MV Agusta BRUTALE 1078 RR Repair Manual (English)

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MV AGUSTA F4 BRUTALE 750 ORO - 750 S - 910 S - 910 R - 989 R - 1078 RR

Useful Advice4
Table of Contents5
General Index5
General Description7
- General Description8
- How to Consult this Manual9
- How to Use the Manual9
- Purpose of the Manual9
- Glossary and Symbols10
- Right Hand and Left Hand Standard11
- Safety12
- Index14
- Summary of each Chapter14
- Warning14
- Operative Technical Specifications15
Motorcycle Identification15
Maintenance17
Rev17
- Maintenance18
- Technical Data19
- Technical Information19
- Technical Data20
- Components in Carbon Fibre (F4 Brutale 750 Oro)24
- Magnesium Components (F4 Brutale 750 Oro)25
- Periodical Maintenance Schedule26
- Engine Oil and Oil Filter28
- Maintenance and Tuning Operations28
- Engine Coolant38
- Engine Coolant Substitution39
- Electric Fan Brutale 750 Oro - S / 910 S - R My40
- Electric Fans Brutale 910 S - R / 989 R / 1078 Rr My 2007/0840
- Valve Mechanism Adjustment41
- Spark Plugs53
- Air Filter82
Bodywork84
- Brakes and Clutch85
  - Check Brake and Clutch Fluid Levels85
  - Substitution and Bleeding of the Brake/Clutch Fluid87
- Brake/Clutch/Gearchange Commands Check88
- Accelerator Control90
- Brake Pads Check/Substitute90
Dair Intake Injection System91
- Ignition/Steering Block Switch92
- Locks Check92
- “LOCK” Position92
- “P” Position92
- Fuel Cap Lock93
- Personal Compartment Lock93
- Steering94
- Transmission Chain94
  - Chain Lubrication96
  - Front Wheel Bearing97
  - Tyres Checks97
  - Wheels Check98
- Rear Shock Absorber99
- Rear Wheel Hub99
- Swingarm Bearings99
- Side Stand Check100
- Front Fork101
- Screws and Nuts101
- Tube Band Fasteners101
  - Assembly of the Battery Terminals102
  - Battery Maintenance102
  - Electrical System Maintenance102
  - Placement and Assembly of Terminals (Wire Terminals) on the Battery - View104
- Instruments and Warning Lights105
  - Luminous Warning Indication Lights105
  - Multi-Function Display106
  - Clock (Hours and Minutes)107
  - Modifications to the Display Functions107
  - Speedometer (K.p.h. – M.p.h.)107
  - Display Function Selection108
  - Thermometer108
  - Resetting of the Tripmeters109
  - Dipped Headlamp – Bulb Substitution110
  - Lights Check110
  - Dipped Headlight – Replacing Bulb112
  - Front Direction Indicators – Bulb Substitution112
  - Front Lights – Replacing Bulb112
  - Rear Direction Indicators – Bulb Substitution113
  - Number Plate Light – Bulb Substitution114
  - Rear Light/Stop Light – Bulb Substitution114
  - Fuses – Substitution115
- Front Headlamp117
  - Adjusting Front Headlight118
  - Bodywork120
  - Fairing Assembly Exploded View121
- Disassembling Front Headlamp122
- Disassembling Instrumental Panel123
- Disassembling Handlebar124
- Disassembling Headlight Support125
- Fuel Tank Exploded View126
- Fuel Tank Side Panel Removal127
- Fuel Tank Removal128
  - Removing of the Fuel Tank Plug131
  - Air Filter Compartment View133
- Air Filter Compartment Removal134
- Airbox Removal136
- Tail Unit Removal139
- Under-Tail Assembly Exploded View143
- Disassembling under Tale Unit144
- Air Intake Injection System148
- Injection System Technical Characteristics149
- Injection Time (Injection Volume)149
- Injection-Ignition System149
- Injection Arrest Control150
- Injection Time Compensation150
  - Ignition System Description151
  - Position of Engine-Control System Parts (Brutale 750 ORO-S-910 S-R (MY 05-06)152
  - Position of Engine-Control System Parts (Brutale 910 S-R MY 2007 - Brutale 989 R-1078 RR MY 2008)153
