRUTALE ORO model, the footrests are adju-
stable. Operate as follows for the adjustment from the
original position:

• Slacken (without removing) the eccentric adjustment

screw (situated at the rear of the footrest support)
using a 12 mm hexagonal spanner.

• Loosen (without remove) the two fixing screws of the

frame board support using a 6 mm setscrew wrench.

• Lay (without tightening) the eccentric adjustment

rear screw. Effectuate the adjustment by utilising the
correct size screwdriver.

Adjust both footrests to the same adjustment

value.

• Tighten the two footrest fixing screws utilising a tor-

que wrench.

Torque pressure: 24 ÷ 28 N·m

• Tighten the rear eccentric adjustment screw.

24÷28 N•m

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 Maintenance

BRAKE PADS
Front brake caliper
Check/substitute ➝ At the first 1000 kilo-
metres and then very
6000 kilometres
B
Check the condition and thickness of the brake pads
on the pincers.
Rear brake caliper

The brake pads have small channels that assist in

checking the wear. If these channels are not visible or
are about to disappear, it is therefore necessary to sub-
stitute the brake pads as described in chapter H
“Brakes”. Disc

Wear limit: 1 mm. Pads

If the brake pads are substituted, it is neces-

sary to effectuate a proper running-in period Groove
before reaching an optimal braking effi-
ciency.

Wear limit 1 mm

ACCELERATOR CONTROL
Accelerator play check➝ At the pre-delivery
check, at the first 1000
kilometres and then
every 6000 kilometres 1

The accelerator 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 accelerator
handgrip).

The lack of play on the closure of the acce-

lerator (1) can stop the complete closing of
the throttle valve and the accelerator could
remain in the open position, thereby leaving
the engine with a fast tickover. It is the same
for the opening transmission (2).

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 Maintenance

After making adjustments, check that the throttle val-

ves open slightly by activating the choke lever (1), as
indicated in the following figure.

If interventions have been carried out on

the throttle bodies, the transmission of the
accelerator control must be analysed not
only at the accelerator 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..

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 Maintenance

LOCKS
Check ➝ At the pre-delivery, at the first 1000
kilometres and then every 6000 kilo-
metres
OFF ON
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
All electrical circuits are disactivated. The key can be
pulled out.
OFF
“ON” position
All electrical circuits are activated, the instruments and
warning lights carry out self-diagnosis and the engine

LOCK
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
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”.

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 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. Press
and hold the cap, let the key go free, bring it into a lon-
gitudinal 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 in the lock.
Turn the key clockwise and at the same time press the
passenger seat slightly.
Lift and take out the passenger seat.

For reassembling the part refer to the following indica-

tions:
• Turn the key in the lock
• Press the passenger seat
• Release the key
• Press again the passenger seat, verifying it is well
fastened to the structure.

After having removed or lifted the passenger

seat, and in any case before using the
motorcycle, ensure that the components are
correctly placed and well fastened to the
supporting structure of the motorcycle.

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 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. A

If it is necessary to carry out adjustments, operate as D

described in chapter F “Suspension and wheels”. B

TRANSMISSION CHAIN
Check ➝ At the pre-delivery, at the first 1000
kilometres and then every 6000 kilo-
metres

Substitute ➝ Every 6000 kilometres (Brutale ORO)

Every 12000 kilometres (Brutale S)

Place the motorcycle on the rear stand.

The chain tension check should be effectuated with the
motorcycle having a static set-up quota equal to the fol-
lowing standard values (see chapter F “Suspension and
wheels”):
BRUTALE ORO - S (MY 03): 190 mm
BRUTALE S (MY 04): 200 mm
The clearance “h” between the axis of symmetry of the
chain and the chain cover should be equal to the fol-
lowing values as shown in the figure.
BRUTALE ORO - S (MY 03): h = 6 mm
BRUTALE S (MY 04): h = 11 mm “h”
Manually rotate the rear wheel and effectuate this check
on more than one point of the chain. The play must be
constant whilst the wheel turns. If the chain is slack in
only certain places means that the some links are stret-
ched or seized.
Visually check the transmission chain for the following
defects:

• Slack pins • Excessive use

• Damaged rollers • Incorrect chain
• Dry and rusty links adjustment Grease
O-ring
• Bent or seized links • Damaged O-rings

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 sequen-
ce described in chapter F “Suspension and wheels”.

