Motorcycle Art

MV AGUSTA BRUTALE 675 - BRUTALE 800 - RIVALE 800

Engine workshop manual

©2013
The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A.

Part. N° 8A00B7597 - Edition N° 2

Printed - November 2013
Engine workshop manual
MV AGUSTA BRUTALE 675 - BRUTALE 800 - RIVALE 800
Statement

This manual, to be used by the MV Agusta authorised workshops, has been realised with
the purpose of assisting authorised personnel in maintenance and repairs operations of
the motorcycle. The knowledge of technical data herein noted, determines the complete
professional training of the technician. With purpose of making the reading of this manual
immediately comprehensible, the paragraphs have been aligned with detailed illustrations
that highlight the argument dealt with.

Useful advice

To prevent any problems and to reach an excellent final result, MV Agusta recommend
skeeping to the following guidelines:

- In the case of an eventual repair, evaluate the client’s impressions who states that there
is an abnormal functioning of the motorcycle and to formulate the right questions to
clarify the symptoms of the problem.

- Clearly diagnose the cause of the abnormality. The basic fundamental theories can be
absorbed by reading this manual that must necessarily be integrated to the personal
experience and the participation of training courses that are periodically organised by
MV Agusta.

- Rationally plan the repair to avoid slack periods, e.g. the collection of spare parts, the
preparation of tools and equipment, etc.

- To reach the part to be repaired limiting the work to the essential operations. With
regards to this, a valid help would be to consult this manual with regards to the
sequences of removal demonstrated in this manual.

Informative note
MV Agusta S.p.A. is committed to a policy of continuous improvement of their products. For
this reason, there could be slight differences between that which is written here and the
motorcycle on which repairs and/or maintenance are about to be carried out. MV Agusta
models are exported to many countries where different norms in relation to the highway
code
and homologation procedures are valid. Hoping that you will comprehend these problems,
MV Agusta S.p.A. reserves the right to make modifications to its products and technical
documentation at any moment and without prior announcement.

Respect and defend the environment

Everything that we do has repercussions on the entire planet and its resources. MV Agusta,
wanting to protect the interest of the people, would like to make the client and the
technicians
of the technical assistance centres aware and to adopt modalities of use of the motorcycle
and the disposure of its parts in full respect of the norms in force in terms of environmental
pollution, disposal and the recycling of waste.

-2-
 General index

GENERAL DESCRIPTIONS ................................................................ A

Rev. 0

MAINTENANCE ................................................................................... B
Rev. 0

ELECTRICAL COMPONENTS ............................................................ C

Rev. 0

HEAD ................................................................................................... D
Rev. 0

CLUTCH ............................................................................................... E
Rev. 0

GEAR ................................................................................................... F
Rev. 0

STARTING ........................................................................................... G
Rev. 0

COOLING AND LUBRICATION .......................................................... H

Rev. 0

ENGINE BLOCK .................................................................................. I

Rev. 0

TIGHTENING TORQUES..................................................................... L
Rev. 0

SPECIAL TOOLS ................................................................................. M

Rev. 0

ANALYTICAL INDEX ........................................................................... N

Rev. 0

-3-
General description

SECTION A
REVISION 0

-1-
 General description

SUMMARY

HOW TO CONSULT THIS MANUAL ...................................................................................... Pag. 3

PURPOSE OF THE MANUAL ................................................................................................. Pag. 3
GLOSSARY AND SYMBOLS .................................................................................................. Pag. 4
RIGHT HAND AND LEFT HAND STANDARD ........................................................................ Pag. 6
SAFETY .................................................................................................................................... Pag. 7
Carbon Monoxide ................................................................................................................. Pag. 7
Petrol .................................................................................................................................... Pag. 7
Engine oil .............................................................................................................................. Pag. 7
Engine coolant ...................................................................................................................... Pag. 7
Brake fluid ............................................................................................................................. Pag. 8
Thread-locking fluid .............................................................................................................. Pag. 8
Nitrogen - rear shock absorber ............................................................................................. Pag. 8
Battery .................................................................................................................................. Pag. 8
Hot parts ............................................................................................................................... Pag. 8
WARNING ................................................................................................................................. Pag. 9
INDEX ....................................................................................................................................... Pag. 9
OPERATIVE TECHNICAL SPECIFICATIONS ........................................................................ Pag. 10
MOTORCYCLE IDENTIFICATION ......................................................................................... Pag. 10

-2-
 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
Fitting countershaft head.
Fit the half-bearing on the countershaft head without
lubricating .
After placement, lubricate the half-bearing with engine
oil.
Check for the presence of the 2 countershaft head
blocking rings on the lower block.
Fit the countershaft head with the arrow stamped on
the back pointing in the direction of travel.

PURPOSE OF THE MANUAL

Principally, this manual has been written for MV Agusta
dealers and qualified mechanics. It is not possible to
document all the knowledge necessary for a mechanic
in a manual. Those who utilise it must have a basic
knowledge of mechanical concepts and the inherent
procedures in the techniques of repairing motorcycles.
Without this knowledge, the maintenance and repair
operations can render the motorcycle unsafe for use.

Updates
MV Agusta S.p.A. is committed to a policy of continuous
updating of the models produced. The modifications
and significant changes to the specifications and the
procedures will be communicated to the official dealers
and will appear in future editions of this manual. All
information, instructions and technical data included
in this manual are based upon information on the
product updated at the moment of going to print. MV
Agusta S.p.A. reserves the right to carry out changes
at any moment without prior notice and without incurring
any obligation.

-3-
 General description

A GLOSSARY AND SYMBOLS

ATTENTION This signifies that the lack or During this kind of procedure
the incomplete observance inflammable vapours might develop
of this advice can be gravely and metallic parts might be expelled
dangerous for your safety at high velocity.
and for the safety of other Thus, it is necessary to:
persons.
- work far from exposed flames and
sparks;

- wear protective clothing;

- wear protective eye-glasses.

WARNING This signifies that the lack of In case it should be necessary, due
observance of these to wear, to substitute a particular, re-
instructions can bring the lative to a cylinder, we strongly
risk of damage to the suggest that you check and if
motorcycle and the necessary, substitute the same
equipment. particular in all of the cylinders for
more satisfying results.In particular, we
recommend that at the same time you
substitute:

- pistons with relative elastic bands

and piston pins;

- valves with relative springs, semi-

cones,disks and grazings;

- Valve guides with relative valves,

springs, semi-cones and grazings;

- bed bearing;

- whatever else under goes uniform

wear, a side from the position of
the relative cylinder.

In order to allow the motorto function

under the best conditions, it is
necessary that all of the couplings are
within the accepted tolerances
established. A tight coupling, is in fact,
cause for seizure as soon as the
organs in motion begin to heat, while
a loose coupling is cause for
vibrations which accelerates wear on
the particulars in motion.

-4-
 General description

NOTE Supplies key information for the best All of the countersigns indicting right, left, A
fulfilment of the operation. superior, inferior, front and back, refer to
the motor-bike in the normal direction of
march.

The motor supports numbering of the

cylinders and of the attached components,
increases moving from left towards right
in regards to the direction of march.

This symbol indicates "the Use the recommended coolant.

procedures to be carried out with
an empty cooling circuit".

Utilise a specific tool or equipment

for the correct carrying out of the Use the recommended thread-locking
operation described. fluid.

Use the recommended sealant.

Tighten to the specified torque.

Tolerance or limit of use. Use the recommended adhesive.

Utilise the tester. Carry out accurate cleaning.

Use the recommended oil. Use new components.

Use the recommended grease. Substitute the component.

Do not leave litter about.

-5-
 General description

A RIGHT HAND AND LEFT HAND STANDARD

To clarify the right hand and left hand standard that is used in this manual, herewith below is a diagram of the
motorcycle and the engine against which are indicated the right and left sides.

Lh Side Rh Side

Cylinder 3

Cylinder 2

Cylinder 1

Rh Side

Lh Side

-6-
 General description

SAFETY A
The information contained in this paragraph is fundamental so that the operations carriedout
ATTENTION 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
consciousness and death.
• If it is necessary to switch on the engine, check that the environment is well ventilated. Never switch on the
engine in an enclosed environment.
• Switching on the engine can only be carried out in an enclosed environment when there are the appropriate
devices for the evacuation of exhaust gases.

Petrol
• Petrol is extremely inflammable and under certain conditions can be explosive.
• Keep sources of heat, sparks and flames away from the work area.
• Always work in a well-ventilated area.
• Never use petrol as a cleaning solvent. Generally, avoid handling it unless it is absolutely necessary.
• Do not use petrol for cleaning components by using compressed air.
• Keep petrol out of reach of children.

Engine oil
• Engine oil can cause skin illnesses if in constant and long contact with the skin.
• If the skin comes into contact with engine oil, wash the parts affected as soon as possible with soap and water.
• If engine oil comes into contact with the eyes, rinse abundantly with water and seek medical attention.
• If engine oil is swallowed, do not provocate vomiting to avoid the aspiration of the product into the lungs.
Transport the injured person immediately to hospital.
• Used oil contains dangerous substances and poisonous for the environment. To substitute oil, it is necessary
to be equipped to deal with the collection of used oil in respect of the norms in force.
• Do not dispose of used oil in the environment.
• Keep used oil out of the reach of children.

Engine coolant
• Under certain situations, the ethylene glycol contained in the engine coolant is inflammable and its flame is
invisible. Ethylene glycol would cause serious burns if ignited because it is invisible.
• Avoid bringing the engine coolant into contact with hot parts. Such parts could be sufficiently hot to ignite the
coolant.
• The engine coolant (ethylene glycol) can cause irritation of the skin and is poisonous if swallowed.
• If the engine coolant comes into contact with the skin, immediately remove any contaminated clothing and
wash with soap and water. If it comes into contact with the eyes, abundantly rinse with clean water and immediately
consult a doctor. If swallowed, do not provocate vomiting to avoid the aspiration of the product into the lungs.
Administer clean water and transport the injured person immediately to hospital and show the product to a
doctor.
• If exposed to high concentrations of vapour, transport the injured person to a non-poisonous atmosphere and
if necessary call a doctor.
• Do not remove the radiator cap when the engine is still hot. Being under pressure, the engine coolant can be
violently ejected and therefore provocate burns.
• The engine coolant contains dangerous and poisonous substances and is therefore dangerous for the
environment. To substitute used engine coolant, it is necessary to be equipped to deal with the collection of
used oil/of used engine coolant in respect of the norms in force.
• Do not dispose of engine coolant in the environment.
• Keep engine coolant out of reach of children.

-7-
 General description

A Brake fluid
• Brake fluid is extremely corrosive.
• Avoid any contacts with the eyes, skin and the mucous membrane.
• If brake liquid comes into contact with the skin, remove all contaminated clothing and wash immediately with
soap and water.
• If brake fluid comes into contact with the eyes, abundantly rinse with water and call a doctor.
• If swallowed, do not provocate vomiting to avoid aspiration of the product into the lungs. Immediately call a
doctor.
• Take the injured person immediately to hospital, if he has breathed brake fluid into the lungs.
• In the case of exposure to high concentrations of vapour, move the injured person to a non-poisonous
atmosphereand if necessary call a doctor.
• In the case of accidental contact, rinse abundantly with water and call a doctor.
• Keep brake fluid out of reach of children.
Thread-locking fluid
• As it is not classified as dangerous, the prolonged contact with the skin, particularly with regards to abrasions
can provocate sensitiveness and dermatitis. In the case of contact with the skin, rinse abundantly with running
water.
• Move the injured person into the open air and call a doctor if the injured person feels ill after having breathed
in the product.
• In the case of contact with the eyes, rinse abundantly with water for at least 15 minutes.
• If the thread-locking fluid has been swallowed, drink an abundant quantity of water or milk. Do not provocate
vomiting to avoid the aspiration of the product into the lungs. Immediately call a doctor.
• Keep out of reach of children.
Nitrogen - rear shock absorber
• The rear shock absorber contains nitrogen under pressure.
• Before disposing of used shock absorbers, discharge the nitrogen via the depressurising valve.
• Utilise only nitrogen to pressurise the shock absorber. The use of unstable gases can cause explosions that
could cause burns.
• Do not place the shock absorber near to flames or sources of heat as this could cause explosions with
consequent burns.
• Keep out of reach of children.
Battery
• The battery produces explosive gases. Keep it away from sparks, flames or cigarettes. During recharging,
adequately ventilate the environment.
• The battery contains a solution of sulphuric acid (electrolyte).
• Sulphuric acid is corrosive and it destroys many materials and clothing. On contact with small quantities of
water it generates a violent reaction that manifests itself by creating large quantity of heat and spurts of hot
acid. Sulphuric acid attacks many metals thereby liberating hydrogen: an inflammable gas that forms an
explosive mixture when mixed with air.
• Contact with sulphuric acid can cause burns. In the case of contact, remove immediately all contaminated
clothing and wash the skin with abundant quantities of water. Take the injured person to hospital if necessary.
• In the case of contact with the eyes, rinse immediately with abundant water. Call a doctor and continue with the
treatment until the doctor arrives.
• If the electrolyte is swallowed, rinse the mouth with water without swallowing. Take the injured person immediately
to hospital and explain to the doctor there what the injured person has swallowed.
• The battery contains dangerous substances that are poisonous for the environment. It is necessary to be
equipped to dispose of this product in respect of the norms in force.
• Do not dispose of used batteries in the environment.
• Keep out of reach of children.
Hot parts
• The engine and the exhaust system become very hot and maintain this temperature for some time after the
engine has been switched off. Wait for these parts to cool down before handling them or working on the
motorcycle near to them. Use protective gloves.

