MV Agusta BRUTALE 750 S, Brutale 750 Oro, Brutale 910 S, Brutale 1078 RR, Brutale 989 R, Brutale 910 R Workshop Manual

MV AGUSTA F4 BRUTALE 750 ORO - 750 S - 910 S - 910 R - 989 R - 1078 RR
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© 2008
The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta Motor S.p.A.
Part No. 8A0099360 - Edition No. 5

Printed – December 2008

Manuale di officina
Motorcycle Workshop mototelaio
Manual
MVAGUSTA BRUTALE 750 ORO - 750 S - 910 S - 910 R - 989 R - 1078 RR

Statement
This manual, to be used by the MV Agusta authorised workshops has been realised with the
purpose of assisting authorised personnel in maintenance and repairs operations of the
motorcycle. The knowledge of technical data herein noted, determines the complete profes-
sional training of the technician.
With purpose of making the reading of this manual immediately comprehensible, the para-
graphs have been aligned with detailed illustrations that highlight the argument dealt with.
Useful advice
To prevent any problems and to reach an excellent final result, MV Agusta recommends
keeping to the following guidelines:
- In the case of an eventual repair, evaluate the client’s impressions who states that there
is an abnormal functioning of the motorcycle and to formulate the right questions to
clarify the symptoms of the problem.
- Clearly diagnose the cause of the abnormality. The basic fundamental theories can be
absorbed by reading this manual that must necessarily be integrated to the personal
experience and the participation of training courses that are periodically organised by
MV Agusta.
- Rationally plan the repair to avoid slack periods, e.g. the collection of spare parts, the
preparation of tools and equipment, etc.
- To reach the part to be repaired limiting the work to the essential operations.
With regards to this, a valid help would be to consult this manual with regards to the
sequences of removal demonstrated in this manual.
Informative note
MV Agusta S.p.A. is committed to a policy of continuous improvement of their products. For
this reason, there could be slight differences between that which is written here and the
motorcycle on which repairs and/or maintenance are about to be carried out. MV Agusta
models are exported to many countries where different norms in relation to the highway
code and homologation procedures are valid. Hoping that you will comprehend these prob-
lems, MV Agusta S.p.A. reserves the right to make modifications to its products and tech-
nical documentation at any moment and without prior announcement.
Respect and defend the environment

Everything that we do has repercussions on the entire planet and its resources.
MV Agusta, wanting to protect the interest of the people, would like to make the client and
the technicians of the technical assistance centres aware and to adopt modalities of use of
the motorcycle and the disposure of its parts in full respect of the norms in force in terms of
environmental pollution, disposal and the recycling of waste.
-2-
Freni
General Index
GENERAL DESCRIPTION ........................................................................................ A

Rev. 0
MAINTENANCE ........................................................................................................ B
Rev. 4
BODYWORK ............................................................................................................ C
Rev. 2
AIR INTAKE INJECTION SYSTEM .......................................................................... D

Rev. 2
ELECTRICAL SYSTEM ............................................................................................ E

Rev. 3
F
SUSPENSION AND WHEELS .................................................................................. Rev. 4
G
FRAME ...................................................................................................................... Rev. 3
H
BRAKES .................................................................................................................... Rev. 3
L
COOLING SYSTEM AND LUBRICATION SYSTEM................................................ Rev. 4
M
SPECIAL TOOLS ...................................................................................................... Rev. 4
N
TORQUE PRESSURES ............................................................................................ Rev. 4
O
DIAGNOSTICS .......................................................................................................... Rev. 0
P
Rev. 4
ANALYTICAL INDEX ................................................................................................
-3-
General description
SECTION
Revision 0
A
-1-
General description
A SUMMARY
HOW TO CONSULT THIS MANUAL .........................................................................................................PAGE 3

PURPOSE OF THE MANUAL ....................................................................................................................PAGE 3
GLOSSARY AND SYMBOLS .....................................................................................................................PAGE 4
RIGHT HAND AND LEFT HAND STANDARD ..........................................................................................PAGE 5
SAFETY .....................................................................................................................................................PAGE 6
WARNING ..................................................................................................................................................PAGE 8
INDEX..........................................................................................................................................................PAGE 8
OPERATIVE TECHNICAL SPECIFICATIONS ...........................................................................................PAGE 9
-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
Steering pin tightening 10°
Screw in the steering pin flange ring, without tighte-
ning.
This operation must be done manually. 2
Check that the steering base is at the end of its travel,
to the right.
Using the special tool tighten the ring (1) by rotating it
10° calculated approximately as one third of the
movement between the two holes of the ring (2) of the
steering head (see the figure).
Specific tool N. 800091645 30° 1
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

This signifies that the lack of
ATTENTION
or the incomplete observan-
ce of this advice can be gra- Use the recommended suspension fluid.
vely dangerous for your
safety and for the safety of
other persons.
This signifies that the lack of Use the recommended coolant.

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

the correct carrying out of the operation Use the recommended sealant.
described.
Tighten to the specified torque. Use the recommended adhesive.
Tolerance or limit of use. Carry out accurate cleaning.
Utilise the tester. Use new components.
Use the recommended oil. Substitute the component.
Use the recommended grease. Do not leave litter about.
The information marked with this symbol

Use the recommended brake fluid ★ refer to the F4 Brutale model series ORO.
-4-
General description
RIGHT HAND AND LEFT HAND STANDARD A

In order to specify the right/left convention used within the chapters of this manual, see the following motorcycle
and engine scheme where all sides which refer to are reported.
Cylinder 3 Cylinder 2
Cilindro 3 Cilindro 2
Cylinder 4 Cylinder
Cilindro 4 Cilindro 11
Right
Latoside
DX
Lato side
Left SX
Left
Latoside
SX Lato DX
Right side
-5-
General description
A SAFETY
The information contained in this paragraph is fundamental so that the operations carried
ATTENTION
out on the motorcycle can be conducted with minimum risk to the mechanic.
Carbon Monoxide
• Exhaust gases contain carbon monoxide (CO) that is poisonous. Carbon monoxide can cause the loss of consciou-
sness and death.
• If it is necessary to switch on the engine, check that the environment is well ventilated. Never switch on the engine
in an enclosed environment.
• Switching on the engine can only be carried out in an enclosed environment when there are the appropriate devices
for the evacuation of exhaust gases.
Petrol
• Petrol is extremely inflammable and under certain conditions can be explosive.
• Keep sources of heat, sparks and flames away from the work area.
• Always work in a well-ventilated area.
• Never use petrol as a cleaning solvent. Generally, avoid handling it unless it is absolutely necessary.
• Do not use petrol for cleaning components by using compressed air.
• Keep petrol out of reach of children.
Engine oil
• Engine oil can cause skin illnesses if in constant and long contact with the skin.
• If the skin comes into contact with engine oil, wash the parts affected as soon as possible with soap and water.
• If engine oil comes into contact with the eyes, abundantly rinse with water and consult a doctor immediately.
• If engine oil is swallowed, do not provocate vomiting to avoid the aspiration of the product into the lungs. Transport
the injured person immediately to hospital.
• Used oil contains dangerous substances and poisonous for the environment. To substitute oil, it is recommended to
go to an authorised MV Agusta dealer who is equipped to deal with the collection of used oil in respect of the norms
in force.
• Do not dispose of used oil in the environment.
• Keep used oil out of the reach of children.
Engine coolant
• Under certain situations, the ethylene glycol contained in the engine coolant is inflammable and its flame is invisible.
Ethylene glycol would cause serious burns if ignited because it is invisible.
• Avoid bringing the engine coolant into contact with hot parts. Such parts could be sufficiently hot to ignite the coo-
lant.
• The engine coolant (ethylene glycol) can cause irritation of the skin and is poisonous if swallowed.
• If the engine coolant comes into contact with the skin, immediately remove any contaminated clothing and wash with
soap and water. If it comes into contact with the eyes, abundantly rinse with clean water and immediately consult a
doctor. If swallowed, do not provocate vomiting to avoid the aspiration of the product into the lungs. Administer clean
water and transport the injured person immediately to hospital and show the product to the doctor.
• If exposed to high concentrations of vapour, transport the injured person to a non-poisonous atmosphere and if
necessary call a doctor.
• Do not remove the radiator cap when the engine is still hot. Being under pressure, the engine coolant can be vio-
lently ejected and therefore provocate burns.
• The engine coolant contains dangerous and poisonous substances and is therefore dangerous for the environment.
To substitute used engine coolant, it is advisable to go to the authorised MV Agusta dealer who is equipped to deal
with the collection of used engine coolant in respect of the norms in force.
• Do not dispose of engine coolant in the environment.
• Keep engine coolant out of reach of children.
-6-
General description
Brake fluid A
• Brake fluid is extremely corrosive.
• Avoid any contacts with the eyes, skin and the mucous membrane.
• If brake liquid comes into contact with the skin, remove all contaminated clothing and wash immediately with soap
and water.
• If brake fluid comes into contact with the eyes, abundantly rinse with water and call a doctor.
• If swallowed, do not provocate vomiting to avoid aspiration of the product into the lungs. Immediately call a doctor.
• Take the injured person immediately to hospital, if he has breathed brake fluid into the lungs.
• In the case of exposure to high concentrations of vapour, move the injured person to a non-poisonous atmosphere
and if necessary call a doctor.
• In the case of accidental contact, rinse abundantly with water and call a doctor.
• Keep brake fluid out of reach of children.
Thread-locking fluid
• As it is not classified as dangerous, the prolonged contact with the skin, particularly with regards to abrasions can
provocate sensitiveness and dermatitis. In the case of contact with the skin, rinse abundantly with running water.
• Move the injured person into the open air and call a doctor if the injured person feels ill after having breathed in the
product.
• In the case of contact with the eyes, rinse abundantly with water for at least 15 minutes.
• If the thread-locking fluid has been swallowed, drink an abundant quantity of water or milk. Do not provocate vomi-
ting to avoid the aspiration of the product into the lungs. Immediately call a doctor.
• Keep out of reach of children.
Nitrogen - rear shock absorber