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 Maintenance

Adjust➝ At the first 1000 kilometres and then

every 6000 kilometres

To adjust the chain tension, proceed as follows:

B Slightly loosen the 2 screws of the back wheel hub until
they can freely turn.

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

Rear hub eccentric adjuster screw torque

pressure: 28 ÷ 32 N·m

After tightening the screws of the rear wheel hub,

recheck the chain tension so that any eventual varia-
tions can be found. If the tension of the chain is varied
in respect of the adjustment before tightening the rear
wheel hub, then repeat the adjustment procedure of
the transmission chain.

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 Maintenance

Chain lubrication

Lubricate➝ At the first 1000 kilometres and at

6000 kilometres and then at every
12000 kilometres B
Clean the chain with a clean cloth and/or a jet of air.

The chain is the type with sealing rings (O-

RING); in order to avoid damages you
should not clean the chain using jets of
steam or high pressure water, or using fuel
or cleansing solvents on the market.

Then apply a light and even coating of lubricant on the

whole chain without reaching the surrounding parts, in
particular the tyres.

Use only the lubricant recommended (see

page 11 in this chapter) in order to effecti-
vely protect the gearing chain and avoid
from splashing when the motorcycle is run-
ning.

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 Maintenance

TYRES
Check pressures➝ At the pre-delivery, at the first
1000 kilometres and then every
6000 kilometres
B Check wear ➝ At the first 1000 kilometres and
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.

Description BRUTALE ORO BRUTALE S

Brand and PIRELLI - Dragon Evo MTR 21
type Corsa (Ant.) / MTR 22 Corsa (Post.)
PIRELLI Diablo Corsa
DUNLOP - Sport Max D 207
Race Replica MICHELIN Pilot Sport
MICHELIN Pilot Power
DUNLOP - Sport Max D 207
Race Replica
Inflation pressure (*)
Front 2.3 bar (33 psi) 2.3 bar (33 psi)
Rear 2.3 bar (33 psi) 2.3 bar (33 psi)

The use of the motorcycle with excessively worn tyres

diminishes the roadholding and is therefore dange-
rous. It is highly recommended to change the tyres
when the tyre tread reaches the following minimum.

Ride with extreme care during the initial kilo-

metres after replacing the tyres. 1.5 mm
Utilise exclusively the tyres recommended.
Tyre tread minimum limit = 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”.

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 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 planarity,
the eccentricity and the ovalisation of the wheel. See
the control procedures described in chapter F
“Suspension and wheels”.

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 Maintenance

REAR WHEEL HUB

Check and lubricate bearings ➝ Every 12000
kilometres
Substitute ➝ Every 12000
B 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 fixing nut of the crown
flange (see chapter F “Suspension and wheels”).
Loosen the nut of the wheel pin (see chapter F
“Suspension and wheels”).
Remove the brake caliper (see chap. H “Brakes”) and
its support flange.
Extract the wheel pin.
Check and overhaul the rear wheel hub unit (see chap-
ter F “Suspension and wheels”).
OSCILLATING ARM BEARINGS
Check and lubricate ➝ Every 36000 kilometres

If excessive play is found on the rear fork, due to the

bearings assembled on the central pin of the
fork/frame, substitute them as described in chapter F
“Suspension and wheels”.

REAR SHOCK ABSORBER

Check and adjust ➝ At the first 1000 kilometres
and then every 12000 kilo- A
metres

Verify the length in the seat of the back damper spring,

check the absence of leakages or oil blow-by and the
adjusting functionality.

Spring adjustment standard “A”:

- Brutale ORO / Brutale S (MY 03):

A = 151 mm
- Brutale S (MY 04):
A = 154 mm

The shock absorber contains gas under high

pressure. Do not touch the shock absorber
valve. Do not attempt in any way to remove the
shock absorber.