-8-
 General description

WARNING A
The information contained in thisparagraph is important
so that the operations carried out on the motorcycle
can be conducted without damaging the motorcycle.

• Thoroughly clean the motorcycle before

disassembling it.
• During disassembly, clean all parts and place them
in containers respecting exactly the order of
disassembly.
• Always use the special utensils where necessary
andeach time where prescribed.
• Always use adhesives, sealants and lubricants where
prescribed. Respect the instructions about their
technicalcharacteristics.
• Always substitute parts such as gaskets, O-rings,
securitywashers with new parts.
• Slackening or tightening nuts or screws, always start
withthose of a greater dimension or from the centre.
Alwaysrespect the torque values indicated.
• Utilise only MV Agusta spare parts.

INDEX

GENERAL INDEX SUMMARY OF EACH CHAPTER

-9-
 General description

A
OPERATIVE TECHNICAL SPECIFICATIONS

MOTORCYCLE IDENTIFICATION

The registration number of the motorcycle is stamped on the right side of the steering head.

The engine registration number is stamped on the upper engine casing, near the forks.

2) Engine 3) Homologation
registration data
number

1) Frame
registration number

Below is an example of engine and frame registration number:

ZCG B3 10 AA Y V 000001
Manufacturer identification

Vehicle model

Progressive frame number

MV AGUSTA # # #
A C 000001
Engine type

Progressive engine number

- 10 -
Maintenance

SECTION B
REVISION 1

-1-
 Maintenance

SUMMARY
B
PLANNED MAINTENANCE SCHEDULE ................................................................................. Page 3
Programmed maintenance schedule .................................................................................... Page 3
      ................................................................................................ Page 5
Table of wear limits ............................................................................................................... Page 6
Cleaning the parts ................................................................................................................. Page 9
Connections .......................................................................................................................... Page 9
General norms for assembling the parts ............................................................................... Page 9
Measuring compression in the cylinder ................................................................................ Page 10
Draining the coolant circuit ................................................................................................... Page 11
Changing the engine oil ........................................................................................................ Page 12
Removing the oil radiator ...................................................................................................... Page 12
   ................................................................................................................................ Page 15
Filling the oil circuit ............................................................................................................... Page 17

-2-
 Maintenance

PLANNED MAINTENANCE SCHEDULE

The following diagram shows the recommended planned maintenance intervals.
                     
Intervals are expressed in Kilometers.
B
WARNING
Use shorter maintenance intervals if the vehicle is used in particularly harsh conditions.

Let us help protect the environment

Everything we do affects the entire planet and its resources.
To protect the common interest, MV Agustaurges its customers and service operators to use the vehicles and
dispose of their components in com-pliance with applicable regulations on environmental pollution control, waste
disposal and recycling.
Programmed maintenance schedule
Km (ml) covered 0 1000 6000 12000 18000 24000 30000 36000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
pre-

. . . . . . .
Service delivery A B C D E F G

Description Operation

Engine oil Substitution

. . . .
At least once a year
. . .
. . . . . . . .
Substitution
       !"#$ 
    % $        
Check level / Top up

.. .. .. .. .. .. .. ..
Engine coolant
Substitution every 2 years

.. .. .
Cooling Check for leakages
Electric fan Check functioning

.
Valves Check / adjustment
Check

. .
Timing chain

.
Substitution

Check / Substitution
Timing movable pad

. . .
Substitution

. . .
At least every substitution of the timing chai

.. .. ..
Timing chain tensioner Check / Substitution
Check / Substitution
Spark plugs

. .. .. .. .. .. ..
Substitution

&   ' *+    

. . . . . . .
Throttle body Check and adjustment

.
$   ' *+    
Check level
 :     

.. .. .. .. .. .. .. ..
Substitution
every 2 years

Check Functioning and Circuit

Brake / Clutch Cleaning of contact lever and

Brake pads (front and rear)

pump piston area

Check / Substitution . .. . .. . .. .
.. .. .. .. .. .. .. ..
Check for defects and leakages
Fuel tubes
Substitution every 3 years
Check functioning

.. .. .. .. .. .. .. ..
Accelerator control
Verify / adjust play

. .. .. . .. . .. .
Starter control Check functioning
   *;    Check / Adjustment

. . .
Check / Adjustment
Transmission chain Lubricate
Substitution

-3-
 Maintenance

Programmed maintenance schedule

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

. . . . . . .
B Service
pre-
delivery A B C D E F G

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 / Substitution
+   ' *$< 

. .. .. .. .. .. .. ..
Check / Adjustment
Steering bearings
Lubrication

. . . . . . . .
Check for pressure
Tyres
Check for wear

. . . . .
Wheel rims Visual check
Every tyre substitution

Check
.
.. .. .. .. .. .. .. ..
Front wheel bearings Every tyre substitution
Substitution

. . . .. . .. . .
Side stand Check functioning

Check functioning
Side stand switch
Substitution

..
Check / Lubricate
roller bearings and guide
Rear wheel hub
Substitution / Lubricate

.. . .. . .. . ..
roller bearings and guide
Rear fork bearings Check / Lubrication

..
Chain guide frame plate Check / Adjustment

.. .. .. .. .. ..
Rear shock absorber Check / Adjustment

.. ...
Front fork oil Substitution

.. .. .. .. .. ..
Battery connections Check and clean

.
Electrical system Check functioning
Instruments Check functioning

.. .. .. .. .. .. .. ..
Lights / Visual signals Check functioning
bulb replacement

Horn Check functioning

Check functioning

.. .. .. .. .. .. .. ..
Front headlight bulb replacement
Adjust at every variation of riding set-up of the motorcycles

.. .. .. .. .. .. .. ..
Ignition switch Check functioning
Locks Check functioning

.. .. .. .. .. .. .. ..
Torque settings - nuts and bolt Check / Tightness
Tube band fasteners Check / Tightness
General lubrication
General check

-4-
 Maintenance

Table of lubricants and uids

  =       +   

Engine lubrication oil ENI I-RIDE MOTO2 5W/40 (*) SAE 5W40 - API SL B
Ethylene - Glycol
Engine coolant AGIP ECO PERMANENT Diluited with 50 %
of Distilled Water

 '    $@J:$Q&XYJ==Z[ =Z[

Chain lubrication oil D.I.D. CHAIN LUBE -

* To nd the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers.
Eni I-Ride moto2 50W/40 has been manufactured for the Brutale and Rivale 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 SL
– Conforming to ACEA A3
– Conforming to JASO MA, MA2
– Grade SAE 5 W-40
Engine Oil
SAE 5W-40

API SL
NOTE The above specifications indicated are ACEA A3
marked either on their own or together with JASO MA, MA2
others on the container of the lubricating oil.

-5-
 Maintenance

Table of wear limits

ITEM STANDARD WEAR LIMIT

B VALVES

Ø Sealing external diameter

+0,05
Exhaust ............................................ 26,7 -0,05 mm

+0,05
Inlet .................................................. 31,8-0,05 mm

Sealing face thickness

+0,1
Exhaust ............................................ 1,27 -0 mm

+0,1
Inlet .................................................. 1,0 -0 mm

Stem - Guide clearance

Exhaust ............................................ 0,02 ÷ 0,04 mm....................... Coupling: 0,10 mm

Inlet .................................................. 0,01 ÷ 0.03 mm....................... Coupling: 0,08 mm

+0
Ø inner guide.................................. 4,5 +0,012 mm.......................... 4,55 mm

Valve stem

Exhaust ............................................ 4,4725 ± 0,0075 mm............... 4,4425 mm

Inlet .................................................. 4,4825 ± 0,0075 mm............... 4,4525 mm

Valve Spring :

Single

- Exhaust/Inlet .................................. 42 mm..................................... 41,5 mm

Twin

- External (Exhaust/Inlet) ................. 37,9 mm.................................. 37,4 mm

- Internal (Exhaust/Inlet) .................. 33,8 mm.................................. 33,3 mm

Valve - Cam clearance

Exhaust ............................................ 0,20 ÷ 0,29 mm

Inlet .................................................. 0,15 ÷ 0,24 mm

-6-
 Maintenance

ITEM STANDARD WEAR LIMIT

CYLINDER AND PISTONS

B

   !  ............................. ................................................ 0,015 mm

Piston-Cylinder play ......................... 0,016 ÷ 0,042 mm................... 0,10 mm

Piston-Pin play ................................. 0,002 ÷ 0,010 mm................... 0,03 mm

Wrist pin-Connecting rod clearance. 0,015 ÷ 0,029 mm................... 0,06 mm

Piston ring width

-0,01
1° segment ...................................... 0,8 mm............................. 0,75 mm
-0,03

0
2° segment. ..................................... 0,8 mm............................. 0,75 mm
-0,02

-0,03
Oil scraper ....................................... 1,5 mm............................. 1,38 mm
-0,08

Maximum piston ring-cylinder clearance

1° segment ...................................... 0,2 ÷ 0,4 mm........................... 0,6 mm

2° segment ...................................... 0,2 ÷ 0,4 mm........................... 0,6 mm

Oil scraper ....................................... 0,2 ÷ 0,7 mm........................... 1 mm

CLUTCH

Friction drive plate thickness ........... 3 mm....................................... 2,8 mm

Springs............................................. 51,7 mm.................................. 49,5 mm

-7-
 Maintenance

ITEM STANDARD WEAR LIMIT

B GEAR SHIFT

Gear fork - Groove pivot play. ............... 0,35 ÷ 0,15 mm....................... 0,65 mm

Shift drum groove width ........................ 7,05 ÷ 7,15 mm....................... 7,35 mm

Ø Fork pivot .......................................... 6,8 ÷ 6,9 mm........................... 6,7 mm

Minimun idle gear axial play ................. 0,10 mm

Maximum gear fork play ....................... ................................................ 0,70 mm

Primary gear limit.................................. ................................................ 5,60 mm

Secondary gear limit ............................. ................................................ 4,60 mm

Fork selection gear limit

Primary (5a - 6a) ................................ ................................................ 4,65 mm

Secondary (1a - 2a, 3a - 4a) .............. ................................................ 3,65 mm

Fork - Pit play. ....................................... 0,2 ÷ 0,3 mm........................... 0,7 mm

CRANKCASE - DRIVE SHAFT

Crankshaft - crankcase plain

bearing clearance ................................. 0,014 ÷ 0,044 mm................... 0,06 mm

Connecting rod - crankshaft plain

bearing clearance ................................. 0,029 ÷ 0,057 mm................... 0,08 mm

Crankshaft axial clearance ................... 0,2 mm

-8-
 Maintenance

Cleaning the parts

All of the parts must be cleaned with special biodegrada-
ble solvents and dried with compressed air. Proceed with B
the cleaning process of all the parts before disassembling
them as well as after the particular parts have been di-
sassembled. Clean each part even before reassembling.

Connections
In order to allow the motor to function in the best condi-
tions it is absolutely necessary that all of the connections
meet the standards established by the manufacturer. A
  {         ! ]
while a connection with excessive toleration causes vi-
brations which accelerate the wear of the components.

General norms for assembling the parts

For reassembling invert the disassembling procedure,
              
Gaskets, oil spill protector, metallic locks.
Tightening rings in deformable material and self blocking
nuts must always be substituted.
The bearings are dimensioned for a determined number
of working hours. Substitution is therefore recommended
           { 
The above mentioned is in addition suggested for dimen-
sional controls of the single components mentioned in
the relative paragraphs.
It is absolutely necessary to carefully clean all of the
components; the bearings and all of the other parts
subject to wear must be lubricated with motor oil before
reassembling.
Nuts and screws must be locked to the pre established
torques.

Following are the descriptions of the disassembling,

revision and reassembling procedures of the various
        ]  !
sequence of a completely disassembled motor.

Disassemble the motor from its frame as described in

the relative paragraph;
Drain the oil from the oil cup;
Remove the spark plugs covering the openings with
clean rags to avoid small objects (rings, etc.) from falling
into the motor.

-9-
 Maintenance

Measuring compression in the cylinder

The following tools are necessary in order to carry out
this procedure:
Spark plug key: n°800089013
B Compression measurer
Adapter for the compression measurer.
A) Heat the motor to the usual functioning tempe-
rature (of regime);
B) Switch off the engine, remove the tank, air box
and spark plugs;
C) Measure cylinder compression.

Drag the motor into rotation by means of the starting

 {      
compression measurer indicator (compression meter) no
longer rises; the compression measurement obtained is
the maximum.

Be sure the battery is completely charged.

Cylinder compression control (280 rpm-min.)

Engine Type Min Press. (bars) Max Press. (bars)
B3 7,5 14

- Repeat the procedure for the other cylinders.

N.B.: If the compression in the cylinder is lower than

the minimum value of the reported range, check the
following points:
A) carbon deposits on the walls of the combustion
chamber and on the piston ceiling;
B) the head gasket is not of the correct measure-
ments;

N.B.: If the compression in the cylinder is lower than

the minimum value of the reported range, check the
following points:
A) The seat of one or more valves is damaged and
the valves do not maintain the compression
pressure;
B) One or more valves have null functioning play;
C) The piston, cylinder play is excessive;
D) The cylinder head is twisted and/or the head gasket
is damaged;
E) Excessive play between ring and cable.

NOTE Before carrying out the compression trial,

accurately check the battery tension since
the compression value which appears is
            
the motor, and consequently by the battery
tension.