• The rear shock absorber contains nitrogen under pressure.
• Before disposing of used shock absorbers, discharge the nitrogen via the depressurising valve.
• Utilise only nitrogen to pressurise the shock absorber. The use of unstable gases can cause explosions that could
cause burns.
• Do not place the shock absorber near to flames or sources of heat as this could cause explosions with consequent
burns.
Battery
• The battery produces explosive gases. Keep it away from sparks, flames or cigarettes. During recharging, adequa-
tely ventilate the environment.
• The battery contains a solution of sulphuric acid (electrolyte).
• Sulphuric acid is corrosive and it destroys many materials and clothing. On contact with small quantities of water it
generates a violent reaction that manifests itself by creating large quantity of heat and spurts of hot acid. Sulphuric
acid attacks many metals thereby liberating hydrogen: an inflammable gas that forms an explosive mixture when
mixed with air.
• Contact with sulphuric acid can cause burns. In the case of contact, remove immediately all contaminated clothing
and wash the skin with abundant quantities of water. Take the injured person to hospital if necessary.
• In the case of contact with the eyes, rinse immediately with abundant water. Call a doctor and continue with the treat-
ment until the doctor arrives.
• If the electrolyte is swallowed, rinse the mouth with water without swallowing. Take the injured person immediately
to hospital and explain to the doctor there what the injured person has swallowed.
• The battery contains dangerous substances that are poisonous for the environment. It is advisable to substitute it at
an MV Agusta dealer that is equipped to dispose of this product in respect of the norms in force.
• Do not dispose of used batteries in the environment.
Hot parts
• The engine and the exhaust system become very hot and maintain this temperature for some time after the engine
has been switched off. Wait for these parts to cool down before handling them or working on the motorcycle near to
them. Use protective gloves.
-7-
General description
A WARNING
The information contained in this
WARNING paragraph is important so that the
operations carried out on the
motorcycle can be conducted without damaging the motorcy-
cle.
• Thoroughly clean the motorcycle before disassembling it.

• During disassembly, clean all parts and place them in con-
tainers respecting exactly the order of disassembly.
• Always use the special utensils where necessary and
each time where prescribed.
• Always use adhesives, sealants and lubricants where pre-
scribed. Respect the instructions about their technical
characteristics.
• Always substitute parts such as gaskets, O-rings, security
washers with new parts.
• Loosening and tightening nuts or screws, always start
from the bigger ones or the centre. Always comply with the
torque wrench settings.
• Utilise only MV Agusta spare parts.
INDEX
GENERAL INDEX SUMMARY OF EACH CHAPTER
-8-
General description
OPERATIVE TECHNICAL SPECIFICATIONS A
MOTORCYCLE IDENTIFICATION
1) Frame registration number
2) Engine registration number
3) Homologation date
4) "Limited series" number ★
The registration number of the motorcycle is stamped on the right side of the steering head.
The engine part number is stamped on the top half casing near the fork.
4)
4)“Limited
numero series” number ★
"serie limitata" 1) numero
1) Frame registration
di matricolanumber
telaio
3)
3) Homologation date
dati di omologazione
2) numero
2) Engine registration
di matricola number
motore
★ Only for the F4 BRUTALE series ORO: the pre-