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 Maintenance

Compression and extension adjustment (rear suspen-

sion):
CLICK!
CLICK! CLICK!
N.B. This operation can be made with the CLICK! CLICK!
CLICK!
shock absorber in position on the B
motorcycle.
For further checks on the round joints
where the rear shock absorber is atta-
ched, it is necessary to carry out the pha-
ses of removal described in chapter F
“Suspension and wheels”.

SIDE STAND
Functional check ➝ At the pre-delivery, first 1000
kilometres and then every
6000 kilometres
With the side stand lowered, check that it is not possi-
ble to switch on the engine. 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.
Disconnect the electrical connectors.
Remove the 2 fixing screws of the switch.
Remove the switch.
After having substituted the switch, tighten the two
screws to the prescribed torque.
Torque pressure: 5 ÷ 7 N·m

Apply Loctite Media 243 5÷7 N•m

Reconnect the electrical connector.
Check that the side stand is not worn.

To remove the side stand, operate as follows:

- After having removed the side stand switch, unhook
the two springs; 1
- remove the nut placed behind the hanger attachment;
- remove the screw (1).
For reassembling perform the operations in reverse
tightening the nut complying with the prescribed torque.
Torque wrench setting of stand plate
screws (2):
25 ÷ 28 N·m
Torque wrench setting of hanger nut:
24 ÷ 28 N·m
Apply Loctite Media 243
2
The substitution of the springs must be car-
ried out utilising the appropriate tool. 25÷28 N•m 24÷28 N•m
Before refastening the springs, verify that
the stand can freely turn (without damages
or frictions).

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 Maintenance

FRONT FORK
Substitute oil ➝ every 24000 kilometres

The front fork is vitally important for the rideability and

B roadholding of the motorcycle. It is therefore necessary
to substitute the fork oil at the prescribed intervals.

Quantity oil: about 655 cc

Specified oil:
- Brutale ORO / S (MY 03): SAE 5
- Brutale S (MY 04): 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 prescri-
bed. 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.

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 Maintenance

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 B
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 kilo-
metres and then
every 6000 kilome-
tres
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 the figure for the correct assembly.

Insert the battery in the proper compartment.

The first charge of the battery must be

performed before assembling it on the
motorcycle.

Assembly of the battery terminals

Mount the two positive terminal (+) leads onto the rela-
tive pole of the battery, respecting the order indicated
in figure. Pay attention to the colours of the cables in
order to set them in the right way.

- 77 -
 Maintenance

Turn the screw of the positive terminals and tighten

them complying with the prescribed torque by using a
torque wrench.

B Torque wrench setting: 7 ÷ 8 Nm

7 ÷ 8 N•m

When the leads are mounted, replace the protection

cover on the positive pole (see the figure).

Mount the two negative terminal (-) leads on the relati-

ve pole of the battery following the placement shown in
the figure.

- 78 -
 Maintenance

Turn the screw of the negative terminals and tighten

them complying with the prescribed torque by using a
torque wrench.

B
Torque wrench setting: 7 ÷ 8 N•m

Before tightening, verify that the cables are

correctly oriented.

7÷8 N•m

At the end of assembly, ensure that the cable

of the positive terminal is placed inside the
structure of the back sub-frame (see the
figure).

PLACEMENT ANDE ASSEMBLY

POSIZIONAMENTO MONTAGGIO OF
DEI TERMINALS (WIRE TERMINALS)
TERMINALI (CAPICORDA) ON THE BATTERY
SULLA BATTERIA.
NEGATIVE WIRE (-)
CAVO NEGATIVO (-)

NEGATIVE POLE (-)

POLO NEGATIVO (-)

NEGATIVE WIRE (-)

CAVO NEGATIVO (-)
CAUTELA:
CAUTION: Prima di effet-
Before POSITIVE POLE (+)
tuare il serraggio, assicu- POLO POSITIVO (+)
tightening,
rarsi che i caviensure
siano cor-
rettamente orientati
that the wires (vedi
are
figura).
correctly oriented
(see the figure)