- 10 -
 Maintenance

Draining the coolant circuit

J       {  
vehicle, it will be necessary to loosen the strap (1) and
disconnect the coolant delivery tube (2) from the radiator
B
to the pump as described in the frame workshop manual.

Place a container under the engine and unscrew the co-

olant drain cap (3), tilting the engine to aid the drainage.
       {  {    
800089426) and tighten the cap to a torque of 25 Nm
with medium-strength thread lock.
2
1

800089426

- 11 -
 Maintenance

Changing the engine oil

For replacing the oil, refer to the data in the table.
1
B
Lubricating system Q.ty
component Litre
crankcase and oil sump 2.75
radiator and hoses 0.25
residual 0.2

Y {   ~%]

place a container under the engine to catch the used oil

and unscrew the oil drain cap (2).

NOTE The quantity of oil which drains off from the

sump should be about 2.75 L.

To complete the procedure properly it is also

recommended to replace the oil contained in
the oil radiator.

If the engine is installed on the vehicle, it may be

necessary to remove the oil radiator. 2

Removing the oil radiator

X{ {%[%;  -
tors plate.
 {€%%;    
plate and to radiator (coolant).

4
3

- 12 -
 Maintenance

   ;  {‚%

7
B

Move the radiator slightly towards the front of the

motorcycle, then slide the oil radiator from the peg (8)
pulling it rightwards.
8

Unscrew the three screws (8) and remove the retaining

plate (9); then, maintaining the oil radiator in lower poition
than the engine, extract the hoses with the seal rings
that will be replaced on refitting. 9

10

- 13 -
 Maintenance

Keep the radiator in the indicated position to help it to

drain.

B NOTA The quantity of oil contained in the radiator

and hoses is around 0.5 L.

Oil hoses removal

Remove the 2 screws (1) fastening the retaining plates
(2) and extract the hoses from the radiator.
1

Radiator check and clean

The dirt and extraneous material embedded in the
radiators must be removed.
It is recommended to use compressed air for the clea-
ning of the radiator.
:       
screwdriver

- 14 -
 Maintenance

 
The surfaces should be clean and degreased.
${{ % ƒ
       B
3

GREASE

   [%  €%        {  
retaining plates and approach the screws in by hand
without tightening them .

5
4

Insert the hoses (1) and (2) with the new greased seal
rings in their respective locations in the case.
Fit the retaining plate (6), screw in the three screws (7) 7
by hand without tightening them. 4

- 15 -
 Maintenance

    { ]    -

tor making attention to the correct positioning of the oil
hoses and tighten the screws (1, 2 and 3) to the couple
of 10 Nm. 1
B

  {[%;   

engine (couple 10 Nm)
4
NOTE WARNING: Do not turn the pipes once the
screws have been tightened

  {€%%;  -

taining plates on to the oil radiator to a couple of 10 Nm.

5 6

- 16 -
 Maintenance

 { {‚%;   

engine to a couple of 10 Nm.
7
7
B

Filling the oil circuit

drai plug„%{ {{  to
a couple of 25 Nm.
Fill with eni i-Ride moto2 5W-40 engine oil, referring
to the quantities given in the table below the operation
performed.

Lubricating system Q.ty

component Litre
crankcase and oil sump 2.75
radiator and hoses 0.25 8
residual 0.2

Close the cap with its seal ring.

             

necessary to turn the engine over for a few
seconds so that the oil passing through
the pump reaches all the points requiring
lubrication.

Follow the instructions given on the following page to

perform this operation.

ENGINE
OIL

- 17 -
 Maintenance

Remove fuse no. 1 for the fuel pump and coils.

Turn the key to the RUN position and,

B

keeping the clutch lever in, press the start button twice
for approx 4 seconds each time.
 Z&&    ~ 
its holder.

Y {             

between the min and max marks.
Top up if necessary.

- 18 -
Electrical components

SECTION C
REVISION 0

-1-
 Electrical components

SUMMARY

ELECTRICAL COMPONENTS ............................................................................................... Page 3

C Engine oil pressure sensor ................................................................................................... Page 4
Alternator .............................................................................................................................. Page 4
Starter motor ......................................................................................................................... Page 5
PICK-UP ................................................................................................................................... Page 6
COILS ....................................................................................................................................... Page 6
Coolant temperature sensor ................................................................................................. Page 8
Gear sensor .......................................................................................................................... Page 8

-2-
 Electrical components

ELECTRICAL COMPONENTS

Tightening A B C D E F G H I L
torques Nm 10 10 22 22 12 6 8 6
Thread blockers medium medium medium medium medium

OIL Apply motor oil SS Apply silicone sealing

NO OIL Do not apply neither oil nor other types of substances HSC Apply HSC Molikote
GR Apply grease M Apply mastic for gaskets

-3-
 Electrical components

Engine oil pressure sensor

Remove the connector and check (with a cold engine)
that there is no continuity between the pole of the
sensor (1) and the engine mass.
Otherwise, replace the sensor.
Apply a medium strength thread-locking compound on
the thread of the sensor and tighten to a torque of 22
C Nm.

Alternator
Check:
For this operation it is sufficient to disconnect the 2
connector of the alternator from the system.

Switch the tester to Ohm and check that when the poles
are connected two by two, there is an impedence of
0.2 Ohm

Switch the tester to continuity and check that there is

no continuity between each pole and the engine mass.

Removal and Assembly:

remove the cover (1) of the phonic wheel (and the
alternator) by undoing the 8 screws (2) , together
with the gasket.

-4-
 Electrical components

Remove the gasket (3), taking care not to damage it.

Remove the two screws (4) and the cable retaining plate
(5).
Remove the stator from the cover by unscrewing the 6 5
three screws (6).
Refit, paying attention that the cable is correctly
positioned and tightening the screws to the required
torque with medium-strength threadlocker.

Starter motor
- Check:
Using the tester, check that there is continuity
between the positive pole (7) and the engine mass.
Otherwise replace the starter.

- Removal: 7
Remove the two fixing screws (8). Pull out the starter
motor, taking care not to damage the O-Ring on the 8
shaft.

- Assembly:
Evenly grease the O-ring and re-assemble to the
shaft.
Re-assemble the starter motor on the engine block.
Insert the two screws (8) by hand, then tighten to
the prescribed torque.

-5-
 Electrical components

PICK-UP
Use a tester to check that the impedance value between
the negative and positive poles of the pick-up connector
is that given in the table.

C 1

PHONIC WHEEL GAP

To ensure correct operation of the pick-up it is
necessary to measure the gap between it and the
phonic wheel using a feeler gauge as shown in the
figure.
Gap value: 0.6 - 0.7 mm.
The cover on the phonic wheel must be removed (Sec.D
pag.6) to perform this procedure.

COILS
Remove the coil fastening screw (2) and the two screws
(3) fastening the coils and the filter case support plate 2 3
(4).

-6-
 Electrical components

Detach the coils.

Use a tester to check that there is an impedance value

of 3.8 K ± 10% between pole no. 2 of the connector
and the high-voltage positive of each coil.

Place the terminals of the tester between poles no. 1

and 2 of the coil connector and check that the
impedance value is 1 ± 10%.

-7-
 Electrical components

Coolant temperature sensor

Remove the sensor (1) and check the impedance
values between its poles with reference to the table.
1
TEMP. °C RESIST. TEMP. °C RESIST.

- 40 100,950 + 40 1,598
C
- 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

Refit the sensor, tightening it to a torque of 22 Nm using

medium-strength thread-locker.

Gear sensor
- Check:
Remove the sensor and use a tester to check that
the impedance values between the pole of the
connector (OUT) and the sensor contacts are as
listed in the table.

POLES Impedance

N 15400 ± 150,4
1st 6650 ± 66,5
2nd 3650 ± 36,5
OUT 3rd 2210 ± 22,1
4th 1330 ± 13,3
5th 732 ± 7,3
6th 316 ± 3,2

-8-
Head

SECTION D
REVISION 1

-1-
 Head

SUMMARY

HEAD ........................................................................................................................................ Page 3

Removing head cover ........................................................................................................... Page 4
Removing thermostat cover .................................................................................................. Page 5
Removing alternator cover .................................................................................................... Page 6
D DISTRIBUTION CONTROL UNIT ............................................................................................. Page 8
Chain tensioner ..................................................................................................................... Page 9
Removing the valve gear components ................................................................................. Page 10
Dismantling the head ............................................................................................................ Page 12
Inspection of the head group ................................................................................................ Page 14
Dismounting cylinder head pieces ........................................................................................ Page 15
Valve removal ....................................................................................................................... Page 15
Maintenance of the valve slot ............................................................................................... Page 17
Substitution of the valve slot ................................................................................................. Page 18
Valve guide check and maintenance .................................................................................... Page 19
Removal of the valve guide .................................................................................................. Page 19
Guide valve installation ......................................................................................................... Page 20
Valve ..................................................................................................................................... Page 20
Valve-guide valve coupling ................................................................................................... Page 21
Springs .................................................................................................................................. Page 21
Valve reassembly .................................................................................................................. Page 21
Head assy assembly ............................................................................................................. Page 23
Cylinder-head tightening sequence ...................................................................................... Page 26
CAMSHAFT AND DRIVING SHAFT TIMING ........................................................................... Page 28
Regulating valve play ............................................................................................................ Page 32

-2-
 Head

HEAD

From serial
n° 003272

Tightening A B C D E F G H I L
torques Nm 12 8÷10 10+85° 10 10 10 6-8
Thread blockers medium sealant medium

OIL Apply motor oil SS Apply silicone sealing

NO OIL Do not apply neither oil nor other types of substances HSC Apply HSC Molikote
GR Apply grease M Apply mastic for gaskets

-3-
 Head

Removing head cover

Remove the 6 fastening nuts (1)
1

and remove the head cover (2), being careful not to

damage the gasket .

Remove the seal (3).

         

3
           
  

-4-
 Head

     

          

Remove the cover (5), the gasket (6) and the thermostat
(7). 5
6

Remove the screws (8) with the retaining plate (9) and
    
10

-5-
 Head

    

From the left-hand side of the engine, remove the cover
(1) of the phonic wheel (and the alternator) by undoing
the 8 screws (2) , together with the gasket (3).

D 1

Put the cover away in a location away from moisture

and dust.

-6-
 Head

Turn the crankshaft by turning the alternator nut with a

19 mm socket wrench until piston no. 3 reaches TDC in
     

In this position the “M” notch on the phonic wheel is lined

up with the reference notch on the crankcase.

The reference notches on the control wheels of the cam

!    "#   ##$

NOTE            

          
         
    

-7-
 Head

DISTRIBUTION CONTROL UNIT

Tightening A B C D E F G H I L
torques Nm 8 12 8
Thread blockers medium

OIL Apply motor oil SS Apply silicone sealing

NO OIL Do not apply neither oil nor other types of substances HSC Apply HSC Molikote
GR Apply grease M Apply mastic for gaskets

-8-
 Head

   
Remove the central screw-cap and withdraw the spring
and the pin.

              

head. Remove the chain tensioner.

Remove the pad’s screw.

Disassembly the chain tensioner and check the correct

working of each part.
The internal pin must run clearly and the inner spring
must give a quick response.
Replace the assembly in case of malfunction. If
everything works properly lubricate the parts and install
the assembly with the chain tensioner in the minimum
  ## $
Install in this order: the pin in the spring, the spacer and
the screw cap.
Lock the screw cap by hand till you feel the tensioner
% #   &' *
Acting this way the chain tensioner is adjusted.

-9-
 Head

    

Firstly remove the outermost screws of the camshaft
head following the indicated scheme in order to balance
     $ #   

Removing the shaft head.

Release the distribution chain.

- 10 -
 Head

First remove the intake side camshaft.

/         -

side camshaft.

Support the distribution chain with a metallic bar in or-

derto get it back in the following operations.

;       $   <=   

  

- 11 -
 Head

Remove the seal rings, taking care not to damage them.

     
Unscrew the 10 fastening screws of the head, starting
   #      %  
diagonal pairs.

Remove the head and place it onto a clear place.

Avoid placing the head upside down.

- 12 -
 Head

     ## #  

if necessary.

Remove the two blocking rings.

  ## !     $

undoing the fastening pin. If it should be necessary to
#       #
(see the scheduled maintenance table), it is advisable
#  #    ! >  %   #$
clean all surfaces.

- 13 -
 Head

  ## $   ! 

;      

    

Remove carbon deposits from the combustion cham-
bers. Clean away eventual encrustments from the ca-
nalizations of the cooling liquid. Check to be sure that
are no crack and that the holding surfaces are free of
crevices, runs or any other kind of damage. Verify the
planarity of the stroke surfaces. Verify the perfect state
of the spark plug threads.

- 14 -
 Head

     

In order to carry out this procedure the following tools
are necessary: 800094798
tool no. 800094796 for valve removal
tool no.8000B7254 for valve removal
tool no.8000B7255 to remove semi cones
tool no. 800094798 to take out rubber holdings

!         " 

    #  $  
     
8000B7255 D
Remove the cylinder head as indicated the paragraph
“Removal of head group”.

%
A) Take out the cups (1) with the help of a magnet and 800094796
number them with a marker so as to reassemble them
in the same position. 8000B7254
B) Remove the tablets (2) of play adjustment with a
magnet and place them inside the relative cup so as
to reassemble them in the same position.
 ?     @ # #$ #J
8000B7255 so as to avoid bending the valves:
C) Fit the head on tool no. 800094796 with base plate
8000B7254
D) Hammer on the superior disk with a rubber hammer
to unblock the semi cones

E) Press the springs on the superior disk

F) Take out the semi cones with a magnet
G) Slowly release the disk pusher.