sence of the nameplate indicates that the motorcy-
cle has been constructed on a limited series basis.
Each example is identified by a progressive num-
ber stamped on a nameplate in 24 carat gold.
Below is an example of the designation of the frame registration number:
ZCG F4 01 AA Y V 000000
Manufacturer identification
Vehicle model
Progressive frame number
-9-
General description
- 10 -
Maintenance
SECTION
Revision 4
B
-1-
Maintenance
SUMMARY
TECHNICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3
B COMPONENTS IN CARBON FIBRE (F4 BRUTALE 750 ORO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 8
MAGNESIUM COMPONENTS (F4 BRUTALE 750 ORO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 9
PERIODICAL MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 10
MAINTENANCE AND TUNING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 12
ENGINE OIL AND OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 12
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 22
ELECTRIC FAN BRUTALE 750 ORO - S / 910 S - R MY 05/06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 24
ELECTRIC FANS BRUTALE 910 S - R / 989 R / 1078 RR MY 2007/08 . . . . . . . . . . . . . . . . . . . . . . . .PAGE 24
VALVE MECHANISM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 25
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 37
FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 38
FUEL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 48
FUEL UNION TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 51
ASSEMBLY OF FUEL TUBES (BRUTALE 750 S - 750 ORO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 51
ASSEMBLY OF FUEL TUBES (BRUTALE 910 S - 910 R - 989 R - 1078 RR . . . . . . . . . . . . . . . . . . . .PAGE 54
THROTTLE BODY ADJUSTMENT AND TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 56
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 66
BRAKES AND CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 69
BRAKE/CLUTCH/GEARCHANGE COMMANDS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 72
BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 74
ACCELERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 74
LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 76
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 78
TRANSMISSION CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 78
TYRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 81
FRONT WHEEL BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 81
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 82
REAR WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 83
SWINGARM BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 83
REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 83
SIDE STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 84
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 85
SCREWS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 85
TUBE BAND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 85
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 86
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 86
INSTRUMENTS AND WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 89
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 94
FRONT HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 101
-2-
Maintenance
TECHNICAL INFORMATION
2020 760
805
135
1410
TECHNICAL DATA
Description BRUTALE 750 ORO BRUTALE 750 S BRUTALE 910 S BRUTALE 910 R BRUTALE 989 R BRUTALE 1078 RR
CHARACTERISTICS
Wheelbase (mm) (*) 1410 1410 1410 1410 1410 1410
Total length (mm) (*) 2020 2020 2020 2020 2020 2020
Maximum width (mm) 760 760 760 760 760 760
Seat height (mm) (*) 805 805 805 805 805 805
Ground clearance (mm) (*) 135 135 135 135 135 135
Trail (mm) (*) 101.5 101.5 101.5 101.5 101,5 101,5
Dry weight (kg) 179 185 185 185 185 185
Fuel tank capacity (lt) (**) 19 19 19 19 19 19
Fuel reserve (lt) (**) 4 4 4 4 4 4
Sump oil quantity (kg) 3.5 3.5 3.5 3.5 3,5 3,5
ENGINE
Type 4 Stroke four cylinder, 16 valves
Bore (mm) 73.8 73.8 76.0 76.0 79,0 79,0
Stroke (mm) 43.8 43.8 50.1 50.1 50,1 55
Displacement (cm3) 749.4 749.4 909.1 909.1 982,3 1078,37
Compression ratio 12 : 1 12 : 1 13 : 1 13 : 1 12,2 : 1 13 : 1
Starter system Electrical
Cooling Cooling with separate liquid and oil radiators
Engine casing and covers Die-cast
Cylinder head and cylinders Chill-cast
Valves Bi-metal / mono-metal
* : The data declared are not binding. They are susceptible to variations due to riding conditions.
** : The data declared are not binding. They are susceptible to variations due to external temperature, engine temperature and the evaporation point of the petrol used.
-3-
Maintenance
TECHNICAL DATA
Description BRUTALE 750 ORO BRUTALE 750 S BRUTALE 910 S BRUTALE 910 R
TIMING
Type D.O.H.C. radial valves
LUBRICATION
Type Wet sump
B IGNITION – FUEL FEED SYSTEM
Type “Weber-Marelli” integrated ignition-injection system 1.6 M. “Weber-Marelli” integrated ignition-injection system 1.6 M (MY05/06) or 5 SM (MY07).
Electronic inductive discharge ignition, “Multipoint”. Electronic inductive discharge ignition, “Multipoint”.
Spark plugs (alternatively) NGK CR9 EB Champion G59c NGK CR9 EB Champion G59c NGK CR9 EB NGK CR9 EB
Spark gap (mm) 0.7 ÷ 0.8 0.6 ÷ 0.7 0.7 ÷ 0.8 0.6 ÷ 0.7 0.7 ÷ 0.8 0.7 ÷ 0.8
CLUTCH
Type Wet multi-plate
PRIMARY TRANSMISSION
N° teeth - engine crankshaft gear Z = 47 Z = 47 Z = 50 Z = 50
N° teeth - clutch gear Z = 81 Z = 81 Z = 79 Z = 79
Transmission ratio 1.72 1.72 1.58 1.58
SECONDARY TRANSMISSION
N° teeth – pinion wheel Z = 14 Z = 14 Z = 15 Z = 15
N° teeth – crown wheel Z = 41 Z = 41 Z = 43 Z = 43
Transmission ratio 2.93 2.93 2.87 2.87
GEAR CHANGE
Type Extractable six speed, with gearing always inserted
Gear ratios (total ratios)
1st 2.92 (14.71) 2.92 (14.71) 2.92 (13.23) 2.92 (13.23)
2nd 2.21 (11.14) 2.21 (11.14) 2.12 (9.64) 2.12 (9.64)
3rd 1.78 (8.97) 1.78 (8.97) 1.78 (8.06) 1.78 (8.06)
4th 1.50 (7.56) 1.50 (7.56) 1.50 (6.79) 1.50 (6.79)
5th 1.32 (6.65) 1.32 (6.65) 1.32 (5.98) 1.32 (5.98)
6th 1.21 (6.10) 1.21 (6.10) 1.21 (5.48) 1.21 (5.48)
FRAME
Type Tubular framework in wire-drawn steel tubes 25 CrMo (TIG welding)
Swingarm fulcrum plates Magnesium alloy Aluminium alloy Aluminium alloy Aluminium alloy
FRONT SUSPENSION
Hydraulic telescopic forks with the stems positioned upside down, equipped with
Type
a system of external adjustment for extension, compression and spring preload
Ø stems (mm) 50 with Titanium Nitride 50 50 50 with carbonitriding
Telescopic movement (mm) 135 135 (MY 03) / 133 (MY 04) 133 129
REAR SUSPENSION
Progressive, single-steering damper adjustable in extension, in compression
Type
(high/low speed), and in spring-preloading
Swingarm Magnesium alloy Aluminium alloy Aluminium alloy Aluminium alloy
Wheel travel (mm) 120 120 120 120
FRONT BRAKE
Type Floating double disk with the braking area in steel
Ø Discs (mm) 310 310 310 320
Disc flanges Aluminium Steel Steel Aluminium
Calipers (Ø pistons mm) 6 pistons (Ø 22.65; Ø 25.4; Ø 30.23) 4 pistons (Ø 34 )
REAR BRAKE
Type Disc type in steel
Ø Discs (mm) 210 210 210 210
Caliper (Ø pistons mm) 4 pistons (Ø 25.4)
FRONT WHEEL
Material Magnesium alloy Aluminium alloy Aluminium alloy Forged aluminium alloy
Dimensions 3.50” x 17” 3.50” x 17” 3.50” x 17” 3.50” x 17”
REAR WHEEL
Dimensions 6.00” x 17” 6.00” x 17” 6.00” x 17” 6.00” x 17”
TYRES
Front 120/65-ZR 17 (56 W) or 120/65-ZR 17 (56 W) or
120/70-ZR 17 (58 W)
120/70-ZR 17 (56 W-58W) (**) 120/70-ZR 17 (56 W-58W) (**)
Rear 190/50-ZR 17 (73 W) 190/50-ZR 17 (73 W)
190/55-ZR 17 (75 W)
o 180/55-ZR 17 (73 W) o 190/55-ZR 17 (75 W)
Brand and type PIRELLI - Dragon Evo MTR 21 Corsa (Front)
PIRELLI - Dragon Supercorsa Pro
PIRELLI -Dragon Evo MTR 22 Corsa (Rear)
MICHELIN - Pilot Power
MICHELIN - Pilot Sport / Pilot Power PIRELLI - Dragon Supercorsa Pro
DUNLOP - Sport Max D 208
DUNLOP - Sport Max D 207 Race Replica
Race Replica (**)
DUNLOP - Sport Max D 208 Race Replica (**)
Tyre pressures (*)
Front 2.3 bar (33 psi) 2.3 bar (33 psi) 2.3 bar (33 psi)
Rear 2.3 bar (33 psi) 2.3 bar (33 psi) 2.3 bar (33 psi)
* : In the event of different make tyres being used as opposed to those advised, refer to the pressure values marked on the side of the tyre by the manufacturer.
** : Check that the dimensions of the 120/70 front tyre correspond to the dimensions in the motorcycle’s registration booklet. If a 120/70 tyre is used, move the clamp of the front
mudguard next to the upper holes located on the feet of the front suspension’s fork.
-4-
Maintenance
TECHNICAL DATA
Description BRUTALE 989 R BRUTALE 1078 RR
TIMING
Type D.O.H.C. radial valves D.O.H.C. radial valves
LUBRICATION
Type Wet sump Wet sump
IGNITION – FUEL FEED SYSTEM
Type “Weber-Marelli” integrated ignition-injection system 1.6 M.
B
Electronic inductive discharge ignition, “Multipoint”.
Spark plugs (alternatively) NGK CR9 EB NGK CR9 EB
Spark gap (mm) 0.7 ÷ 0.8 0.7 ÷ 0.8
CLUTCH
Type Wet multi-plate Oil bath multi-disc with mechanical antiskipping device
PRIMARY TRANSMISSION
N° teeth - engine crankshaft gear Z = 50 Z = 50
N° teeth - clutch gear Z = 79 Z = 79
Transmission ratio 1.58 1.58
SECONDARY TRANSMISSION
N° teeth – pinion wheel Z = 15 Z = 15
N° teeth – crown wheel Z = 41 Z = 41
Transmission ratio 2.73 2.73
GEAR CHANGE
Type Extractable six speed, with gearing always inserted
Gear ratios (total ratios)
1st 2.92 (12.59) 2.92 (12.59)
2nd 2.12 (9.14) 2.12 (9.14)
3rd 1.78 (7.68) 1.78 (7.68)
4th 1.50 (6.47) 1.50 (6.47)
5th 1.32 (5.69) 1.32 (5.69)
6th 1.21 (5.22) 1.21 (5.22)
FRAME
Type Tubular framework in wire-drawn steel tubes 25 CrMo (TIG welding)
Swingarm fulcrum plates Aluminium alloy Aluminium alloy
FRONT SUSPENSION
Hydraulic telescopic forks with the stems positioned upside down, equipped with
Type
a system of external adjustment for extension, compression and spring preload
Ø stems (mm) 50 50
Telescopic movement (mm) 130 130
REAR SUSPENSION
Progressive, single-steering damper adjustable in extension, in compression
Type
(high/low speed), and in spring-preloading
Swingarm Aluminium alloy Aluminium alloy
Wheel travel (mm) 120 120
FRONT BRAKE
Type Floating double disk with the braking area in steel
Ø Discs (mm) 310 320
Disc flanges Steel Aluminium
Calipers (Ø pistons mm) Radial with 4 pistons (Ø 32) Monobloc radial with 4 pistons (Ø 34)
REAR BRAKE
Type Disc type in steel Disc type in steel
Ø Discs (mm) 210 210
Caliper (Ø pistons mm) 4 pistons ( Ø 25.4 ) 4 pistons ( Ø 25.4 )
FRONT WHEEL
Material Aluminium alloy Aluminium alloy
Dimensions 3.50” x 17” 3.50” x 17”
REAR WHEEL
Dimensions 6.00” x 17” 6.00” x 17”
TYRES
Front 120/70-ZR 17 (58 W) 120/70-ZR 17 (58 W)
Rear 190/55-ZR 17 (75 W) 190/55-ZR 17 (75 W)
Brand and type PIRELLI - Diablo Corsa III PIRELLI - Dragon Supercorsa Pro
DUNLOP - Sport Max Qualifier DUNLOP - Sport Max Qualifier RR
Tyre pressures (*)
Front 2.3 bar (33 psi) 2.3 bar (33 psi)
Rear 2.3 bar (33 psi) 2.3 bar (33 psi)
* : In the event of different make tyres being used as opposed to those advised, refer to the pressure values marked on the side of the tyre by the manufacturer.
** : Check that the dimensions of the 120/70 front tyre correspond to the dimensions in the motorcycle’s registration booklet. If a 120/70 tyre is used, move the clamp of the front
mudguard next to the upper holes located on the feet of the front suspension’s fork.
-5-
Maintenance
TECHNICAL DATA
Description BRUTALE 750 ORO BRUTALE 750 S BRUTALE 910 S BRUTALE 910 S
ELECTRICAL SYSTEM
Voltage 12V 12V 12V 12V
Front dipped beam light bulb 12V 55W 12V 55W 12V 55W 12V 55W
B Front main beam light bulb 12V 60W 12V 60W 12V 60W 12V 60W
Front sidelight bulb 12V 5W 12V 5W 12V 5W 12V 5W
Rear light bulb 12V 5W 12V 5W 12V 5W 12V 5W
Rear stop light bulb 12V 21W 12V 21W 12V 21W 12V 21W
Direction indicators 12V 10W 12V 10W 12V 10W 12V 10W
Battery 12V - 9Ah 12V - 9Ah 12V - 9Ah 12V - 9Ah
Alternator 650W at 5000 r.p.m. 650W at 5000 r.p.m. 650W at 5000 r.p.m. 650W at 5000 r.p.m.
BODYWORK
Tank Thermo-plastic material Thermo-plastic material Thermo-plastic material Thermo-plastic material
Air filter compartment conveyors Carbon fibre Thermo-plastic material Thermo-plastic material Thermo-plastic material
Tank side panel Carbon fibre Thermo-plastic material Thermo-plastic material Thermo-plastic material
Tail unit rear side panel Carbon fibre Thermo-plastic material Thermo-plastic material Thermo-plastic material
Tail unit Carbon fibre Thermo-plastic material Thermo-plastic material Thermo-plastic material
Instrumentation protection Carbon fibre Thermo-plastic material Thermo-plastic material Thermo-plastic material
Ignition switch cover Carbon fibre Thermo-plastic material Thermo-plastic material Thermo-plastic material
Front mudguard Carbon fibre Thermo-plastic material Thermo-plastic material Thermo-plastic material
Chain guards Carbon fibre Thermo-plastic material Thermo-plastic material Thermo-plastic material
Oil cooler protection Carbon fibre Thermo-plastic material Thermo-plastic material Thermo-plastic material
Number plate carrier Thermo-plastic material Thermo-plastic material Thermo-plastic material Thermo-plastic material
Rear-view mirrors Thermo-plastic material Thermo-plastic material Thermo-plastic material Thermo-plastic material
Exhaust pipes guard Aluminium Aluminium Aluminium Aluminium
-6-
Maintenance
TECHNICAL DATA
ELECTRICAL SYSTEM
Voltage 12V 12V
Front dipped beam light bulb 12V 55W 12V 55W
Front main beam light bulb 12V 60W 12V 60W B
Front sidelight bulb 12V 5W 12V 5W
Rear light bulb 12V 5W 12V 5W
Rear stop light bulb 12V 21W 12V 21W
Direction indicators 12V 10W 12V 10W
Battery 12V - 9Ah 12V - 9Ah
Alternator 650W at 5000 r.p.m. 650W at 5000 r.p.m.
BODYWORK
Tank Thermo-plastic material Thermo-plastic material
Air filter compartment conveyors Thermo-plastic material Thermo-plastic material
Tank side panel Thermo-plastic material Thermo-plastic material
Tail unit rear side panel Thermo-plastic material Thermo-plastic material
Tail unit Thermo-plastic material Thermo-plastic material
Instrumentation protection Thermo-plastic material Thermo-plastic material
Ignition switch cover Thermo-plastic material Thermo-plastic material
Front mudguard Thermo-plastic material Thermo-plastic material
Chain guards Thermo-plastic material Thermo-plastic material
Oil cooler protection Thermo-plastic material Thermo-plastic material
Number plate carrier Thermo-plastic material Thermo-plastic material
Rear-view mirrors Thermo-plastic material Thermo-plastic material
Exhaust pipes guard Aluminium Aluminium
-7-
Maintenance
★ COMPONENTS IN CARBON FIBRE (F4 BRUTALE 750 ORO)