- Fuel Pump Control System154
  - Fuel Feed System155
  - Air Intake Injection System Components156
  - Fuel Pump156
  - Fuel Pressure Regulator157
  - Atmospheric Air Temperature/Pressure158
  - Intake Air Pressure Sensor158
- Sensors158
  - Intake Air Temperature Sensor159
  - Throttle Body Position160
- Engine Pick-Up161
- Timing Wheel Gap161
- Actuators162
  - Fuel Injector162
  - Ignition Coils162
- Diagnostics System163
- Ignition and Injection System Diagnostics163
- Injection System - Electrical Diagram164
MV Agusta Brutale Oro – S Engine Control Unit Pinout165
Eelectrical System167
- Electrical System168
- Connectors169
- Couplings169
- Fuses169
- Semiconductor Parts170
- Electrical Diagram Brutale 750 Oro-S / 910 S-R My 05/06)171
- Parts List172
- Electrical Diagram Brutale 910 S - R (My 2007) 989 R - 1078 Rr (My 2008)173
- Parts List174
- Battery Assembly175
- Initial Battery Charge175
- Battery Terminal Assembly177
- Charging System180
  - Warning Function180
  - Ignition Switch “ON” with Engine off181
  - Recharging (Voltage Less than the Regulated Voltage)182
  - Recharge (Voltage more than the Regulated Voltage)183
  - Rotor Coil Disconnected184
  - Disconnection of Terminal S of the Regulator185
  - Terminal B Disconnected186
  - A List of Possible Problems that Could Occur When the Warning Light Is Switched on187
  - Battery Current Loss Check188
- Battery Efficiency Check188
- Charge Feed Check189
- Cpu190
- Function Diagram190
  - Starter System Diagram191
  - Ignition Key in the "OFF" Position193
  - Ignition Key in the on Position / Safety Switch in the off Position194
  - Ignition Key in the on Position / Safety Switch in the RUN Position195
  - Ignition Key in the on Position / Safety Switch in the RUN Position/Start Activated/Side Stand Raised/Gear Engaged/Clutch Released/Engine Switched on196
  - Ignition Key in the on Position / Safety Switch in the RUN Position/Start Activated/Side Stand Raised/Gear Engaged/Clutch Pulled In/Engine Switched on197
  - Ignition Key in the on Position / Safety Switch on the RUN Position/Start Activated/Side Stand Lowered/Gear Engaged/Clutch Pulled In/Engine Does Not S198
  - Ignition Key in the on Position / Safety Switch on the RUN Position/Start Activated/Side Stand Lowered/Gear Not Engaged/Clutch Not Pulled In/Engine Sw199
  - Fuses Info200
- Starter Motor Removal200
- Starter Motor Assembly201
- Starter Motor Check201
- Starter Relay Check202
- Ignition/Side Stand Safety System Parts Check203
- Gearchange Position Switch204
- Side Stand Switch204
- Spark Plugs Info205
- Run off Safety Switch206
- Instrumentation208
- Fuel Level Warning Light Check Switch209
- Oil Pressure Sensor209
- Instrument Panel Water Sensor210
- Key Ignition Switch210
- Starter Relay Activation210
- Left Direction Indicator211
- Right Direction Indicator211
- RPM Indicator211
- Speed Sensor211
- Cooling Fan System212
- Horn213
- Switches214
Suspension and Wheels215
- Suspension and Wheels216
- Front Wheel Exploded View217
- Front Wheel Removal (Brutale 750 Oro - 750 S - 910 S)219
- Front Wheel Assembly (Brutale 750 Oro - 750 S - 910 S)226
- Front Fork Overhaul231
- Steering Assembly Overhaul244
- Rear Wheel Hub and Swingarm257
- Rear Wheel Removal258
- Swingarm Removal and Overhaul265
- Chain Removal (MY 2007 and Previous)270
- Chain Reassembling (MY 2007 and Previous)271
- Riveting of Pin (MY 2007 and Previous)272
- Chain Removal (MY 2008)273
- Chain Reassembling (MY 2008)274
- Wheel Balance Check292
- Front Wheel Balancing292
- Rear Wheel Balancing293
Frame295