- 15 -
 Head

Then remove in the following order:

B) The springs (5) and (4, from serial number 003272)
C) If necessary remove the rubber holdings using tool
n° 800094798
D) Remove the lower valve spring washers (6).

Before of slide out the titanium valves, in order

to avoid the damaging of the valve guides,
remove the burrs caused by by half-cones
carefully using an oil stone.
D
E) Slide the valve out of the combustion chamber.

800094798

- 16 -
 Head

'     

Check the stroke surface [A] between the valve [B] and
the slot [C] : no traces of pitting or cracks must appear.
<    # KQW!     ! 
on the valve slot.
If this should appear to be too elevated it is possible to
repair the slot.

!(     )  


+0,5 D
 X   &Y%Z 
-0,5

+0,5
standard : inlet 31,8 mm TOO
-0,5 OPTIMAL
WIDE

Measure the width of the stroke [E] with a varnished

gauge or with Prussian blue.
If it should turn out to be too wide, too thin or irregular it
will be necessary to repair it.
TOO
IRREGULAR
* )   )    THIN
+0,1
 X   %&Z K;W
0

+0,1
standard : inlet 1,0 mm [E] Monocutting milling
0 Valve

The repair must be carried out by milling the slots using Inlet 60° 45°
the appropriate monocutting milling machines at °(1) ;   60° 45°
and °(2).Ten proceed with the grinding of the valves
  !  #

   +    

 

 %@  #

%     )      

 (       ,    
) +   - 

          

   )    / :

- 17 -
 Head

;    

The following tools are necessary for this procedure:
prick-puncher n°800095319 for inlet slot; prick-puncher
J=^_@=!    #
Proceed as follows:
A) Remove the worn slots carefully milling them so as
not to damage the head lodging
B) Check the lodging diameter on the head and choose
the oversized valve slot considering that the assem-
bling interference should be 0,10÷0,15 mm.
C) Valve slots are furnished with an increased replace-
 !%@  # 
Q/# #$#$     
of 180°C and cool the new slots with dry ice.
E) Place the slots perfectly in frame into its lodging, using
the special n°800095319 prick-puncher (INLET) and
n°800095318 (EXHAUST)
F) Let cool and proceed with the milling of the slots and
grinding the valves referring to the following quotients:

800095319 800095318
Valve

+0,5
Ø Inlet 31,8 mm
-0,5
+0,5
 x;  &Y%Z 
-0,5
+0,1
[E] Inlet 1,0 mm
0
+0,1
 K;W;  %&Z 
0

- 18 -
 Head

%  )  

In order to carry out this procedure the following tools
are necessary: 800095429
Control tampon n° 800095429
Punch n° 8000A2385

valve stem-valve guide play: < </=< <> 

< <?=< <@(
coupling limit : < <J 
< /(
internal guide Ø limit: @ KK D

Proceed with an accurate visual check of the valve guide.

In order to determine the coupling wear between guide 8000A2385
and valve stem it is necessary to measure the play using
a control tampon and micrometer.

*  J<<<QK@?Q"X@ KK$ 

  

           

      )  
      

   
After having removed the valves and rubber holdings as
described in the relative paragraph, continue as follows:
Slowly and evenly heat the cylinder head up to 100°.
Using the punch n°8000A2385 remove the valve guide.
Continue with a visual check of the slot to verify its State.

- 19 -
 Head

[    

Assemble an oversized valve guide as follows:

{#  ##  ! 

Slowly and evenly heat the cylinder head up to 150°.
If necessary cool the valve guides with (N2) nitrogen
liquid; or dry ice.
Insert the valve guide using the special n°8000A2385
tampon up to the stroke and let rest until the tempera-
D ture has stabilized.
Check to be sure the valve slides freely in the valve
guide otherwise coat it with a 4,5 H7 reamer or broach
N°8000A2625.

%

The stem diameters must not fall below:

@ @J?K#< <> 
 @ @Z?K#< <>(

The width “A” of the sealing surfaces should fall in the

range :
 < Q=/ > 
 / Z=? ?(

Check to be sure that the stem and the surface in contact

with the valve slots are in good condition.
No traces of pitting, cracking, deformations or traces
of wear should appear. Verify that the stem is perfectly
rectilinear.

COINCIDENT COINCIDENT
EXHAUST INTAKE
CAMSHAFT PLAN CAMSHAFT PLAN

- 20 -
 Head

Valve-guide valve coupling

Coupling play at assembly must be:
0,01 ÷0,03 mm inlet
0,02 ÷0,04 mm exhaust
The maximum coupling limit permitted is even to
0,08 mm inlet
0,10 mm exhaust
If a major play should result, substitute valve and val-
veguide.

Springs
Check to be sure that the free value of length is not in- Until serial number 003271
ferior to the suggested limit and in such case substitute
the springs:

Unti serial number 003271:

L= 42 mm
Limite de service: 41,5 mm
From serial number 003272
From serial number 003272:

- External L= 37,9 mm
Limite de service: 37,4 mm

- Internal L= 33,8 mm
Limite de service: 33,3 mm

Valve reassembly
A) Carefully degrease the guide 800095581
B) Insert the lower washer (6) and make sure that they
are properly seated.
C) Assembly new rubber valve seals onto the guide
using tool n°800095581;
D) Apply oil to the valve stem before inserting into the
guide.

- 21 -
 Head

Assembling the valve.

Insert in the order of:

A) Insert the spring.
B) Slide the semi cones into the superior disk slot and
thus place the disk on the springs.
C) Fit the head on the valve removal tool no. 800094796
with base plate no. 8000B7254 and compress the
spring with tool 800095179 up to insertion of the half
cones.
D D) Using a rubber hammer strike a slight blow on the
valve so as to place the semi cones.

NOTE Before placing the valve retainers be sure

that the head is not resting on a plane in order
to avoid distorting the valve. Place it onto two
bases which allow the valve to move.

800095179

E) Insert the tablet of the correct thickness and lubricate

its surface.
F) Make sure it easily turns in its slot.
G) Insert the cup after lubricating the slot.

- 22 -
 Head

]  

Insert the distribution chain from above onto the phonic
wheel gear.

Insert the centering bushes between the head and the

cylinder.

}     !  # #   !   !##$

degreasing them and their pins.

- 23 -
 Head

Fit the gasket on the cylinder head.

^  _       

      
   

^  _    )    

        


Before placing the head in position, lubricate the female

threads (on the engine block), screw threads and under
the screw heads as indicated.

Place the head in position, keeping the distribution chain

raised to avoid having to recover it later.

- 24 -
 Head

Pay attention that the screws are properly engaged.

NOTE *        

     *  
            #


Once the head has been positioned, screw the screws

in by hand        .

Support the distribution chain with a metallic bar.

}!  #$ %  #$  -

wand tighten it to a couple of 8 Nm.

- 25 -
 Head

Tighten the 8 screws initially to 10 Nm in opposing pairs.

;` b  %

 /#J -#     /<`

 J#/ f    #

 /#J     /<`

     

 /#J j   JKk/l

     

 Q#/< *     /<`

- 26 -
 Head

Loosen the 8 screws.

Retighten them to 10 Nm.

?  ##$=_J~J # -

ning wrench, ensuring that the corresponding torque is
between 53.5 and 61.5 Nm.

      JKk/l  

   +K>K#:/K`  
     
          
+   

- 27 -
 Head

Reinsert the two spacers with the previously greasedseal

rings.

*     

  

CAMSHAFT AND DRIVING SHAFT TIMING

Keep the chain tightened.

Turn the crankshaft clockwise so as to line up the “”

notch on the phonic wheel with the reference mark on
the engine block.

- 28 -
 Head

In this position piston no. 3 is at TDC.

     %          !

so that the phase notch “M” on the conveyor wheel is
parallel to the head plane and facing outwards.

EXHAUST
SIDE

- 29 -
 Head

Insert the intake camshaft with the “M” mark on the 30th
pin of the distribution chain, starting to count from the
 €<!     !

NOTE            

          
         
    

Check the correct position of all the O Rings under the

head stands.

Place the stand in position.

Gradually approach the screws.

^  _       

      

- 30 -
 Head

Lubricate the parts of the chain tensioner and install

the assembly with the chain tensioner in the minimum
  ## $
Lock the screw cap by hand till you feel the tensioner
.

Lock it with to 12 Nm torque. Acting this way the chain

tensioner is adjusted.
Tighten the two screws at a torque of 8 Nm.

When this is done, tighten the stand following the indi-

cated tightening sequence.
Tightening torque 12 Nm.

- 31 -
 Head

b      

         )
      )   
         

Lining up the notch on the phonic wheel with that on

the case (3rd cylinder at TDC), the two “M” marks on
the camshafts should be opposite and horizontal to the
head plane.

1  ><  

   
Verify that the spark plugs have been disassembled.

;      

    )  )
    .

A) Rotate the drive shaft until completely unwinding the

springs relative to the valves on which intervening
(TDC).
B) Measure valve play with a thickometer.

- 32 -
 Head

###$   ##$

0,15 ÷0,24 mm 0,20 ÷0,29 mm

play
C) Calculate the D difference between the compared
play and optimal play shown on the chart
D) Read the value of S thickness on the tablet;
E) Choose a new tablet with an S+D thickness.
D
           
   )   / :

Insert the thermostat and assembly the cover with the-

previously greased seal ring. Insert the two screws and
tighten them to a couple of 8 Nm.

Insert the head degassing pipe (1) with the previously

greased o-ring. Make sure that the valve cover seals are in goodcon-
ƒ #$ #&     ditions.
couple of 10 Nm. Assembly the ignition coil gasket (3).

1 3

- 33 -
 Head

Apply a layer of gasket silicone on the semi moons on

the head in correspondence with the camshaft.

„#     #  

Manually position the screws, thus tighten at 8 Nm.

   # %  #  #     

plate, tightening the screws to a torque of 8 Nm.

- 34 -
Clutch

SECTION E
REVISION 1

-1-
 Clutch

SUMMARY

CLUTCH .................................................................................................................................... Page 3

Clutch disassembly ............................................................................................................... Page 4
Clutch overhauling ................................................................................................................ Page 8
Clutch reassembly ................................................................................................................ Page 9

-2-
 Clutch

CLUTCH

SLIPPER TYPE

STANDARD

Tightening A B C D E F G H I L
torques Nm 120 10 10 4,5
Thread blockers medium medium medium

OIL Apply motor oil SS Apply silicone sealing

NO OIL Do not apply neither oil nor other types of substances HSC Apply HSC Molikote
GR Apply grease M Apply mastic for gaskets

-3-
 Clutch

Clutch disassembly

Remove the 8 screws which fasten the clutch cap to

the Crankcase.
Remove the clutch cap together with the gasket.

Remove the 6 disk pusher plate tightening screws

STANDARD
together with the springs and the relative holders.

SLIPPER TYPE

Remove the disk pusher plate.

-4-
 Clutch

Manually remove all of the attrition disks that you can.

STANDARD SLIPPER TYPE

Unscrew the nut using tool n°800079015 to hold the

clutch hub still and remove it. STANDARD

To execute this operation the following tool is

necessary:

Tool n° 800079015

800079015

SLIPPER TYPE

(Standard clutch) remove the nut and the washer.

(Slipper clutch). Remove the nut, the spacer and STANDARD
the spring

SLIPPER TYPE

-5-
 Clutch

Extract the clutch hub (1).

STANDARD
1
SLIPPER TYPE

Remove the washer (2)

2

and the clutch housing (3).

-6-
 Clutch

Remove the roller cage (4), the spacer (5) and the
shim washer (6).
4 6

E
5

If it is necessary to remove the clutch housing, check

that the rubber stoppers (7) are not scratched or
cracked. 7

Reinstall, paying attention to the correct orientation

of the rubbers on the ange (8).
Tighten the 6 screws (9) to a torque of 10 Nm with
medium-strength thread lock.

-7-
 Clutch

Clutch overhauling
Check the rod for straightness and wear.

Check the friction plates for wear.

The standard thickness is 3 mm.
Maximum allowed wear limit : 2,8 mm.
No signs of burning, grooves or other damages are
allowed. Replace the whole plates group even if only
one is damaged.

Put the plate on a table and check the deformation.

The maximum limit of deformation is 0,1 mm.

Measure the length “L” of the springs with a gauge.

Service limit: 39 mm

Replace the springs exceeding the service limit.

-8-
 Clutch

Clutch reassembly
Reposition the shim washer with the smallestdiameter
facing towards the engine.

Make attention to the correct positioningof

the washer.

ENGINE
SIDE E

Position the spacer, the roller cage

and the clutch housing.

-9-
 Clutch

Alternate pushing the clutch case in and rotating it

in order to help it mesh with the pump transfer and
countershaft gears and avoid them grinding.

Fit the washer.

Make sure the washer is positioned in front of the 2
friction drum, since it was sheared and therefore has
a sharp corner and a rounded corner. Position the
rounded corner on the engine side.

Assembly the clutch hub.