1 - Right air filter compartment side panel 8 - Ignition switch cover
2 - Left air filter compartment side panel 9 - Tail unit
B 3 - Right tank side panel 10 - Front mudguard
4 - Left tank side panel 11 - Top chain protection
5 - Right cylinder cover 12 - Lower chain protection
6 - Left cylinder cover 13 - Oil cooler protection
7 - Instrument panel protection
-8-
Maintenance
★ MAGNESIUM COMPONENTS (F4 BRUTALE 750 ORO)

1 - Steering base
2 - Frame side plates
3 - Front wheel rim
4 - Rear wheel rim
B
5 - Swingarm
2 5
1
2 3
-9-
Manutenzione
Maintenance
PERIODICAL MAINTENANCE SCHEDULE

The following table shows the recommended intervals for the interventions of periodical maintenance. Periodical main-
tenance is necessary to keep the motorcycle in an optimum condition. The intervals are expressed in kilometres.
For motorcycles used in particularly severe conditions, maintenance operations must be
B WARNING
carried out more frequently.
We respect and defend the environment.
Everything that we do has repercussions on the whole planet and on its resources.
MV Agusta, to protect the interests of the everyone, ask clients and technical assistance operators to use
the motorcycle and dispose of its used parts with respect to the norms in force in terms of environmental
pollution, disposal and recycling of refuse.
★ The information marked with this symbol refers only to the F4 BRUTALE 750 ORO model.
■ The information marked with this symbol refers only to the B4 750 ORO - 750 S - 910 S - 910 R
(MY 05-06) models.
Programmed maintenance schedule
0 1000 6000 12000 18000 24000 30000 36000
Km (mi) covered (600) (3800) (7500) (11200) (14900) (18600) (22400)
Service Pre- A B C D E F G
delivery
Description Operation
● ● ● ● ● ● ●
Engine oil Substitution
At least once a year
Substitution ● ● ● ● ● ● ●
Engine oil filter (Utilise only original
MV Agusta oil filters) At every substitution of engine oil
Check level and top-up ● ● ● ● ● ● ● ●

Engine coolant
Substitution At least every two years
Cooling system Check for leakages ● ● ● ● ● ● ● ●
Electric fan Check functioning ● ● ● ● ● ● ● ●
Valves Check / adjustment ■ ● ● ●
Check ■ ● ●
Timing chain
Substitution ●
Check / Substitution ■ ● ●
Timing chain tensioner ●

Substitution
At least every substitution of the timing chain
Timing chain tensioner Check / Substitution ● ● ●
Check / Substitution ■ ● ● ●
Spark plugs
Substitution ● ● ●
Fuel filter Check / Substitution ● ● ●
Throttle body Check and adjust ● ● ● ● ● ● ●
Air filter Check / Substitution ● ● ● ● ● ●
Check level ● ● ● ● ● ● ●
Brakes / Clutch fluid ●

Substitution
At least every two years
Check functioning ● ● ● ● ● ● ● ●
Brakes and clutch Check circuit ● ● ● ● ● ● ● ●

Cleaning of contact lever / ● ● ● ● ● ● ● ●
pump piston area
Brake pads Check / Substitution ● ● ● ● ● ● ●
( front and rear )
Check for defects and ● ● ● ● ● ● ●
leakages
Fuel tubes
Substitution At least every three years
Check functioning ● ● ● ● ● ● ● ●
Throttle control
Check/adjust play ● ● ● ● ● ● ● ●
Starter control Check functioning ● ● ● ● ● ● ● ●
- 10 -
Maintenance

0 1000 6000 12000 18000 24000 30000 36000
Km (mi) covered (600) (3800) (7500) (11200) (14900) (18600) (22400)
delivery
Description Operation
Transmission and flexible controls Check / Adjust ● ● ● ● ● ● ● ●
Check / Adjust ● ● ● ● ● ● ● ●
B
Transmission chain Lubricate ● ● ● ●
Substitution ★ ★● ★ ★● ★ ★●
Check ● ● ● ●
Front sprocket / stop washer ★ ★● ★ ★● ★ ★●

Substitution
At least at each substitution of the transmission chain
Check ● ● ● ●
Rear sprocket ★ ★● ★ ★● ★ ★●
Substitution
At least at each substitution of the transmission chain
Rear sprocket spring drive Check ★ ★● ★ ★● ★ ★●

Steering head flange ring Check / Adjust ● ● ● ●
Check / Adjust ● ● ● ●
Steering bearings
Lubricate ●
Check for pressure ● ● ● ● ● ● ● ●

Tyres
Check for wear ● ● ● ● ● ● ●
● ● ● ● ● ● ●
Wheel rims Visual check
Every tyre substitution
● ● ● ● ●
Check
Front wheel bearings
Every tyre substitution
Substitution ●
Visual check for knocks ★ ★ ★ ★ ★ ★ ★