PROTECTION COVER
CAPPUCCIO DI PROTEZIONE
POSITIVE WIRE (+)
CAVO POSITIVO (+)
ATTENZIONE:
ATTENTION:Alla fine having
After dell’ope- fini-
razione di montaggio, assicurar- POSITIVE WIRE (+)
shed
si che ilthe
cavoassembly,
del terminale ensure
posi- that CAVO POSITIVO (+)
tivo sia posizionato
the positive terminalall’interno
wire is pla-
della struttura del telaietto poste-
ced (vedi
riore inside the rear sub-frame
figura).
structure (see the figure)

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 Maintenance

INSTRUMENTS AND WARNING LIGHTS Luminous warning Luminous warning indication light
Check ➝ At the pre-delivery, at the first 1000 indication light
kilometres and then every 6000 kilo-
metres
B SET
The instrumentation check must be carried out com- button Tachometer
pletely on all its functions as listed in the following list.
If even one of the functions does not function correctly,
consult chapter E “Electrical system” for complete
details. Multifunction
display
Turning the ignition key to the “ON” position activates
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
motorcycle at that moment.

Luminous warning indication lights

1 Main beam warning light (blue)
It lights up only when the main beam is switched on. 1 9

2 Dipped beam or sidelights warning lights (green)

6 8
It lights up when the dipped beam or sidelights posi-
tions are activated. 2
3 Gears in neutral warning light (green)
It lights up when the gear position is in neutral”.
4 Direction indicators warning light (green)
It lights up when the direction indicators are activa-
ted.
5 Fuel reserve warning light (orange)
It lights up when the fuel tank contains approxima-
tely four litres of fuel.
3
6 Engine oil pressure warning light (red) 4 5
It lights up when the oil pressure inside the oil lubri-
cation system is insufficient.
If the oil pressure warning light lights up
whilst riding the motorcycle, stop immedia-
tely. Check the oil level and if necessary top
up. If the warning light lights up and there is
a correct level of oil in the engine, do not
continue riding. Contact the nearest authori-
sed assistance centre.
7 Rev limiter warning light (red)
It lights up when the engine exceeds 12700 r.p.m.
The limiter intervenes at 13100 r.p.m.
8 Side stand warning light (red)
It lights up when the side stand is in the lowered
position.
9 Battery charge warning light (red)
It lights up when the alternator does not supply suf-
ficient current to recharge the battery.
If it lights up whilst riding the motorcycle, go to the
nearest authorised assistance centre.

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 Maintenance

Multi-function display
10 Speedometer
The speedometer indicates the speed. The value of
the scale can be written in kilometres per hour 10 13
(k.p.h.) or miles per hour (m.p.h.). The highest B
value on the scale is 299 k.p.h. (185 m.p.h.).
11
11 “SET” button
If pressed, the “SET” button can select the figure of
the display to effectuate adjustments. If pressed
again, the figures are confirmed.

12 Total mileometer “TOTAL”

Indicates the total mileage, from 0 to 99999.9 (kilo-
metres or miles).
Partial tripmeter 1 “TRIP 1” 12

Indicates partial mileage, from 0 to 9999.9 kilometres

or miles.
Partial tripmeter 2 “TRIP 2”
Indicates partial mileage, from 0 to 9999.9 kilometres or
miles.
Clock
Indicates the time (0 - 24).

13 Thermometer
Indicates the temperature of the engine coolant.
The value can be in centigrade (°C.) or in
Fahrenheit (°F.).
The temperature field goes from 40°C. to 140°C.
(104°F. to 284°F.).:
- under 40°C. (104°F.) the indication does not
appear. Three flashing lines appear which means
that the temperature signal is very low.;
-between 40° and 49° C (104° and 120° F) the indi-
cation flashes wich means that the temperature is
low;
- between 50°C. and 105°C. (122°F. and 221°F.) the
indication is fixed;
- between 106°C. and 140°C. (223°F. and 284°F.)
the indication flashes which means that the tem-
perature is too high.