STANDARD
1
SLIPPER TYPE

- 10 -
 Clutch

(Standard clutch)
Grease the side of the washer in contact with the hub. STANDARD

(Slipper clutch)
Install the two springs and the washer on the hub. SLIPPER TYPE

Insert the nut, screwing it down manually until it makes

contact with the washer. STANDARD

SLIPPER TYPE

- 11 -
 Clutch

Use the tool no. 800079015 to lock the clutch

housing, thentighten the nut to 120 Nm with medium STANDARD
threadblocker.

800079015

E
SLIPPER TYPE

Notice: three types of packed disks are used;

to assemble them, see the diagram.

Attention: before installation, lubricate the

friction discs with engine oil.

First t in one of the two disks (1) with the larger

friction cells and a plain disk (3). Fit in the spring
holder (5), the spring (6) with the narrower diameter
facing the engine and the packed disk with the larger
inner diameter (4); then, t in the other ve packed
disks (2), alternating them with the plain disks (3),
and lastly t in the last outer disk (1); then, alterna-
ting with the smooth discs (3), t the other friction
discs (2) and nally the remaining external disc (1).

- 12 -
 Clutch

Quantity STANDARD SLIPPER TYPE

Part
Standard Clutch Slipping Clutch

1 2 2
2 5 6
3 7 8
4 1 1
5 1 1
6 1 1

Engine
side

- 13 -
 Clutch

Once the discs have been tted, insert the clutch

control rod STANDARD

SLIPPER TYPE

(Only for standard clutch)

Fit in the clutch disc pusher,

(Only for standard clutch)

Fit in the clutch disc pusher, the six spring holders,

The spring supports have an edge with aconcave

segment which must be orientedtowards
the center of the clutch plate pusher;for
correct assembly refer to the scheme below.

- 14 -
 Clutch

the plates, the springs, the self-centring washers and

STANDARD
the screws

SLIPPER TYPE

tighten the screws to the prescribed torquein following

a crossed run. STANDARD

SLIPPER TYPE

If necessary, replace the cover gasket, lining it up with

the centring pins.

The contact surfaces must always be clean

and degreased.

- 15 -
 Clutch

Orient the clutch control shaft on its seat as indicated.

Position the clutch cover,

put the plate in position (1) and tighten the screws

by hand.

Tighten the screws to 8 Nm. 8 Nm 1

- 16 -
7UDQVPLVVLRQ

6(&7,21 F
5(9,6,21

-1-
 7UDQVPLVVLRQ

6800$5<

75$160,66,21  3DJH 3

5HPRYLQJWKHWUDQVPLVVLRQ 3DJH 4
2YHUKDXOLQJWKHWUDQVPLVVLRQ 3DJH 5
7UDQVPLVVLRQEUHDNGRZQ  3DJH 8
0DLQVKDIW  3DJH 11
/D\VKDIW  3DJH 12
*HDUVHOHFWRUGUXP 'HVPR  3DJH 14
*HDUVKLIW  3DJH 15
7UDQVPLVVLRQ DVVHPEO\  3DJH 18

-2-
 7UDQVPLVVLRQ

TRANSMISISON

7LJKWHQLQJ
WRUTXH A B C D E F G H I L
Nm 140 8 8 6 25 (M8) 25
7KUHDGORFNHUW\SH PHGLXP PHGLXP
VWUHQJWK VWUHQJWK

OIL $SSO\HQJLQHRLO SS $SSO\VLOLFRQHVHDODQW

NO OIL 'RQRWDSSO\RLORURWKHUVXEVWDQFHV HSC $SSO\0ROLNRWH+6&
GR $SSO\JUHDVH M $SSO\JDVNHWVHDODQW

-3-
 7UDQVPLVVLRQ

5HPRYLQJWKHWUDQVPLVVLRQ
5HPRYH WKH FOXWFK IROORZLQJ WKH LQVWUXFWLRQV LQ WKH
UHODWLYHSDUDJUDSK5HPRYHWKHFOXWFKURG5HPRYH
WKHIDVWHQLQJVFUHZVIURPWKHWUDQVPLVVLRQFRYHU

F
8VLQJDUXEEHUPDOOHWGHOLFDWHO\VWULNHWKHPDLQVKDIW
  IURP WKH FOXWFK HQG KROGLQJ D KDQG RQ WKH
WUDQVPLVVLRQFRYHUXQWLOLWPRYHVIURPWKHFUDQNFDVH

([WUDFWWKHWUDQVPLVVLRQDVVHPEO\  IURPWKHHQJLQH
EORFN

-4-
 7UDQVPLVVLRQ

2YHUKDXOLQJWKHWUDQVPLVVLRQ
- Place the transmission assembly (2) on the 3 2
transmission overhaul device (3) (Cod.
8000B7177).

- On the rear part insert the spacer (4) on the main

shaft and lock it by manually screwing down the
flywheel (5).

-5-
 7UDQVPLVVLRQ

- Fix the front of the transmission assembly to the

device, fastening the flange (6) with the three 7
screws (7). 7

- Check the condition of the front clutching teeth of 1

the gears which must be in perfect shape and sharp
edged.
The neutral gears must rotate freely on their shafts.
All of the neutral gears must present a minimum
axial play of 0.10 mm.
Ensure that the shafts rotate freely without
impediments, checking the state of the bearings.

- Check the measurements of the main shaft (1) and

lay shaft (8), comparing them with the figures “A” e 8
“B” respectively.

Figure A
0DLQVKDIW

1a
2a 3a
4a 5a
6a
A
A= 47.65 - 47.90 with 5th gear engaged
B B= 59,305 - 59,905 with 6th gear engaged

-6-
 7UDQVPLVVLRQ

Figure B
/D\VKDIW

F
6a 5a
3a 4a
2a
1a

A
B
A= 30.30 - 30.81 with 2nd gear engaged
B= 41.00 - 41.71 with 3rd gear engaged C
C= 83.54 - 84.15 with 4th gear engaged
D= 94.60 - 95.31 with 1st gear engaged D

- Visually inspect the gear selection forks to look for

bending or other damage.
Every fork that appears damaged must be
substituted because it can cause difficulty when
engaging a gear and cause sudden disengagement
under load.
Check the play of each fork using a feeler gauge in
the groove of its gear. If play is above 0.7 mm
replace the gear or fork in relation to the service
limits of each part.

*HDUJURRYHOLPLW  5,6 mm 3ULPDU\

4,6 mm 6HFRQGDU\

)RUNOLPLW  4,65 mm 3ULPDU\WKWKJHDU

3,65 mm 6HFRQGDU\VWQGUGWKJHDU

7KHIRUNVPXVWVOLGHHIIRUWOHVVO\
7KH JHDUV PXVW VOLGH HIIRUWOHVVO\ DQG ZLWKRXW
H[FHVVLYHIULFWLRQ

-7-
 7UDQVPLVVLRQ

7UDQVPLVVLRQEUHDNGRZQ
- Straighten the safety washer (9) and, blocking the
pinion (10), unscrew the nut (11) then remove the
pinion and washer.
9

11
10
F

- It is necessary to manually engage 6th gear in order 10

to separate the main and lay shaft, then unscrew
the nut (12) fastening the selector drum (desmo)
to the gearshift.

12

-8-
 7UDQVPLVVLRQ

- Unscrew the three screws (7) and remove the

flange (6). 7

7
6

- Unscrew the flywheel (5) and remove the spacer

(4), freeing the main shaft.

5
4

-9-
 7UDQVPLVVLRQ

- Extract the transmission shafts from the plate and

place them on the bench.

- Remove the selector drum (desmo) (13) and

detach the main shaft (1) from the lay shaft (8). 13

1 8

13

- 10 -
 7UDQVPLVVLRQ

0DLQVKDIW

.H\ 13
1) Stop ring 12
2) Shim washer 11
3) QGJHDUJHDUV=  1a 10
4) 5ROOHUFDJH Z= 13 9
5) WKJHDUJHDUV=  8
6) 6KLPZDVKHU
7
5 a 6
7) 6WRSULQJ 5
Z= 21
8) UGJHDUJHDUV=  4a 4
WKJHDUJHDUV=  Z= 19 3
9) 6WRSULQJ 3a 2
Z= 18
10) 6KLPZDVKHU
11) 5ROOHUFDJH 6a
12) WKJHDUJHDUV=  Z= 22
2a
13) 6KDIWZLWKVWJHDUJHDUV=  Z= 16 F
1

- Disassemble the main shaft starting with the

removal of the stop ring (1), removing all the
components as in the figure.
- Check that the gear teeth are intact and the threads
and grooves of the shafts and gears are in perfect
condition.
- Check the state of the front dog clutches.
- Check the state of the roller cages, if they are worn
replace them.

If it is necessary to replace one or more

gears, replace also the corresponding
gears on the lay shaft – gears must be
replaced in pairs.

- Refit the gears onto the shaft, proceeding in the

reverse order of removal and checking the
measurements in figure A.

Figure A
0DLQVKDIW

1a
2a 3 a
4 a
6a 5a
A A= 47.65 - 47.90 with 5th gear engaged
B B= 59.305 - 59.905 with 6 th gear
engaged

- 11 -
 7UDQVPLVVLRQ

/D\VKDIW

19 18
17 16
21 15
14
20 13
12
1 a 11
Z= 37
10
9
5a 8
Z= 30 7

F 4a
Z= 30

6 3a
5 Z= 32
4
3
2

6a 1
Z= 29

2a
Z= 34

.H\ 11) Grooved washer

1) Lay shaft 12) 4th gear gears; Z= 30
2) Roller cage 13) Roller cage
3) 2nd gear gears; Z= 34 14) Grooved washer
4) Grooved washer 15) Stop ring
5) Stop ring 16) 5th gear gears; Z= 30
6) 6th gear gears; Z= 29 17) Shim washer
7) Stop ring 18) 1st gear gears; Z= 37
8) Grooved washer 19) Roller cage
9) 3rd gear gears; Z= 32 20) Shim washer
10) Roller cage 21) Stop ring

- 12 -
 7UDQVPLVVLRQ

- Disassemble the lay shaft starting with the removal

of the stop ring (21), removing all the components
as in the figure.
- Check that the gear teeth are intact and the threads
and grooves of the shafts and gears are in perfect
condition.
- Check the state of the front dog clutches.
- Check the state of the roller cages, if they are worn
replace them.

If it is necessary to replace one or more

gears, replace also the corresponding
gears on the other shaft – gears must be
replaced in pairs.

- Refit the gears onto the shaft, proceeding in the

reverse order of removal and checking the
measurements in figure B.
F

)LJXUH%
/D\VKDIW

6a 5a
a 3a 4a
2
1a
A
A= 30.30 - 30.81 with 2nd gear engaged
B
B= 41.00 - 41.71 with 3rd gear engaged C
C= 83.54 - 84.15 with 4th gear engaged
D= 94.60 - 95.31 with 1st gear engaged
D

- 13 -
 7UDQVPLVVLRQ

*HDUVHOHFWRUGUXP 'HVPR
- Remove the stop ring (1), remove the fork pin (2)
and then the fork (3), then repeat the same
operations for fork (4) and fork (5).

([DPLQH WKH VHOHFWRU GUXP   ‡'HVPRˆ  ZKRVH

JURRYHV  PXVWQRWEHVPRRWKHGIURPZHDU
7KHSOD\EHWZHHQWKHIRUNSLQ  DQGJURRYHV  ZLWK
QHZFRPSRQHQWVLVPP
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7KHZLGWKRIWKHJURRYHV  IRUQHZGUXPVLV
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1
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9HULI\WKHZRUNLQJFOHDUDQFHEHWZHHQWKHIRUNSLQDQG
WKHVKLIWGUXPJURRYHPHDVXULQJWKHGLPHQVLRQVZLWK 5
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5HDVVHPEOHWKHYDULRXVSDUWVE\DFWLQJLQWKHRSSRVLWH
ZD\
5
4

6 7

- 14 -
 7UDQVPLVVLRQ

*HDUVKLIW
,I QHFHVVDU\ GLVDVVHPEOH WKH JHDU VKLIW DVVHPEO\ 2
DVIROORZV
- Remove the shift control rod (1), unhooking it from
the gear selector (2).

1
F

- Position the rod (1) in a vice, using aluminium plates

so as not to damage it, unhook the spring and 2
separate it.

- 15 -
 7UDQVPLVVLRQ

- Check spring (2), spring (3), the shaft (1) and the
plate (4) for wear; if any component is found to be
damaged it should be replaced.
2 4 3

- Refit the rod, following the removal procedure in

reverse, without fitting it to the shift flange.
- Check that the gear locker pawl (5) moves freely
without obstruction and the thumbwheel (6) turns
freely without excessive play; if the spring (7) or
the pawl (5) must be replaced, unscrew the screw
(8) to remove the assembly. On reassembly, lock
the screw (8) with Loctite 243 to 10 Nm.

6
8 5
7

- Unscrew the two screws (9) holding the shift

bearing and remove them with their washers.
9

- 16 -
 7UDQVPLVVLRQ

- Move the pawl and remove the shift selector (2).

- Unscrew the nut (10) to disassemble the selector; Up to serial

check the state of the shift selector, the cams must
not be worn and be free of impediments. Check number 003271
that the bearing (11) turns freely and that there are
no worn parts in the assembly (12).
- Refit the shift selector, following the removal
procedure in reverse, tightening the nut (10) to 25
Nm.

From serial
number 003271

- Tighten the screws (9), appropriately greased with

their washers to 10 Nm with Loctite 243.