- Frame296
- Frame Removal Preliminary Operations297
- Throttle Body Removal301
- Coil Dismantling (Brutale 910 S-R / Brutale 989 R/1078 RR MY 07-08)303
- Secondary Air System Dismantling (Brutale 910 S-R / Brutale 989 R-1078 Rr My 07-08)305
- Frame Disassembly308
- Frame Check309
- Frame Control Reference Measurements312
- Steering Head Housing Check313
- Assembly Frame to the Motorcycle314
- Rear Sub-Frame Removal318
- Rear Frame Unit Assembly320
- Engine Removal321
- Side Stand Removal321
- Gearchange Lever Removal322
- Removal of Exhaust Group (Brutale 750 Oro-S/Brutale 910 S-R MY 05/06)324
- Exhaust Group Removal (Brutale 910 S-R / Brutale 989 R / 1078 RR MY 07-08)327
Brakes335
- Brakes336
- Front Brake System337
- Front Brake Pads Substitution (Brutale 750 ORO - 750 S - 910 S)338
- Front Mudguard Removal338
- Front Brake Pads Substitution (Brutale 910 R)340
  - Front Brake Pad Replacement (Brutale 989 R)342
  - Front Brake Pad Replacement (Brutale 1078 RR)344
- Substitution and Bleeding of the Front Brake Fluid348
- Front Brake Calipers Substitution (Brutale 750 ORO - 750 S - 910 S)352
- Front Brake Calipers Substitution (Brutale 910 R - 989 R - 1078 RR MY 07-08)353
- Front Brake Pump Removal353
- Front Brake Lever Removal355
- Clutch Lever Removal356
- Front Brake Discs357
  - Front Brake Disc Removal358
  - Front Disc Assembly359
- Rear Brake System360
- Rear Brake Pads Substitution361
- Rear Brake Pads363
- Substitution and Bleeding of the Rear Brake Fluid364
- Rear Brake Caliper Substitution366
- Rear Brake Pump Removal367
- Rear Brake Disc368
- Rear Brake Disc Removal369
Cooling System and Lubrication System371
- Cooling System and Lubrication System372
- Complete Cooling System Assembly and Lubrication System Diagrams373
- Cooling System Leakage Check374
- Expansion Tank Cap Check374
- Engine Coolant Extraction375
- Expansion Tank Removal375
- Disassembling Water Radiator378
- Cooling Fan Dismantling (Brutale 750 Oro - S / 910 S-R My 05/06)382
- Cooling Fan Dismantling (Brutale 910 S-R / 989 R / 1078 Rr My 07/08)383
- Checking Cooling Fan Starter385
- Cooling Fan Reassembly (Brutale 750 Oro- S / 910 S-R My 05/06)385
- Cooling Fan Reassembly (Brutale 910 S-R / 989 R / 1078 Rr My 07/08)385
- Removing Thermostat Valve390
  - Checking Thermostat Valve391
  - Reassembing Thermostat Valve392
- Reassembling Expansion Tank395
- Assembling Water Radiator397
- Removing Oil Radiator403
- Reassembling Oil Radiator408
Special Tools415
Special Tools416
Torque Pressures427
- Torque Pressures428
- MV Augusta Brutale 750 S Motorcycle Frame Torque Pressures430
- MV Agusta Brutale 910 S (MY 05/06) Motorcycle Frame Torque Pressures432
- MV Agusta Brutale 910 R (MY 2006) Motorcycle Frame Torque Pressures434
- MV Agusta Brutale 910 S MY 07 Motorcycle Frame Torque Pressures436
- MV Agusta Brutale 910 R MY 07 Motorcycle Frame Torque Pressures438
- MV Agusta Brutale 989 R MY 08 Motorcycle Frame Torque Pressures440
- MV Agusta Brutale 1078 RR MY 08 Motorcycle Frame Torque Pressures442
Diagnostics445
- Diagnostics446
- Electrical Parts Diagnostics446
- Frame Diagnostics448
Analytical Index451
Analytical Index452

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MV Agusta BRUTALE 1078 RR Specifications

General

Displacement	1078 cc
Transmission	6-speed
Engine Type	4-cylinder, 4-stroke
Torque	117 Nm
Frame	Tubular steel trellis
Front Suspension	Marzocchi upside-down telescopic hydraulic fork
Rear Suspension	Progressive Sachs, single shock absorber
Front Brakes	Dual 320 mm discs
Rear Brakes	Single steel disc
Fuel Capacity	16.5 liters