Attention: if the temperature is over 120° C

(248° F), stop the motorcycle and check the
coolant level and the fan running on the
right side of the radiator. If it is necessary
to top up the coolant, wait for the cooling of
the engine. Non aprire il tappo di carica-
mento del liquido di raffreddamento a
motore caldo. If the temperature indicator
continues to mark values higher than 120°
C (248° F) even if the level is correct and the
fan works, not proceed running and contact
an authorized assistance centre.

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 Maintenance

Modifications to the display functions

Modifications can be made to the clock function, the
tripmeter function and the thermometer function. This
operation must be effectuated with the engine switched
B on and the gears in neutral.

Clock (hours and minutes)

Repeatedly press the starter button until the visualisa-
tion of the hour appears.

Pressing the “SET” button, the first figure of the hour

starts to flash.

Press the starting button to adjust the digit; release

when the desired digit is reached.

N.B. To obtain the quick scrolling of the selected

digit, press and hold the engine starting but-
ton more than two seconds.

Repeat the procedure for the second figure of the hour,

for the first and second figures of the minutes.

Press the “SET” button to confirm the figures and to

interrupt the selection (the flashing).

Speedometer (k.p.h. – m.p.h.)

Repeatedly press the starter button until the visualisa-
tion of the “TOTAL” speedometer function.

Press the “SET” button. The measuring unit of the

speedometer starts to flash.

N.B. The instrumentation has an integral

memory which stores all parameters also
when the engine is off. Except for the clock,
which is set to zero, all parameters are in
memory also in case of battery disconnec-
tion.

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 Maintenance

Press the starter button to pass from kilometres per

hour to miles per hour and vice versa. Varying the
measuring unit of the speedometer automatically
varies also the mileometer (total and partial).
B
Press the “SET” button. The measuring unit of the ther-
mometer starts to flash. Proceed to the successive
adjustment.

Thermometer (°C. - °F.)

Press the starter button to pass from °C. to °F. and vice
versa.

Press the “SET” button to confirm the measuring unit.

Display function selection

The selection of the “TOTAL” mileometer, the partial
“TRIP 1” mileometer, the partial “TRIP 2” mileometer
and the clock must be carried out with the engine swit-
ched on.

Repeatedly pressing the starter button, the functions

appear in a cyclic mode.

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 Maintenance

Resetting of the tripmeters

The values of the “TRIP 1” and “TRIP 2” can be reset
as follows.

B Press the starter button to activate the “TRIP 1”.

Press the starter button for more than four seconds.

The value will start to flash.

Press the starter button for less than four seconds; the
value zeroes. If instead the starter button is pressed for
more than four seconds, the resetting procedure is
interrupted.

Pressing the engine starting button, activate the func-

tion “TRIP 2”.

Press the engine starting button for more than four

seconds; the value starts to blink.

Now pressing the engine starting button for less than

four seconds the value is set to zero.
If you press the engine starting button for more than
four seconds the zero setting is interrupted.

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 Maintenance

LIGHTS
Check ➝ At the pre-delivery, at the first 1000
kilometres and then every 6000 kilo-
metres
B
If any of the warning lights or the main lights are burnt
out, replace them as follows.

Dipped headlamp – bulb substitution

Remove the two side fixing screws (1) of the front
headlight.
Pay attention to take out the register from the proper
seat when the headlamp is removed from the support.
1

Before removing the front headlight from its support,

disconnect the connector (2) placed on the back of the 2
headlamp.

- 85 -
 Maintenance

Put the headlamp on a table in order to perform the fol-

lowing operations.
Remove the back screw of the headlamp.
Remove the front part of the headlamp from its support
B shell.

Disconnect the connector of the dipped headlight.

Remove the protection cover.
Release the check spring.

Extract the bulb of the dipped headlight.

Do not touch the glass of the bulb with your

hands. In case of contact clean using a
degreasing product.

Insert the new bulb.

Refasten the check spring.
Place the protection cover again.
Reconnect the connector of the dipped headlight.
Reassemble the front part of the headlamp from its
support shell.
Retighten the back screw.
Reinsert the connector of the headlamp.
Place the headlamp on its support again and retighten
the two side fixing screws, watching to reinsert the
register in its seat.