- 17 -
 7UDQVPLVVLRQ

7UDQVPLVVLRQDVVHPEO\
- Position the main (1) and lay shaft (2) gears in
neutral. 2

F
- Bring the two shafts together and position the
selector drum (3) inserting fork (4) between the
3 5
gears of 2nd and 6th gear, fork (5) between the gears
of 4th and 5th gear of the lay shaft (2) and fork (6) in 4
the groove on the gears of 3rd and 4th gear.

1 2

- Place the transmission shafts (2) on the

transmission overhaul tool (7) (Cod. 8000B7177).
7

- 18 -
 7UDQVPLVVLRQ

- Fasten the main shaft, positioning the spacer (8)

and screwing on the flywheel by hand (9). 8

- Place the gear selector (10) in neutral, aligning the

pawl wheel (11) with the longest pin (12) of the
selector.

12

10
11

- 19 -
 7UDQVPLVVLRQ

- Fit the flange (13) introducing the pin (12) of the

selector in the marked hole (14) of the selector
drum.
- Fasten the flange (13) with the three screws (15). 12

13

13

15
15

14
15

- 20 -
 7UDQVPLVVLRQ

- Place the gear selector in 1st gear.

1^
F

- Screw the nut (16) down to a torque of 25 Nm +

Loctite 243.
16

- 21 -
 7UDQVPLVVLRQ

Place the transmission in neutral before

screwing on the pinion nut.

- After placing the transmission in neutral, refit the

pinion (17) on the lay shaft, replacing the safety
washer, then screw on the nut (18) to 12 - 13 Nm + 18
Loctite 243 then fold down the safety washer.

- Check that the transmission is operating correctly

17
by manually engaging the gears, checking that they
do not stick and that there is play in the forks in the
grooves of the sliding gears.

F
1st and 4th GEAR >>>

QGDQGUG*($5 >>>

- 22 -
 7UDQVPLVVLRQ

WKDQGWK*($5 >>>

- Once you have ensured the transmission is

operating correctly, remove it from the device,
following the assembly operations in reverse.
- Place the gasket (19) on the flange, lightly greasing
it so that it does not come out of its seat when
reinstalling the transmission

19

- Refit the transmission assembly (20) on the engine,

ensuring that the blocking rings are present (21), 20

21

- 23 -
 7UDQVPLVVLRQ

then tighten the eight screws (22) to a torque of 25

Nm. 22 22

22
F

- Assembly the pinion, the safety washer and the

nut. By blocking the pinion, tighten to a couole of
140 Nm with medium threadblockers.

- Hammer the new washer down onto the two

opposite faces of the hexagon as indicated.

- 24 -
Starting

SECTION G
REVISION 0

-1-
 Starting

SUMMARY

STARTING ............................................................................................................................... Page 3

Starter transfer gear .............................................................................................................. Page 4
Starter free wheel ................................................................................................................. Page 5
Refitting the starter assembly ............................................................................................... Page 7
Refitting the starter transfer gear cover ................................................................................ Page 7

-2-
 Starting

A 2xM6-L40
STARTING
A 3xM6-L30

Tightening A B C D E F G H I L
torques Nm 10
Thread blockers

OIL Apply motor oil SS Apply silicone sealing

NO OIL Do not apply neither oil nor other types of substances HSC Apply HSC Molikote
GR Apply grease M Apply mastic for gaskets

-3-
 Starting

Starter transfer gear

After removing the starter motor as described in Sec. 1
C, unscrew the 4 screws (1) and screws (2). Delicately
use a screwdriver on the tip of the lever to separate
the starter cover from the upper half-case.

To remove the cover it is necessary to remove the

G screws (2) as they are not perpendicular to the support
plane.

Check that the gear turns freely and the teeth are not
damaged. 8000B
If removal is necessary, remove the pin (3) and extract 4 3
the shaft (4) to free the transfer gear (5).

-4-
 Starting

Refitting the transfer components requires the tool:

8000B7299
Starter transfer gear 1°
assembly tool : cod.8000B7299

Insert the tool into the seat of the pin, oriented as shown
in the figure.
Oil the shaft (4) and fit the O-ring.

Always use a new O-ring to perform

this operation.
2°
Keeping the gear in position, insert the shaft, remove
the tool cod. 8000B7299 and refit the pin.

Starter free wheel

Extract the starter assembly (6). G

Check that the gears are intact and no components

show signs of scoring or anomalous wear. If they do
they should be replaced.

The gears must always be replaced

in pairs.

Attention: all parts must be cleaned and

lubricated with engine oil when refitting.

-5-
 Starting

Refit the free wheel on the shaft with the arrow pointing
outwards.

Fit the safety ring.

G

Refit the roller cage and the free wheel gear.

Check that by blocking the shaft (1), the free wheel
gear (2) turns only in the direction indicated by the 1 2
arrow.

-6-
 Starting

Refitting the starter assembly

Ensure all surfaces are clean and degreased when
refitting. 3 4
Fit the starter assembly and place the shim washer
(3) and the cap (4).

Check that the assembly has a little play along the

shaft axis.

Refitting the starter transfer gear cover

Spread a little gasket sealant on the previously cleaned G
and degreased contact surfaces of the starter cover.

Refer to the figure for this operation.

In order to avoid oil leaks, the sealant must

go up to the internal edge of the two areas
to the side of the cap.

Ensure that the sealant does not come into

contact with the shaft seats.

-7-
 Starting

Refit the cover in place on the half-case, taking care

that the sealant does not come into contact with the
gears.

Insert the 3 screws (5) and the two screws (6),

G tightening them to the specified torque. 5

-8-
Cooling - Lubrication

SECTION H
REVISION 0

-1-
 Cooling - Lubrication

SUMMARY

Lubrication .......................................................................................................................... Page 4

Removing the oil filter ......................................................................................................... Page 4
Removing the lubrication system ....................................................................................... Page 5
Refitting the lubrication system .......................................................................................... Page 9
Refitting the oil filter ............................................................................................................ Page 14

-2-
 Cooling - Lubrication

Tightening
torque A B C D E F G H I L
Nm 25 10 10 10 10 10 10
Threadlocker type

OIL Apply motor oil SS Apply silicone sealing

NO OIL Do not apply neither oil nor other types of substances HSC Apply HSC Molikote
GR Apply grease M Apply mastic for gaskets

-3-
 Cooling - Lubrication

Lubrication:

The oil and coolant must be drained from their

respective circuits as described in the maintenance
section before performing this operation.
1

Removing the oil filter

Unscrew the screws (1).

Remove the oil filter cover (2) and the spring (3).
2 3
H

Remove the oil filter (4).

-4-
 Cooling - Lubrication

Removing the lubrication system

1
Unscrew the screws (1).
1

Remove the oil sump (2), keeping the gasket (3) and
bushings (4).
2
H

4
3

Remove the coolant pump discharge tube (5).

-5-
 Cooling - Lubrication

Unscrew the two screws (6) and remove the

submerged intake (7).

6 7

Unscrew the two screws (8) and remove the oil

delivery tube (9) from the pump to the heater
exchanger with its O-rings.
9
H 8
8

-6-
 Cooling - Lubrication

Unscrew the two screws (10) and remove the coolant

delivery tube (11).

11

10

Recover the O-rings (12) and (13).

12

13

-7-
 Cooling - Lubrication

Unscrew the two screws (14) and remove the coolant

intake manifold (15), recovering the relative O-rings.

14
15

16

H
15

Unscrew the screw (17) and, if present, the washer (18).

Remove the blocking ring (19) with needle-nose pliers.

19
17

18

-8-
 Cooling - Lubrication

Raise the pump assembly from the gears and remove

it from the engine. 20

Refitting the lubrication system

Insert the pump assembly (20), inserting the part of 20 21
the pump body in its seat in the engine block, then
mesh the gears (21) with the crankshaft transfer gear.
H

Insert the blocking ring (19) with needle-nose pliers.

19

-9-
 Cooling - Lubrication

Screw on the screw (17) and, if present, the washer (18)

to fasten the pump assembly (20). 20
17

18

Grease the seats of the oil delivery tube (7) gaskets.

7

Check that the O-ring gaskets are not damaged; if

they are replace them. Then refit the tube (9), applying 9
light pressure so that the gaskets and the tube insert
themselves correctly into the seat.

- 10 -
 Cooling - Lubrication

Screw down the tube’s (9) two screws (8).

9
8
8

Grease the seats (22) and (23) of the coolant delivery

tube.
23

H
22

Check that the O-ring gaskets are not damaged; if

they are replace them. Then insert gasket (13) on the
engine block and gasket (12) on the tube (11). Grease
the seats again and refit the tube.

12
11
11

13

- 11 -
 Cooling - Lubrication

Screw down the tube’s (11) two screws (10).

11

10

Grease the seat (24) of the submerged intake (7) and

fasten it in position by screwing down the screws (6).

H
6
7

24

Check that the O-ring gaskets (25) and (26) of the

coolant drain tube (5) are not damaged; if they are 26
replace them. Then grease the tube (5) and install it
in its seat on the oil sump.

25

- 12 -
 Cooling - Lubrication

Position the blocking rings (4) in their seats, then fit

the gasket (3) and the oil sump (2).
Screw down the screws (1), those corresponding with 2

4
3

the blocking rings first and then the others. Tightening

torque 10 Nm. 1

NOTE It is preferable to fit the oil filter before

refitting the oil sump to the engine.
1
H

Check that the O-ring gaskets (16) are not damaged;

if they are replace them. Then grease the gasket and
refit the coolant intake manifold (15), screwing down
the screws (14) to a torque of 10 Nm.

14

16
15

- 13 -
 Cooling - Lubrication

Refitting the oil filter

Introduce the oil filter (4) into the sump. 4

Insert the spring (3) in the filter seat, then lubricate

the gasket (5) and fit the cover (2).
2 3

Screw down the screws (1).

1

- 14 -
Crankcase

SECTION I
REVISION 1

-1-
 Crankcase

SUMMARY

CRANKCASE......................................................................................................................... Page 3
Crankcase disassembly ..................................................................................................... Page 4
Removing the countershaft ................................................................................................ Page 8
Removing the gearbpx bearing ......................................................................................... Page 10
Removing the crankshaft ................................................................................................... Page 11
Removing the big ends ...................................................................................................... Page 11
Removing the pistons ........................................................................................................ Page 13
Removing the piston oil jet ................................................................................................. Page 14
Cylinder revision ................................................................................................................ Page 15
Piston revision ................................................................................................................... Page 15
Piston-cylinder coupling ..................................................................................................... Page 16
Piston pin revision .............................................................................................................. Page 16
Piston-pin coupling ............................................................................................................ Page 16
Piston pin - connecting rod coupling .................................................................................. Page 17
Piston rings ........................................................................................................................ Page 17
Piston ring-cylinder coupling .............................................................................................. Page 17
MAINSHAFT .......................................................................................................................... Page 18
Coupling of piston pin-small end bush ............................................................................... Page 19
Coupling half-bearings - crank pin ..................................................................................... Page 19
Overhauling the crankshaft and countershaft .................................................................... Page 21
I Overhauling the half-cases ................................................................................................ Page 21
REASSEMBLY ....................................................................................................................... Page 22
Reassembly the piston oil jet ............................................................................................. Page 22
Cylinder and piston assembly ............................................................................................ Page 23
Re tting the half-cases ..................................................................................................... Page 26
Fitting the crankshaft ......................................................................................................... Page 27
Fitting the connecting rods ................................................................................................. Page 28
Reassembly the gearbox bearings .................................................................................... Page 31
Re tting the countershaft ................................................................................................... Page 32
Crankshaft timing ............................................................................................................... Page 33

-2-
 Crankcase

CRANKCASE

Tightening A B C D E F G H I L
torques Nm 8 10 25 12 10+60° 25 10 10 12 10
Thread blockers strong medium strong

OIL Apply motor oil SS Apply silicone sealing

NO OIL Do not apply neither oil nor other types of substances HSC Apply HSC Molikote
GR Apply grease M Apply mastic for gaskets

-3-
 Crankcase

Crankcase disassembly
Remove as follows as indicated in the relative para-
graphs:
A) The head
B) The clutch
C) The gear
D) Starter
E) Lubrication and cooling system.

Remove:
F) Working on the upper part of the engine, remove
the 12 6mm screws starting with the outermost
ones and the central 8mm screw.

-4-
 Crankcase

At this point it will be necessary to ensure the upper

half-case is fully fastened to the engine support and
A
eliminate the lower fastenings to make it possible to
separate the half-cases.

Add a fastening point (A) to the upper half-case using

the hole of the central M6 screw. Free the lower half-
case from the engine support fastening (B).

And from the engine support fastening (C).

Rotate the engine 180°.

-5-
 Crankcase

G) Remove the 2 M6 screws.

H) Remove the 8 M8 screws, following the order

shown in the gure.

NOTE It is recommended you use an articulated

driver to remove the screws inside the
engine block.

-6-
 Crankcase

Remove the screws using a athead screwdriver.

I) Separate the two cases (1 and 2) by applying le-

verage on the protrusion.
2

L) Remove the lower half-case and rest it on a at,

clean surface.

-7-
 Crankcase

Removing the countershaft

Loosen the 2 screws (1).

Remove the countershaft head with the two rings and

the half-bearing.

-8-
 Crankcase

Remove the countershaft.