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

stand switch Cleaning of contact lever
● ● ● ● ● ● ● ●
area with side stand
Check / lubricate roller bear-
ings and guides ● ●
Rear wheel hub
Substitution /lubrings
icate roller bear-
and guide ●
Rear fork bearings Check / lubricate ●
Rear fork chain guide Check / substitution ● ● ● ● ● ● ●
Chain guide frame plate Check / substitution ● ● ● ● ● ● ●
Rear shock absorber Check / Adjust ● ● ● ●
Front fork oil Substitution ●
Battery connections Check and clean ● ● ● ● ● ● ●
Electrical system Check functioning ● ● ● ● ● ● ● ●
Instrument Check functioning ● ● ● ● ● ● ● ●
Check functioning
Lights/visual signals ● ● ● ● ● ● ● ●
Bulb replacement
Horn Check functioning ● ● ● ● ● ● ● ●
Check functioning
● ● ● ● ● ● ● ●
Front headlight Bulb replacement
Adjust At every variation of the riding set-up of the motorcycle
Ignition switch Check functioning ● ● ● ● ● ● ● ●
Locks Check functioning ● ● ● ● ● ● ● ●
Torque settings – nuts and bolt Check / tightness ● ● ● ● ● ● ● ●
Tube band fasteners Check / tightness ● ● ● ● ● ● ● ●
- 11 -
Maintenance

0 1000 6000 12000 18000 24000 30000 36000
Km (mi) Covered (600) (3800) (7500) (11200) (14900) (18600) (22400)
delivery
B Description Operation
General lubrication ● ● ● ● ● ● ● ●
General check ● ● ● ● ● ● ● ●
Table of lubricants and fluids

Description Recommended product Specification
Engine oil AGIP RACING 4T 10W/60 (*) SAE 10W/60
Ethylene-glycol
Engine coolant AGIP ECO - PERMANENT diluited with 50%
distilled water
Brake and clutch fluid AGIP BRAKE FLUID DOT4 DOT4
Chain lubrication oil MOTUL CHAIN LUBE ROAD –
* : To find the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers.
AGIP Racing 4T 10W/60 has been manufactured for the F4 engine. If the described oil is not available, MV
Agusta suggests using completely synthetic oils with characteristics that
conform or exceed the following norms:
– Conforming to API SJ
Engine oil
– Conforming to ACEA A3 SAE 10 W-60
– Conforming to JASO MA
API SJ
– Grade SAE 20 W-50 o 10 W-60 ACEA A3
JASO MA
N.B. The above specifications indicated are marked either on their
own or together with others on the container of the lubricating
oil.
MAINTENANCE AND TUNING OPERATIONS

Each operation of periodical maintenance is described
in this chapter.
ENGINE OIL AND OIL FILTER
Engine oil
Substitute:→ at the first 1000 kilometres and then

every 6000 kilometres
Oil filter
Substitute:→ at the first 1000 kilometres and then

every 6000 kilometres (or at least
every oil change)
- 12 -
Maintenance
To accede to the oil filter and the discharge and filling

holes of the engine oil, it is necessary to carry out cer-
tain operations beforehand:
• Place the motorcycle on the rear stand.
B
N.B. The substitution of the engine oil must
be done with a hot engine as opposed to
the oil-check that is done with a cold
engine.
Place a container underneath the engine to collect the
1
used oil.
Remove the oil discharge plug (1).
Recover the oil in an appropriate container.

Do not scatter the drainage oil into the envi-
ronment.
Remove the oil filler plug (1) on the right side of the
motorcycle so that it facilitates the discharge of the BRUTALE 910 S - R
used oil. - 989 R - 1078 RR
Only for the Brutale 910 S - 910 R - 989 R - 1078 RR

models: Remove the filler cap (1) using the 10 mm
hexagonal bar attached to a wrench. 1
Wait until the lubrication system is completely empty of

used engine oil.
Substitution of the oil filter
Release the two side clamps of the oil cooler.ly

towards the right of the vehicle.
- 13 -
Maintenance
Unscrew the lower fixing screws of the oil cooler pro-

tection on the lower basis of the water radiator.
Remove the oil cooler protection.
Slightly move the coolers towards the front area of the

motorcycle, then unscrew the nut on the fixing flange of
the exhaust manifilds of the cylinder group.
During this operation pay attention to the

exhaust pipes in order to avoid from scorch-
ing.
For Brutale 750 ORO-S / Brutale 910 S - R MY 05/06

models only:
Release the union spring between compensator and
manifolds of cylinders 3 and 4.
Remove the manifold of cylinders 3 and 4.
- 14 -
Maintenance
For Brutale 910 S – 910 R - 989 R - 1078 RR (MY

2007-08) models only:
Disconnect the lambda probe connector from the main
cabling and pull outwards, on the right side of the vehi-
cle. B
Unscrew the compensatory housing fixing screws.
Special tool: code 8000B2051
At the time of the assembly, apply the recommended

thread locking adhesive to the threads of the screws
and tighten them at the required torque.
Recommended thread-locking fluid: Loctite 243
Torque pressure: 20 ÷ 22 N•m
- 15 -
Maintenance
Remove the exhaust manifolds by turning slightly

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

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

nut: 20÷22 Nm
Loosen the safety clamp and remove it.
- 16 -
Maintenance
Unscrew the oil filter by an appropriate wrench.
FACOM D. 139 tool

Part code 8000A4317
B
Clean accurately any oily parts.
Using a clean cloth to clean accurately the area and

the filter face.
Take out the oil filter from the new engine oil filter kit
(Part Code No. 8000A3702).
Only use original components of MV

Agusta.
- 17 -
Maintenance
Take a new rubber clamp from the motor’s oil filter kit
and place it on the filter as shown in the figure to the
left.
B Only use new parts.
Let the rubber clamp slide until it comes into contact

with the back ring of the oil filter (see figure to the
right).
Lubricate the gasket on the filter with engine oil.
Insert the filter in its seat.
Turn the filter manually until the gasket is into slight

contact with the machined surface.
- 18 -
Maintenance
Tighten the filter using the appropriate tool and a

torque wrench.
FACOM D. 139 tool

Part code 8000A4317 B
Oil filter torque wrench:
24 N·m
24 N•m
After having tightened the filter, take out the clamp for
engine oil filter and its screw from the new oil filter kit.
Only use a new clamp.
Insert the clamp and slide it until it brings in contact

with the oil filter back ring.
Place the clamp lock at a range of 2 mm from the

screwhead on the supporting plate of oil cooler pipes.
2 mm
- 19 -
Maintenance
Tighten the screw of the clamp until it comes into con-

tact with the filter, without tightening.
Mark the screw position drawing a line by a felt-tip both

B on the screw and on the clamp.
Make the last tightening of the screw getting it perform

2 turns and 1/4 further the position marked previously.
Once completed the assembly, ensure that the clamp

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

using a felt pen, both on the filter and the band fasten- -1÷1,5 mm
er. Trace a reference mark also on the band fastener
and the relative screw, with the object of eventually
checking any slackening of the screw.
Do not use the oil filter as a point of grip or

contact.
On the oil discharge plug there is a magnet to attract

any metal residues that could form in the engine during
rotation.
Before replacing the cap, make sure it is completely
clean. Replace the sealing washer with a new one.
Screw in the oil discharge plug and tighten it to the

specified torque.
Torque pressure – oil discharge plug:

35 N·m
35 N•m
- 20 -
Maintenance
Pour around 3 kg of engine oil (as specified in the table

BRUTALE 910 S - R
on page B-11) into the filling hole. - 989 R - 1078 RR 2 1
Close the filler hole using the appropriate cap.

B
models: 1
Before replacing the filler cap, grease the O-ring (1)
with silicone grease (see figure).
Tighten the cap (2) to the prescribed tightening torque.
Tightening torque: 35 N·m
35 N•m 2
Switch on the engine for several minutes.

After switching off the engine, wait at least ten minutes
and then check the oil level. Ensure that the motorcycle
is placed on level ground and is in a vertical position.
The correct level must be as close as possible to the
“MAX” mark shown on the engine casing. Do not sur-
pass this limit.
Check any oil leakages.
Avoid turning the engine over with the oil
level lower than minimum. It could compro-
mise the correct functioning of the engine.
If the level after the topping-up, is over the
“MAX” reference notch, correct it by emp-
tying a little oil out of the engine.
Oil tubes
During normal maintenance procedures check the cor-

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

– Oil filter support
– Oil pump-engine cylinder head delivery tubing.
When oil leaks are identified, even small

ones, externally clean the above parts. If oil
leaks continue, proceed with the overhaul of
components as described in the F4 work-
shop engine manual (Brutale 750: Code
8000A1592; Brutale 910: Code 8000A6440 ;
Brutale 989/1078: Part. Cod. 8000B2577).
- 21 -
Maintenance
ENGINE COOLANT
Check/top-up level ➝ At the pre-delivery, at
the first 1000 kilome-
tres and then every
B 6000 kilometres
Keeping the motorcycle in a vertical position, check

that the level of engine coolant is between the «MIN»
mark found on the expansion tank (1) and the lower
part of the frame tube, that you can see from the open-
ing on the frame protection panel on the left side of the
motorcycle.
If the level is under the minimum line, proceed with top-

ping-up as follows:
• Remove the two fixing screws (2) of the ignition

switch cover (3). 2
• Extract the cover.
With the engine cold, top up the level using the filler
hole (4) of the expansion tank.
Open the expansion tank only when the

engine is cold; the discharge of boiling liq-
uid could cause burns.
If the liquid comes into contact with the skin
or the eyes, rinse abundantly with water.
- 22 -
Maintenance
Engine coolant substitution