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 Maintenance

Dipped headlight – Replacing bulb

Turn the bulb of the dipped headlight counterclockwise
and extract it from its seat. 1
Disconnect the connector from the bulb.
B
Do not touch the glass of the bulb with your
hands. In case of contact clean using a
degreasing product.

Insert the connector in the new bulb.

Reinsert the bulb in its seat and set it turning counter-
clockwise.
Reassemble the headlamp on its support.

Front lights – Replacing bulb

Remove the front headlamp from its support.
Turn the lamp holder counterclockwise and extract it
from its seat.
Extract the bulb removing it from lamp holder.

Do not touch the glass of the bulb with your

hands. In case of contact clean using a
degreasing product.

Insert the new bulb.

Reinsert the lamp holder in its seat and set it turning
counterclockwise.
Reassemble the headlamp on its support.

Front direction indicators – bulb substitution

Remove the fixing screw.

Remove the glass.

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 Maintenance

To extract the bulb press it counterclockwise.

Insert the new bulb pressing and turning it clockwise.
Reassemble the glass and retighten the fixing screw.

Rear direction indicators – bulb substitution

Remove the fixing screw.
Remove the glass.

To extract the bulb press it counterclockwise.

Insert the new bulb pressing and turning it clockwise.
Reassemble the glass and retighten the fixing screw.

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 Maintenance

Rear light/stop light – bulb substitution

Lift the passenger seat.
Extract the bulb holder, rotating it in an anti-clockwise
direction.
B

To extract the bulb, press it down and rotate it in an

anti-clockwise direction.
Insert the new bulb pressing and turning it clockwise.
Reinsert the bulb holder and rotate it in a clockwise
direction.

Number plate light – bulb substitution

Remove the fixing screws of the cable guide.

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 Maintenance

Following the procedure shown in the figure, lower the

cable guide separating it from the upper supporting
surface.

Extract the lamp holder of the number plate light from

its seat.
Extract the bulb taking it out from the lamp holder.
Insert the new bulb.
Reinsert the lamp holder.
Place the cable guide again into contact with the upper
supporting surface.
Retighten the fixing screws of the cable guide.

Fuses – Substitution
The recharge fuse is under the rider seat as shown in
the figure.

Spare fuse

Fuse

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 Maintenance

The fuses are situated on the right side of the motorcy-

cle; to reach them you should disassemble the right
side panel fixed on the tank.

Remove the cover.

Turn the ignition switch on “OFF” before

checking or replacing the fuses in order to
avoid accidental short circuits with conse-
quent risk to damage other electric compo-
nents.

To identify the position and the function of the fuses,

consult the information on the adhesive label and the
electrical system. The reference letters indicated in the
figure correspond to those shown in the electrical dia-
gram.

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 Maintenance

Replace the burnt fuse and reassemble the cover.

Remember that two spare fuses are available in the
toolkit.
B Never use a fuse having an adjustment diffe-
rent from the instructions in order to avoid
from damaging the electrical system of the
motorcycle with the consequent fire risk.

FRONT HEADLAMP
Check adjustment – At every variation of the motorcy-
cle set-up

Each time a variation to the set-up of the motorcycle is

carried out, it is good practice to carry out the adjust-
ment of the headlamp beam.

The adjustment of the front headlight can be perfor-

med operating the screw shown in the side figure.
Clockwise: the headlight leans downward.
Counterclockwise: the headlight leans upwards.
The inclination can be varied for ± 4° in respect of the
standard position.

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 Maintenance

Adjusting front headlight

Place the motorcycle 10 metres from a vertical wall.
Ensure that the ground is even and that the optical axis of the projector unit is perpendicular to the wall.
The motorcycle must be in a vertical position.. Measure the height of the centre of the beam from the ground and
mark it with a cross on the wall using a piece of chalk. B
Switch on the dipped beam. The upper demarcation limit between the dark zone and the illuminated zone must
be not more than 9/10ths of the height from the ground of the centre of the beam.

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 Maintenance

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