NOTE In the case of temporary removal of the

bearings (1) it is recommended you mark
the shaft, the support number and the
case they belong to with a marker pen. For
example the bearing removed from the
countershaft of the no. 1 support of the
upper case (starting from the left) will be
identi ed by the mark S1 CS1.
I

Remove the 3 half-case blocking rings (2) and the

seal ring (3) of the relative conduits. 2

-9-
 Crankcase

Removing the gearbox bearings

This operation must be conducted when the engine is
warm. 1
Remove the secondary shaft bearing clamping screw
(1) and take out the respective retaining plate.
Remove the primary bearing clamping screws (2) and
take out the respective retaining plate.
Use a heat gun to bring the temperature of the be-
arings’ area of the bottom crankcase half to about
125°C.

Use a Te on spacer (3) to push the primary bearing by

tapping it slightly with a hammer.

Take out the bearing (4) of the secondary shaft using

an extractor.

Carry out the same operation to take out the needle

cage (5) of the desmodromic shaft.

- 10 -
 Crankcase

Removing the crankshaft

Disengage the crankshaft from the piston-connecting
rods assembly by removing the big ends.

Tool no. 8000B7214 is required to perform

this operation.

Fit the tool on main journals no. 1 and no.4.

Hand tighten the screws (1) of the tool to lock the

crankshaft in place.
1

Removing the big ends

Loosen the big end retaining screws (2).
2

- 11 -
 Crankcase

Remove each big end from its connecting rod, marking

it to avoid confusion on re tting.

Remove tool no. 8000B7214.

Remove the crankshaft and place it on a support of

the type shown in the gure.

NOTE In the case of temporary removal of the

bearings (1) it is recommended you mark
the shaft, the support number and the
case they belong to with a marker pen.
For example the bearing removed from
the crankshaft of the no. 1 support of the
upper case (starting from the left) will be
identi ed by the mark S1 AS1.

- 12 -
 Crankcase

Removing the pistons

Turn the upper half-case.

NOTE Mark the top of every piston with a marker

pen in order to ensure the correct position
is respected on reassembly.

Extract the pistons moving the connecting rods up

from bottom as indicated, and make attention not to
damage the elastic bands.

Work on one piston at a time to continue

the removal.

Remove the circlips which blocks the pin to the piston.

Slide the pin off.

NOTE Mark each part according to the cylinder no.

it belongs to so they can be reassembled
in their original positions.

- 13 -
 Crankcase

Removing the piston oil jets

To carry out this operation, it is necessary to remove
the main bearings as described on page 12.

Unscrew the three hollow bolts (1).

Take out the three oil jets (2), make sure you do not
damage the nozzles.
2

- 14 -
 Crankcase

Cylinder revision
Check to be sure that enclosures show no sign of
seizures with the pistons.
Check piston ovalization in the following way:
A) Measure the nominal diameter of each cylinder
at a distance of 20 mm from the superior edge
as indicated in the gure.

B) Perpendicularly repeat the measurements to the

preceding ones.
C) Verify that the ovalization is inferior to 0,015 mm
(wear limits).

In the case that not even one cylinder should pass

this veri cation, substitute the entire block.
If the block should be substituted and if necessary
also substitute the pistons and elastic strips. I

Piston revision
Carefully clean the piston ceiling from carbon re-
sidues. Continue with a careful visual check of the
piston; no signs of lines or other damage must appear.
Measure the diameter of the piston at the portion
indicated in the direction perpendicular to the piston
pin axle.
In the case of excessive wear of one of the pistons,
substitute it.
The piston should belong to the same class of the
cylinder selection.

- 15 -
 Crankcase

Piston-cylinder coupling
The cylinder-piston groups are furnished already
coupled; if there should be an exchange of cylinders
and pistons between them it would be necessary to
proceed surveying coupling plays.
Measure the diameter of the (ND) pipe at 20
mmfrom the superior plane, as indicated on the
sketch.
The piston diameter must be measured at 8 mm
from the shell base, in a perpendicular position to
the piston pin axle.
These measurements must be carried out at a stabi-
lized temperature of 20°.
The play between piston and cylinder must fall
between 0,038 e 0,067 mm.
Maximum wear limit permitted 0,10 mm.

Piston pin revision

Verify that the piston pins show no lines or bluish
colours which indicate over heating.

Piston-pin coupling
The (S) play between piston pins and piston must
be of 0,004÷0,012 mm in case the limit is exceeded
it is necessary to substitute the piston pin and piston.
The limited wear permitted is 0,03 mm.

- 16 -
 Crankcase

Piston pin - connecting rod coupling

Play between piston pin and connecting rod
must be of 0,015÷0,032 mm.
Maximum wear limit allowed 0,06 mm.

Piston rings
Verify the absence of lines and traces of shrinkage on
each piston ring. Verify that the edge of the segment
is well de ned and free in the piston rings.
The spare pistons are furnished complete with rings
and piston pins. Whenever segment wear is noticea-
ble it is recommended to change the pistons as well.
I
PISTON RING Standard Wear limit
-0,01
1° SP 0,8 0,75
-0,03

0
2° SP 0,8 0,75
-0,02

-0,03
Oil scraper SP 1,5 1,38
-0,08

Piston ring-cylinder coupling

Introduce the 5 mm segment under the head plane
being careful to position it well in “square” and to
measure the distance between the two ends of the
piston ring.
The maximum play allowed between the ends of the-
ring is the following for each segment:
PISTON RING N°1: 0,2 ÷0,4 mm;
Maximum wear limit allowed: 0,6 mm
INTERMEDIATE PISTON RING: 0,2 ÷0,4 mm
Maximum wear limit allowed: 0,6 mm
OIL SCRAPER: 0,2 ÷0,7 mm
Maximum wear limit allowed:1,0 mm

- 17 -
 Crankcase

MAINSHAFT

Tightening A B C D E F G H
torque
Nm 20 25 25
Angle 90° (50÷60)
Thread blockers strong

OIL Apply motor oil NO OIL Do not apply neither oil nor other types of substances
GR Apply grease SS Apply silicone sealing
HSC Apply HSC Molikote M Apply mastic for gaskets

- 18 -
 Crankcase

Coupling of piston pin-small end bush

Check that the bearing is under good condition and
that there are not wear marks.

Verify that the internal diameter of the small end bush

is between 16,015÷16,025 mm.
The play between the small end bush and the piston
pin must be between 0,015 and 0,032 mm.

If the connecting rod does not conform to

these parameters it will be necessary to
replace it.

Coupling half-bearings - crank pin

I
Verify the measure of the connecting rod and pin
diameters.

- Connecting rod pin

The measure of the roundness of the crank pin must
be performed along the center surface of the crank
pin with three measurements at 120° intervals.
The max. nominal value of roundness is 0,005 mm.
The obtained average value must be comprised in
the values foreseen by the 2 classes of selection
of the crankshaft.

120°

120°
120°

- 19 -
 Crankcase

- Connecting rod
CONNECTING ROD
The measure of the connecting rod must be effected
after having tightened the connecting rod without SCREW TIGHTENING
half-bearings to the prescribed torque. TORQUE
Operation Value
Its recommended to execute the Pre-load 5 Nm
measurement re-using the original used
Intermediate tightening 20 Nm
bolts.

Degrease bolts and connecting rod. L

Lubricate with oil the internal thread, thread and
under head.
Pre-load the bolts to the torque of 5 Nm.
45°
Intermediate tightening to the torque of 20 Nm.
d2
Final tightening by turning clockwise of 90° (1/4 of turn).
d1
Once performed the tightening,effect a measure-
ment on the principal axle of the stem and two to 45° d3
from it as suitable in gure. The internal diameter 45°
of the connecting rod is given by the average of the
three values.

D.i. = (d1 + d2 + d3)/3

Check that the torsional and exion deformation of the

connecting rods does not exceed the following values:

I Flexion: Max 0,1/100 mm

Torsion: Max 0,05/100 mm

If it is necessary to replace one or more parts, refer to

the class and the weight of the connecting rod and to
the color of the bearing, printed on the same.

Connecting Rod Weight Class Selection Table

(L=109,3mm) (L=105,1mm)
Class Weight (g) Class Weight (g)
X 255 ÷ 258 X 250 ÷ 253 Weight
Y 258,1 ÷ 261 Y 253,1 ÷ 256
Z 261,1 ÷ 264 Z 256,1 ÷ 259

The replacement connecting rods must

pertain to the same weight class. Do not
use connecting rods with different weight
Class Colour
classes.

To identify the weight class of the connecting rod, refer SELECTION TABLE FOR F3 CONNECTING ROD
to the table herewith.
Select the half-bearings in base to the color according CONNECTING ROD HEAD DIAMETER
36,000 36,009
to the attached chart. A B
36,008 36,016
CONNECTING ROD 33,016 1.484/1,486 1,486/1,491
NOTE On re tting, the screws and connecting PIN DIAMETER 33,024 RED BLUE
rods must be thoroughly cleaned and
degreased. FUNCTIONING PLAY 0,029/0,057

- 20 -
 Crankcase

Overhauling the crankshaft and countershaft

Clean and check that the teeth of the gears of the two
shafts are intact and have sharp edges.
Check that there are no signs of anomalous wear and
the surfaces are smooth.

Overhauling the half-cases

Replace the main bearings if there is any doubt
as to their condition. Check wear tolerances of the
crankshaft. SELECTION TABLE FOR F3 BEARINGS
For couplings, refer to the classes given in the table.
BENCH CARTER SLOT DIAMETER
The functional clearance of the crankshaft main PIN
A
36,000
B
36,009
36,016
bearings must be between DIAMETER 36,008

1,484 ÷ 1,489 1,489 ÷ 1,494

I
33,014 ÷ 33,022
0,019÷0,046 mm. RED BLUE

FUNCTIONING PLAY 0,019/0,046

The service limit is 0.06 mm.

NOTE The countershaft has one main bearing

selection only. CRANKCASE SUPPORT
HOLES SELECTION MARKS

Insert the blocking rings and lubricate the

cylinder liners with engine oil.

- 21 -
 Crankcase

REASSEMBLY
Make sure the crankcase halves have been thorou-
ghly cleaned and degreased. There shouldn’t be any
obstructions in the areas where the oil passes.
The contact surfaces of the crankcase halves must be
perfectly smooth and clean.

Reassambling the piston oil jets

Make sure there are no obstructions in the conduits of
the jets, which must be perfectly clean.

Do not install damaged or deformed jets. Jets

with features that differ from the original ones
can cause serious damage to the engine.

Insert the jets by pushing them all the way into place
on the top crankcase half.
Make sure the hollow bolts are clean and have been
degreased.

Manually bring the hollow bolts closer and tighten to a

torque of 8 Nm.

- 22 -
 Crankcase

Cylinder and piston assembly

The ringss must be assembled on the piston with the
writing “R” “RN” turned upwards and by following the
outline in the gure.

Assemble the internal ring on the piston.

Assemble the internal ring on the piston.
Assembly the pistons complete with the
previouslydegreased and cleaned connecting rod.

Insert the piston pins into the piston until beat.

Assemble the external rings.

- 23 -
 Crankcase

Insert the centering bush and lubricate the cylinder

barrels with engine oil.

The following tool is required to perform this operation:

Piston installation device

cod. 8000B7207

1
I

Position the device on the half-case as indicted,

centring the blocking rings and lubricating the liners
with engine oil.

- 24 -
 Crankcase

Push the pistons with connecting rods down into their

respective cylinders.

Insert the pistons compressing the segments manually

to avoid damage.

Pull the connecting rods downward until complete

inserting of the pistons into the cylinder.

Once inserted all the pistons, dismantle the tooland

turn the half-crankcase.

- 25 -
 Crankcase

Re tting the half-cases

Carefully degrease and clean from any paste residues.

Fit the bearings in their respective seats (previously

marked during disassembly) in the case without
lubricating them.

After having positioned them put oil on each bush.

Oil the main, rod and countershaft bearings

with engine oil.

- 26 -
 Crankcase

Lubricate journal no. 2 from both sides as it performs

the function of centring the crankshaft.

Fitting the crankshaft

Place the crankshaft in place, bringing the connecting
rods into contact.

Use a feeler gauge to check that the crankshaft has

end play of between 0.1 and 0.25 mm from the main
journals. In case there should be different values
contact the manufacturer.

- 27 -
 Crankcase

Fitting the connecting rods

Tool no. 8000B7214 is required to perform

this operation.

Fit the tool on main journals no. 1 and no.4. Hand

tighten the screws (1) of the tool to lock the crankshaft
in place.

Fit the bearings to the previously cleaned and

degreased big ends, lubricating them with engine oil.

NOTE Measure and note down the length of each

screw before tting.

Always use new bolts, even with used

connecting rods.

• Lubricate the female threads, screw threads and

under the screw heads with oil.

NOTE
Before fitting the big ends, bring the
corresponding connecting rod into contact
with the connecting rod pin by manually
turning the crankshaft.

- 28 -
 Crankcase

• Reassemble the connecting rods on the crankshaft,

by hand tightening the bolts.
• Manually tighten the screws to a torque of 5 Nm.
• Intermediate tightening to the torque of 20 Nm.
• Fully tighten them by turning the screws 90°±5°
clockwise (1/4 turn), using an angle tightening
wrench, checking that the torque value is 50÷60 Nm.

CONNECTING ROD SCREW TIGHTENING TORQUE

Operation Value
Pre-load 5 Nm
Intermediate tightening 20 Nm
Final angle tightening 90°±5°

Each screw on angle tightening should

present a torque value of between 50 and 50
50÷÷60
60Nm
Nm
60 Nm and a lengthening of no more than
0.235 mm; if either of these conditions is
not met it will be necessary to replace the 90°
screw with a new one. 90°

• Measure the length of each screw after nal tighte-

ning and compare it with the value measured before
assembly.
The difference must not exceed the following value:

L2 - L1 < 0,235 mm

When the screws have been tightened, remove the

L2
tool cod. 8000B7214.