Substitution → Every two years
Before proceeding the emptying of the system,

2 B
Perform the following operations in advance:
• Remove the ignition switch cover (see “Engine

coolant level check”);
• Place a container under the engine to collect the
used coolant; 1
• Open the expansion tank cap;
• Remove the coolant discharge screw (1) situat-
ed on the coolant pump (2), thereby letting the
coolant flow out.
8 N•m
Wait for the engine coolant to completely flow out.
Collect the engine coolant in an appropriate
container. Do not scatter the engine coolant
into the environment.
Tighten the engine coolant discharge plug (1) to the
specified torque, after having checked the condition of
the gasket.
Torque pressure, engine coolant discharge
plug : 8 N·m
Fill the cooling system with the appropriate liquid
described in table (see page 11 of this chapter) until
the level is between the «MIN» mark found on the
expansion tank and the lower part of the frame tube
(see figure on next page).
Close the cap.

Start the engine, keep it running for a few minutes, and
then turn off. Wait for the engine to cool.
Carefully check for leaks, blow-bys, dam-

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

expansion tank (3).
It should be between the «MIN» mark found on the
expansion tank and the lower part of the frame tube, as
shown in the figure. Max. level
Min. level
f the level is inferior to the «MIN» mark, top up the 3
coolant level by pouring new coolant into the filler hole.
- 23 -
Maintenance
Complete the assembly of the motorcycle.
ELECTRIC FAN
(BRUTALE 750 ORO - S / 910 S-R MY 05/06)
Check → on pre-delivery and at the first 1000
kilometres and then every 6000 kilome-
tres
To check the functioning of the electric fan, start the
vehicle’s engine and let it warm up.
The electric fan should come into operation when the
instrument panel shows a system temperature ranging
between the following values:
- BRUTALE 750: 97° ÷ 100° C
- BRUTALE 910: 92° ÷ 94° C
If the electric cooling fan does not switch on, carry out
the checks on the various components as described in
chapter L “Cooling system”.
ELECTRIC FANS (BRUTALE 910 S - R / 989 R / 1078

RR MY 2007/08)
Check → on pre-delivery and at the first 1000
kilometres and then every 6000 kilometres
To check the functioning of the electric fans, start the

vehicle’s engine and let it warm up.
The electric fans should come into operation when the
instrument panel shows a system temperature ranging
between the following values:
- BRUTALE 910 S-R / 989 R / 1078 RR: 92° ÷ 94° C

If the electric cooling fans do not switch on, carry out
the checks on the various components as described in
chapter L “Cooling system”.
- 24 -
Maintenance
VALVE MECHANISM ADJUSTMENT

Check and adjust → at 1000 kilometres (only
for MY 06 and earlier) and
B
The valve machanism adjustment must be
performed when the engine is cold.
Remove in order the following components to carry out

the measuring of the play between the camshaft and
the valve cups:
• Passenger seat
• Rider seat
• Left tank side panel
• Right tank side panel
• Ignition switch cover
• Fuel tank
• Air filter compartment
• Throttle body
N.B.: For all removal operations, including the relative
attention notes, please refer to the specific sections in
this manual.
An analogous reference is utilised for the reassembly

of the parts after the maintenance operation.
After removing the components indicated, the vehicle

should look like the picture to the side.
Before proceeding with the various maintenance oper-
ations, it is advisable to thoroughly wash and clean the
motorcycle.
Place the motorcycle (now without the components list-
ed above and clean) on a workstation as indicated in
the figure.
Apply adhesive paper tape to the frame tubes.
This operation will protect the paintwork from knocks,

scratches and abrasions that could occur during the
work activity.
- 25 -
Maintenance
Ensure that all the surfaces of the frame are protected

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

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

and on the terminals of the accelerator control (B).
B
A
For Brutale 750 ORO-S / Brutale 910 S - R MY 05/06

models only:
Pull out the connectors of the coils.
In order to perform this operation, release the sec-
ondary lock (yellow tongue) pulling out from its seat,
then press the black tongue and release the connector.
- 26 -
Maintenance
Unscrew the earth bonding on the engine head cover

and release the coil harness from the frame removing
the two clamps, and extract it on the right side.
Unscrew the fixing screws of the coil plates, and

remove them.
Pull out the coils from their seat.
Unscrew and remove the eight fixing bolts of the cylin-

der head cover.
- 27 -
Maintenance
For BRUTALE 910 S-R / 989 R / 1078 RR MY 07/08 only

Disconnect the coil connectors (1) from the control unit 1
support.
Unscrew and remove the coil backing plate fixing

screws (1).
Remove the coils from their housings.
Remove the cover of the secondary air blade (1) by

unscrewing the remaining two fixing screws (2).
- 28 -
Maintenance
Remove the secondary air blade from the head cover,

only if inspection is necessary.
Operating as shown in the figure, slightly lift up the

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

indicated.
Take care to not ruin or deteriorate the motorcycle

parts in the proximity of the work area.
Proceed with the removal of the cylinder head cover.
To facilitate this operation, it is advisable to move the

rubber engine coolant filling tube situated on the left
side of the motorcycle.
Complete the removal of the cylinder head cover by

sliding it towards the rear part of the motorcycle.
- 29 -
Maintenance
Remove the head cover gasket.
Utilising a syringe, remove the surplus oil that is left in

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

unscrewing the five fixing screws.
- 30 -
Maintenance
Rotate the camshaft by turning the central nut in an

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

incision stamped on tooth (A) of the timing wheel is in
line with the “tooth” (B) that is present on the engine B
casing.
The position of the timing wheel is clearly seen in the

enlargement in respect of the mark on the engine cas-
ing.
A
Also the marks present on the toothed wheels of the

camshaft must be aligned together when the timing
wheel is in this position.
- 31 -
Maintenance
Utilising a feeler gauge of the type shown in the figure,

measure the play between the camshaft and the valve
cups.
Continue measuring the play as illustrated in the figure.
The correct measuring of the play is a fun-

damental operation for the correct function-
ing of the engine.
Carry out the measuring of the play of the following
Carry out the measuring of the play of the following

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

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

measured in the form of a table.
- 32 -
Maintenance
For example, here is a hypothesis of a table in

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

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

EXHAUST Valve n° 16 Valve n° 15 Valve n° 14 Valve n° 13 Valve n° 12 Valve n° 11 Valve n° 10 Valve n° 9
Valve play
Pad thickness
Values measured after having replaced adjusting pins:

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

EXHAUST Valve n° 16 Valve n° 15 Valve n° 14 Valve n° 13 Valve n° 12 Valve n° 11 Valve n° 10 Valve n° 9
Valve play
Pad thickness
- 33 -
Maintenance
The progressive numeration of each valve is illustrated EXHAUST

in the photograph on the right.
Note the anti-clockwise direction of the numeration.

B
INTAKE
To facilitate the operation, it is possible to note before-

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

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

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

n° 4 is in the Top Dead Centre position (T.D.C.) of the
compression stroke.
- 34 -
Maintenance
Check again the timing of the engine, ensuring that the

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

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

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

are scrupulously written in the correct order of the pre-
viously illustrated table.
- 35 -
Maintenance
B Valve play between the valve cup

and the cam
Camshaft
Upper cup for the

springs
Adjustment pad
Valve cup
Valve
The play values measured between the valve cup and

cam must be the following:
For all intake valves 0,15 ÷ 0,24 mm
For all exhaust valves 0,20 ÷ 0,29 mm
If different values are encountered even for one valve, sub-
stitute the camshaft/valve cup play adjustment pads as
described in the F4 workshop engine manual (B4 750:
Part. Code 8000A1592 ; B4 910: Part. Code 8000A6440
B4 989/1078 Part. Code 8000B2577)
If the values are correct, reassemble in reverse order to
disassembly. Consult the F4 workshop engine manual (B4
750: Part. Code 8000A1592 ; B4 910: Part. Code
8000A6440 B4 989/1078 Part. Code 8000B2577) for the
specific torque pressures and the necessary products.
Before proceed to reassemble the engine head cover, it is
recommended to clean accurately the residues of dope
along the seal form on the head and use a new gasket.
- 36 -
Maintenance
Timing chain, mobile timing chain guide and timing

chain tensioner
Timing chain and mobile timing chain guide:

Check → First 1000 kilometres (only B
for MY 06 and earlier) and
then every 12000 kilome-
tres
Substitute → Every 36000 kilometres
Timing chain tensioner:

Check/substitute → Every 12000 kilometres
To disassemble these parts and not being a part of nor-
mal maintenance, it is necessary to proceed as
described in the overhaul section of the F4 workshop
engine manual (B4 750: Part Code 8000A1592; B4
910: Part. Code 8000A6440 ; B4 989/1078 Part. Code
8000B2577).
SPARK PLUGS
Check/substitute ➝ First 1000 kilometres
(only for MY 06 and earli-
er), at 6000 kilometres
and then every 12000
kilometres
Substitute ➝ Every 12000 kilometres
The following components must be removed to accede
to the spark plugs:
• Passenger seat
• Rider seat
• Fianchetto laterale sx
• Right side panel
• Fuel tank
Proceed to pull out 4 coils as described above.
Remove the spark plugs utilising the appropriate 16
mm hexagonal spark plug spanner.
Heat Grade
Check the heat grade of the spark plugs.
Spark plug gap

Measure the gap between the electrodes of the spark
plug with a feeler gauge. Adjust this gap in compliance
with the values written in the table below.
BRUTALE 750 S - 750 ORO

Spark plugs (alternatively) electrode distance “A” (mm)
NGK CR9 EB 0.7 ÷ 0.8
Champion G59c 0.6 ÷ 0.7
BRUTALE 910 S - 910 R - 989 R - 1078 RR

Spark plugs electrode distance “A” (mm)
NGK CR9 EB 0.7 ÷ 0.8
- 37 -
Maintenance
Electrode condition
Check the electrodes for wear or burning. If they are 12 N•m
extremely used or burnt, substitute the spark plugs. Also
substitute the spark plugs in the case of breakage of the
B ceramic isolation or damage to threading.
When the spark plugs are renewed, check the

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

avoid damaging the threads of the motor head. Tighten
to the prescribed tightening torque.
Spark plugs torque pressure: 12 N·m
FUEL FILTERS
Check and substitute → Every 12000 km
For the checking or substitution of the engine intake

system filters (fuel filter, fuel pump filter), it is neces-
sary to remove in sequence the following parts:
• Passenger seat
• Rider seat
• Ignition commutator cover
• The side panels
• Fuel tank
N.B.: In order to perform the above-mentioned opera-

tions, refer to the chapter C “Superstructures”.
Carry out the following operation.
Drain completely the fuel tank using a booster pump as

shown in the figure.
- 38 -
Maintenance
Petrol flange assembly removal

1
Close the tank filler cap.
Turn the tank upside down and remove the nine
1
screws (1) fastening the flange to the tank and the B
three spacers.
1 1
Remove the flange assembly (2) from its seat.

To pull out the flange (2) use three M6 screws (1)
removed previously.
1
Insert the screws (1) into the respective threaded holes.
Screw in sequence until the flange is extracted.
1
2
1
Lift up the flange (1) and disconnect the tubes (2) on

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

Part code 800095850
- 39 -
Maintenance
Extract the complete flange assembly (1).
Remove the sealing O-rings (1) of the flange (2) and

clean them accurately.
Check they are undamaged.
If damaged, replace them with new rings.
1
2
Disconnect the electric connectors of the fuel pump (1).
- 40 -
Maintenance
Remove the fuel probe by using a tube spanner on the

fixing nut of the probe.
Remove the closing screw (1) of the conduit indicated

in the figure so that the remaining fuel flows out of the
conduit.
Remove the two CLIC R 96135 fasteners (1), placed

on top of the fuel filter.
- 41 -
Maintenance
Operate as indicated in the preceding figure and

remove the CLIC R 96135 fastener (1).
Remove the fuel filter (1).
Extract the fuel pump (1) from its seat.
- 42 -
Maintenance
Disassemble the fuel filter (1) on the pump and blow in

compressed air from inner to outer as shown in the fig-
ure.
1 B
Clean the seat of the fuel pump and the fuel bowl.
Remove any residue and ensure that there are no
shavings that have originated from mechanical work.
Degrease the threaded hole and the screw (1) with the
appropriate solvent as shown in the figure.
Clean and dry by blowing with compressed air.
Replace the sealing washer.
Apply LOCTITE 542 thread-locking fluid on the thread

of the screw.
Reassemble the screw and tighten to the specified

torque.
Specified product LOCTITE 542

1
Torque pressure: 10 N·m 10 N•m
- 43 -
Maintenance
Using fine abrasive paper clean the first threading

“crests”of the fuel probe seat as shown in the figure.
This operation is necessary to not compromise the

B good condition of the gasket during the assembly
phase of the probe.
Place the fuel filter on the pump in according to the tim-

ing shown in the figure.
Operate with care so that the net filter is not

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

colour – onto the tube as shown in the figure.
- 44 -
Maintenance
Insert a new fuel filter (1) within the pipe verifying its
right placement (the arrow, marked on the exterior of
the body must be oriented as shown in the figure).
If necessary, utilise alcohol to facilitate the assembly.
Tighten the CLIC R 96 135 fastener (2) – green colour B
– utilising the CLIC 205 pincers.
1
Insert the connection pipe of fuel filter / pump using

alcohol in order to facilitate the assembly.
Assemble the CLIC R 96 135 fastener (1) – green

colour – using the CLIC 205 pincers.
Insert the pump into its seat.
- 45 -
Maintenance
Insert the pipe on the fuel pump.

Facilitate the insertion using alcohol.
Assemble the CLIC R 96 135 fastener (1) – green

B colour – using the CLIC 205 pincers.
Assemble the fuel probe (1) on the die-cast flange.

When reassembling, substitute the gasket (2) with a 2 1
new one and lubricate it with silicone grease.
Apply a light layer of silicone grease also on the
threaded seat of the probe.
Tighten the probe so that the output position of the

electrical wiring is in correspondence with the centre
line of the writing “FRONT” between the two arrows.
- 46 -
Maintenance
Reconnect the electrical connectors.

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

ing the sealing O-Rings (2) in their seat. Before assem-
bling verify that components are undamaged and lubri-
cate them applying silicone grease.
It is recommended to apply a layer of silicone grease
on the seat of the die-cast flange.
The use of worn O-Rings can cause any fuel

leakage from the tank motorcycle, and fire
risk for the motorcycle as a consequence.
Carry out a check on the flange assembly.

Check the correct execution of all the operations car-
ried out and described.
- 47 -
Maintenance
FUEL PUMP ASSEMBLY
- 48 -
Maintenance
Brutale Brutale Brutale Brutale Brutale Brutale

N. Code Q.ty Note I FRAME I I ENGINE I
750 ORO 750 S 910 S 910 R 989 R 1078 RR
1 8A0094275 1 • • • • • •
2 800090927 1 • • • • • •
3 800021480 1 • • • • • •
B
4 80A090925 1 • • • • • •
5 800090925 1 • • • • • •
6 800090939 2 • • • • • •
7 8000A1400 1 • • • • • •
8 800090919 1 • • • • • •
9 800090920 1 1 • • • • • •
9 8000B1002 1 2 • •
10 800093410 1 1 • • • •
10 8A0093410 1 2 • •
11 800093411 1 1 • • • • • •
11 8000B1136 1 2 • •
12 800090921 1 1 • • • • • •
12 8000B1003 1 2 • •
13 800098305 1 • • • • • •
14 8M0092249 2 • • • • • •
15 8S0092249 2 • • • • • •
16 8E0087431 1 • • • • • •
17 8H0087431 1 • • • • • •
18 800088585 1 • • • • • •
19 800090929 1 • • • • • •
20 800093323 1 • • • • • •
21 800093324 1 • • • • • •
22 800090930 1 • • • • • •
23 800098304 1 • • • • • •
1 Per pompa benzina Bosch - For Bosch fuel pump - Pour pompe à essence Bosch - Für Benzinpumpe Bosch - Para bomba
gasolina Bosch.
2 Per pompa benzina Aisan - For Aisan fuel pump - Pour pompe à essence Aisan - Für Benzinpumpe Aisan - Para bomba
gasolina Aisan.
- 49 -
Maintenance
Fuel flange unit assembly
Before starting the assembly of the flange to the fuel

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

Check that the two small overflow tubes (2) remain out-
side of the fuel tank.
Specific pliers: CLIC R 205 1

Part code 800095850
Insert two CLIC R 96 105 band fasteners (1) onto the

small tubes. Insert the two small rubber tubes (2) onto
the appropriate spigot on the die-cast flange.
Tighten the band fasteners by using the CLIC 205 pin-
cers.
1 2
- 50 -
Maintenance
Insert the flange unit into its seat on the tank. Insert the
three spacers into their respective slots located on the 6 ÷ 6,5 N•m
flange. Screw and tighten the nine fixing screws.
Torque wrench of fuel pump flange fixing B

screws: 6 ÷ 6,5 N·m
Proceed with the assembly of the parts removed by fol-

lowing the removal operation in reverse order to that
shown in chapter C “Bodywork”:
• Fuel tank
• Tank side panel
• Rider seat
• Passenger seat
FUEL UNION TUBES