- 29 -
 Crankcase

Lubricate the seal rings and insert them in their

respective seats, previously cleaned of coolant.

Fitting the crankshaft cap.

Assembly the centering bushes.

- 30 -
 Crankcase

Reassambling the gearbox bearings

After cleaning and degreasing the bearings’ seats,
warm up the crankcase half until it reaches a
temperature of 125°C.
Mount the primary bearing on a designated tool and
adjust it so that the grooved area is near the plate seat.
Slide it into place inside the guard. Mount the retaining
plate and tighten the two screws to the required torque.

Turn the crankcase half and carry out the same

operation for the secondary bearing.
Mount the retaining plate and tighten the screw to
the required torque with a high-strength threadlocker.

Mount the needle cage of the desmodromic shaft on

the tool with a wider edge on the outside.
Place it in its seat and push it all the way in by tapping
it slightly with a hammer.

- 31 -
 Crankcase

Insert the half-bearings in the respective seats

on thepreviously degreased and cleaned lower
crankcase.

Lubricate the bearings with engine oil.

Re tting the countershaft

Fit the counterbalance shaft.

- 32 -
 Crankcase

Insert the grooved bearing on the cleaned and

degreased countershaft cap.

Insert the two blocking rings (1) and t the cap with
the arrow pointing in the direction of travel.

Tighten the two screws (2) to a torque of 25 Nm.

- 33 -
 Crankcase

Ensure that the blocking rings are installed on the

upper half-case.

Spread a layer of “THREEBOND” type garnish on

the stroke points of the two half crankcases paying
attention to prevent the paste from coming into contact
with the bushings.

NO
I
YES

NO

- 34 -
 Crankcase

Crankshaft timing
Orient the gears of the main shaft and countershaft on
their respective half-cases so that the timing notches
on them can be easily lined up during assembly.

Bring the half-cases together, paying attention to line

up the two notches on the gears in order to achieve
correct timing.

Couple the two half crankcases carefully beating them

with a plastic hammer until completely closed.

Check that the timing has been maintained.

- 35 -
 Crankcase

Manually drive the M8 and M6 screw without tighte-

ning.
NOTE
All screws have either an equal or visibly
different length; it is therefore impossible
to mix them up during reassembly.

Tighten the 8 screws of the cylinder bank, following

the order indicated,

I Screw Nr. Operation Value

---- Approaching ----

1-8 Intermediate 10 Nm
tightening
+2°
1-8 Final angle 60° +0°
tightening

pre-tighten the screws 1 to 8 to a torque of 10 Nm,

then tighten fully, turning them a further 60°.

- 36 -
 Crankcase

Tighten the two M6 screws of the countershaft to a

torque of 12 Nm.

Rotate the engine 180°.

A C
Restore engine support fastenings (B) and (C) and
eliminate the upper half-case xing point (A) which
uses the M6 screw hole.

Insert the M8 central screw and the other 12 M6

screws.

- 37 -
 Crankcase

Tighten rst the central screw M8 to a couple of 25 Nm.

Tight the other 12 screws at a couple of 10

Nmproceeding outwards from center.

- 38 -
Tightening torques

SECTION L
REVISION 0

-1
 Tightening torques

TIGHTENING TORQUES.......................................................................................................... PAGE 3

-2-
 Tightening torques

TIGHTENING TORQUES TABLE

DESCRIPTION Nm Thread blockers

HEAD
Stand screws 12
Head tightening screws (M10x1,5-L70) 10 Nm + 85°
Chain tightening cap 12
Chain tightening screws 10 medium
Sliding block distribution screws 8
Valve cap screws 10
Spark plug coil screws 8
Exhaust pipes stud bolts 10 medium
CLUTCH
Clutch nut 120 medium
Disk thrust plate screws 10 medium
        
GEAR SHIFT
Pinion nut 140 strong
Gear selection drum tightening screws 25 medium
M6 gear control screws 8 medium
CRANKCASE ACCESSORIES
Alternator tightening screws 10 medium
Motor starter tightening screws 10
Water pump collector tightening screws 8 L
     !# !$&
Gear sensor cover screws 10
ALTERNATOR
'      !$&  
<     !
STARTING
Starting cap screws M6x1 10
SUMP
Sump tightening screws 10

TIGHTENING TORQUES: CONVERSION FACTOR

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

Nm Kgm ftlbs
Nm ------ 0,10197 0,7375
Kgm 9,807 ------ 7,233
ftlbs 1,3559 0,13826 ------

-3-
 Tightening torques

TIGHTENING TORQUES TABLE

DESCRIPTION Nm Thread blockers

CRANKCASE
2nd bearing plate screw M6x1-L20 10
Main bearing plate screw M6x1-L20 10
Cylinder bank screws M8x1,25-L85mm 10+ 60°
Countershaft cap screws M8x1,25-L35 25
Countershaft screws M6x1-L35 10
Central upper crankcase screw M8x35mm 25
Fixing screws M6 10
M6 clutch cover screws 10
COOLING LUBRICATION
Oil drain plug 25
Cooling drain plug 25 medium
Inlet/outlet connectors for radiator oil 21 medium
Piston oil jet screw 8
CONNECTING ROD
Cap screws (*)

(*) See assembling notes

L
STANDARD TORQUES
>?    @ \?   ?  ^ 
indicated in the table below.

Thread Tightening torque

Diameter Kgm Nm ftlbs

M5 0,6 ÷ 0,8 6÷8 4,34 ÷ 5,79

M6 0,8 ÷ 1,0 8 ÷ 10 5,79 ÷ 7,23
M8 2,4 ÷ 2,6 24 ÷ 26 17,36 ÷ 18,8
M10 4,2 ÷ 4,5 42 ÷ 45 30,38 ÷ 32,55

TIGHTENING TORQUES: CONVERSION FACTOR

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

Nm Kgm ftlbs
Nm ------ 0,10197 0,7375
Kgm 9,807 ------ 7,233
ftlbs 1,3559 0,13826 ------

-4-
Service tools

SECTION M
REVISION 0

-1-
 Service tools

-2-
 Service tools

Nr. Code Q.ty Note F3 F3 ORO DESCRIPTION

1 8000B7177 1 • • GEAR CHANGE MOUNTING TOOL
2 800079015 1 • • CLUTCH BLOCKING TOOL
3 8000B7293 1 • • PAD FOR EXHAUST VALVE SEAT
4 8000B7294 1 • • PAD FOR INTAKE VALVE SEAT
5 8000B7295 1 • • CYLINDER HEAD GASKET KIT
6 8000B7296 1 • • ENGINE BLOCK GASKET KIT
7 800095581 1 • • VALVE SEAT MOUNTING PUNCH
8 8000A2625 1 • • BROACH FOR VALVE GUIDE
9 800094798 1 • • VALVE RUBBER CAPS REMOVAL TOOL
10 62N115538 1 • • SPRING WASHER
11 8C0069056 3 • • SCREW M8X30
12 8000A2385 1 • • GUIDE MOUNTING PAD, EXHAUST
13 8000B4368 1 • • GUIDE MOUNTING PAD, INTAKE
14 8000B7214 1 • • CRANK SHAFT INSTALLATION/REMOVAL TOOL
15 800095429 1 • • GAUGE PAD
16 8000B7254 1 • • BASE PLATE
17 800051521 2 • • SCREW M4X6
18 8000B7255 1 • • HALF CONES REMOVAL TOOL
19 800095180 1 • • HALF CONES INSTALLATION TOOL
20 800094796 1 • • VALVES INSTALLATION/REMOVAL TOOL
21 8000B7207 1 • • PISTON ASSEMBLING TOOL
22 8000B6789 1 • • ENGINE REMOVAL/INSTALLATION SUPPORT
23 8000B7299 1 • • MOUNTING TOOL FOR STARTING MOTOR IDLER GEAR PIN

-3-
 Analytical index

SECTION N
REVISION 0

-1-
 Analytical index

ANALYTICAL INDEX WORKSHOP MANUAL BRUTALE 675, BRUTALE 800 AND RIVALE 800

Sec. A - General description Sec. D - Head

Battery .......................................................... A-8 Camshaft and driving shaft timing ............... D-28
_` ...................................................... A-8 Chain tensioner ............................................. D-9
Carbon monoxide .......................................... A-7 Cylinder-head tightening sequence ............. D-26
Engine coolant ............................................... A-7 Dismantling the head ................................... D-12
Engine oil ....................................................... A-7 Dismounting cylinder head pieces ............... D-15
Glossary and symbols ................................... A-4 Distribution control unit .................................. D-8
Hot parts ........................................................ A-8 Guide valve installation................................ D-20
How to consult this manual............................ A-3 Head .............................................................. D-3
Index .............................................................. A-9 Head assy assembly ................................... D-23
  {    .............................. A-10 Inspection of the head group ....................... D-14
Nitrogen - rear shock absorber ...................... A-8 Maintenance of the valve slot ...................... D-17
|@   @  ............... A-10 Regulating valve play .................................. D-32
Petrol ............................................................. A-7 Removal of the valve guide ......................... D-19
Purpose of the manual .................................. A-3 Removing alternator cover ............................ D-6
Right hand and left hand standard ................ A-6 Removing head cover.................................... D-4
Safety ............................................................ A-7 Removing thermostat cover........................... D-5
 `   ....................................... A-8 Removing the valve gear components ........ D-10
Warning ......................................................... A-9 Springs ........................................................ D-21
Substitution of the valve slot ........................ D-18
Valve ............................................................ D-20
Valve guide check and maintenance ........... D-19
Sec. B - Maintenance Valve-guide valve coupling .......................... D-21
Changing the engine oil ................................B-11 Valve reassembly ........................................ D-21
Cleaning the parts ......................................... B-9 Valve removal .............................................. D-15
Connections................................................... B-9
Draining the coolant circuit ...........................B-11
Filling the oil circuit ...................................... B-15
General norms for assembling the parts ....... B-9 Sec. E - Clutch
Measuring compression in the cylinder ....... B-10 Clutch ............................................................E-3
Planned maintenance schedule .................... B-3 Clutch disassembly........................................E-4
Programmed maintenance schedule ............. B-3 Clutch overhauling .........................................E-8
<  ...................................................... B-14 Clutch reassembly .........................................E-9
Removing the oil radiator............................. B-12
} ?}      ......................... B-5 N
Table of wear limits ........................................ B-6
Sec. F - Transmission
Gear selector drum (Desmo) ........................F-14
Gear shift ......................................................F-15
Sec. C - Electrical components Lay shaft .......................................................F-12
Alternator .......................................................C-4 Main shaft ..................................................... F-11
Coils...............................................................C-6 Overhauling the transmission .........................F-5
Coolant temperature sensor ..........................C-8 Removing the transmission ............................F-4
Electrical components ...................................C-3 Transmission ..................................................F-3
Engine oil pressure sensor ............................C-4 Transmission assembly ................................F-18
Gear sensor ...................................................C-8 Transmission breakdown ................................F-8
Pick-up...........................................................C-6
Starter motor..................................................C-5

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 Analytical index

Sec. G - Starting Sec. L - Tightening torques

<   }{ ....................... G-7 Tightening torques ..........................................L-3
<   ?   ........ G-7
Starting ......................................................... G-3
Starter free wheel ......................................... G-5
Starter transfer gear ..................................... G-4 Sec. M- Service tools
Service tools ................................................. M-2

Sec. H - Cooling - Lubrication

Lubrication .....................................................H-4 Sec. N - Index analytique
< }   { ......................H-9 Analytical index workshop manual B3 ..........N-2
<   .....................................H-14
Removing the lubrication system...................H-5
<    ....................................H-4

Sec. I - Crankcase
Coupling half-bearings - crank pin ................. I-19
Coupling of piston pin-small end bush........... I-19
Crankcase ....................................................... I-3
Crankcase disassembly................................... I-4
Crankshaft timing........................................... I-35
Cylinder and piston assembly........................ I-22
Cylinder revision ............................................ I-15
Fitting the connecting rods ............................ I-28
Fitting the crankshaft ..................................... I-27
Mainshaft ....................................................... I-18
Overhauling the crankshaft and
countershaft .............................................. I-21
Overhauling the half-cases ............................ I-21
Reassembly ................................................... I-22
Reassembly the gearbox bearing .................. I-22
Reassembly the pistons oil jet ....................... I-31
N <    ?............................... I-32
< ?   ................................. I-26
Removing the big ends .................................. I-11
Removing the countershaft.............................. I-8
Removing the crankshaft ............................... I-11
Removing the gearbox bearing ..................... I-10
Removing the pistons .................................... I-13
Removing the pistons oil jet........................... I-14
Piston-cylinder coupling................................. I-16
Piston pin - connecting rod coupling.............. I-17
Piston-pin coupling ........................................ I-16
Piston pin revision ......................................... I-16
Piston revision ............................................... I-15
Piston rings .................................................... I-17
Piston ring-cylinder coupling.......................... I-17

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 MV AGUSTA S.p.A. - Technical Assistance Service
Via Giovanni Macchi, 144 - 21100 Varese (VA) ITALY
Tel. (Italy) 800.36.44.06 - (abroad) ++39 0332 254.712
Fax ++39 0332 329.379 - website “www.mvagusta.it”
Part. N. 8A00B7597 Edition No. 2