Check for leaks ➝ First 1000 kilometres and then
Carry out a visual check for eventual leakages from the

fuel feed tubing and the unions (see figure).
Substitute damaged parts if leaks or evaporation are
found.
ASSEMBLY OF FUEL TUBES

(BRUTALE 750 S - 750 ORO)
Substitute ➝ At least every three years
The procedure to follow in the case of substitution of
the feed tubing is as follows:
Remove in this order:

• Passenger seat
• Rider seat
• Tank side panel
• Fuel tank
Insert the fuel tubes onto the unions of the throttle
body.
UTILISE ONLY NEW PARTS.
- 51 -
Maintenance
The fuel tube with the white CPC union is

assembled on the right side of the butterfly
body.
B The fuel tube with the black CPC union is

assembled on the left side of the butterfly
body.
Follow the indication shown in the figure.
Orientate the CPC unions as shown in the figure.
During the check, distend the tubes to eliminate flex-

ions and deformation of the same.
- 52 -
Maintenance
Ensure that the tubes are correctly fitted onto the metal
unions of the butterfly body and check that the rubber
tubes do not cover the curved section of the metal
union.
B
Position the “head” of the fastener as shown in the fig-
ure.
Fix the fuel tubes to the unions of the butterfly body by

utilising the CLIC R 96 135 (green colour) fasteners.
Utilise the CLIC 205 pincers to secure them.
Specified pincers: CLIC R 205

Part code 800095850
Connect the tubes using the clamp provided.

Make sure the two tubes are of the same length.
Conclude the operation by reassembling the compo-

nents in reverse order of disassembly.
- 53 -
Maintenance
ASSEMBLY OF FUEL TUBES

(BRUTALE 910 S - BRUTALE 910 R - BRUTALE 989
R - 1078 RR)
B Substitute ➝ At least every three years

The procedure to follow in the case of substitution of
the feed tubing is as follows:
Remove in this order:

• Passenger seat
• Rider seat
• Tank side panel
• Fuel tank 1
Open and the remove the clamp (1).
Simultaneously press the two blocking tabs and

remove the tube.
Repeat this procedure for the other fuel tube.
Insert the petrol tubes into the joints located on the

throttle body until they are securely fastened.
UTILISE ONLY NEW PARTS.
- 54 -
Maintenance
The fuel tube with the white CPC union is

assembled on the right side of the butterfly
body.
The fuel tube with the black CPC union is B

assembled on the left side of the butterfly
body.
Connect the tubes using the clamp supplied.
Follow the indication shown in the figure
For Brutale 910 S - 910 R - BRUTALE 989 R -

1078 RR (MY2007-08) models only:
The clamp must in any event be fitted in a
higher position than the housing tube, in
order to avoid interference and forcing after-
wards when fitting the tank.
- 55 -
Maintenance
THROTTLE BODY ADJUSTMENT AND TUNING

(Tickover check, CO synchronisation and check)
Check and adjust ➝ First 1000 kilometres and

B then every 6000 kilome-
tres
The throttle body adjusting should be performed start-

ing the engine of the motorcycle, therefore you should
use a flue gas exhauster in order to not saturate the
environment with burnt gas.
The following described operations are fundamental

for the correct functioning and the maximum perfor-
mance of the engine.
When carrying out operations on throttle bodies, it is

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

an auxiliary support. Therefore you should connect the
hydraulic extensions of the fuel pipes and the electrical
extension for feeding fuel pump.
- 56 -
Maintenance
Throttle body adjustment and CO check

(Brutale 750 ORO-S / Brutale 910 S-R MY 05/06)
Verify the parameters of the injection-ignition system
by the MDST diagnosis software.
B
Connect the tool cable of the MDST diagnosis with the

“Diagnostics” tap on the right side of the motorcycle
near the expansion tank of the coolant.
Start the MDST diagnosis software and go to the

“Display instrument panel” screen.
Set the ignition switch to ON.
Select the “Connect” option from the toolbar. Now the
software displays the main operating parameters of the
injection-ignition system: verify that the temperature
and pressure sensors have coherent readings.
- 57 -
Maintenance
Check the throttle angle when the throttle is complete-

ly closed.
• BRUTALE 750 ORO-S:

B Default value: 1.7°
Huntings between 1.5° and 1.7° are allowed only if the
engine is started.
A value above 1.7° is not allowed.
• BRUTALE 910 S-R (MY 05/06):

Default value: 2.3°
Huntings between 1.9° and 2.1° and between 2.3° and
2.5° are allowed only if the engine is started.
A value above 2.5° is not allowed.
If necessary adjust the throttle opening using only the

appropriate screw on the throttle opening pulley.
It is recommended not modify the throttle potentiome-
ter position because the throttle has been set during
the production to the optimal value.
Remove the sealing caps of the small tubes to check

the vacuum pressure.
The number of the cylinder to which the caps are con-
nected is written on the caps.
The small tubes for checking the vacuum pressure are
situated on the left and right side of the motorcycle.
- 58 -
Maintenance
Connect the depression pipes with the vacuometer

complying with the match between the pipe and the
cylinder which is connected to.
In order to perform the following operations, you

should provide with the specific tool kit for setting CO.
Specific tool:
Part code 8000A4686
Remove the sealing caps of the CO drives placed on

the exhausts.
Insert and screw the 2 probes registering CO inside the
specific tool kit (code 8000A4686).
Assemble the 2 pipes with their Y union, also supplied
with tool kit, code 8000A4686, on the probes register-
ing CO.
Connect the Y union with a rubber pipe to the exhaust
gas analyser.
Verify that the ignition switch is set to OFF.

Disassemble the injection-ignition gearcase placed on
the air filter compartment unscrewing the four fixing
nuts.
Reset the earth bonding on the gearcase by using a
nut and a M6 screw (for the correct performance of the
adjusting operations, it is important the gearcase is
earthed).
- 59 -
Maintenance
Remove the seal plate and then the gearcase sealing

cap.
The by-pass screws must first be adjusted as follows:

One turn from the closed position
• BRUTALE 910 S-R (MY 05/06):

One and a half turns from the closed position
Start the engine and warm it up. During this phase you
should not accelerate because the high depression
created in the induction lines could pipe the mercury
from vacuometer.
The engine rotation can be supported by using the
starter.
The attainment of the correct thermal speed is given by
the intervention of the cooling fan.
- 60 -
Maintenance
Balance the pressures in the cylinders: the mercury

columns must reach the same height.
If all the motor parameters are correctly set, the adjust-
ing screws should have the following positions:
B
• BRUTALE 750 ORO-S (MY 03):
1 ÷ 1.5 turns from the closed position
• BRUTALE 750 S (MY 04) - 910 S - 910 R
(MY 05/06):
1 ÷ 3.5 turns from the closed position
The minimum number of turns must fall within the fol-

lowing values:

1100 ÷ 1200 giri/min.
• BRUTALE B4 910 S-R (MY 05/06):
1150 ÷ 1250 giri/min.
Check the CO value using the exhaust gas analyser.

This value must be between the following values
(inclusive):

3.5% + 0.5% (3.0% + 4.0%)
• BRUTALE 910 S-R (MY 05/06):
3.5% + 0.5% (3.0% + 4.0%)
If the CO values are not in the set range, delicately

adjust the trimmer inside the control unit until the val-
ues are within tolerance.
Turning anticlockwise the CO percentage increases,

clockwise the percentage decreases.
- 61 -
Maintenance
The attainment of the correct CO value could involve a

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

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

ensure that everything has been correctly replaced.
- 62 -
Maintenance
ADJUSTMENT AND CALIBRATION OF THROTTLE

BODY (BRUTALE 910 S - R - BRUTALE 989 R - 1078
RR MY 07-08)
After connecting the diagnostic software to the central
unit, before starting the engine check the position of B
the throttle valve:
2.33 degrees (min. 2.1, max 2.5).
If it does not fall within the range, use the TPS feature
to reset it, WITHOUT TOUCHING THE MECHANIC
ADJUSTING SCREW OF THE THROTTLE.
After resetting the throttle (TPS) start the engine to

warm it up.
You will see that after starting the engine the Lambda
channel (mvolt), which was next to zero, will start to
rise.
After starting the Lambda control (Lambda % range),

the Lambda (mvolt) will range between a high of 1000
mvolt and a low of 0 mvolt (minus the diagnostic soft-
ware lag). To see the range more clearly, adjust the two
graphic settings.
The above behaviour means the Lambda probe is in
working order.
Otherwise, if the Lambda (mvolt) shows a fixed value
of about 0 mvolt or 1000 mvolt, after about thirty sec-
onds, with the Lambda % controller fixed at -25% or
+25%, the system will send out a ‘Lambda probe volt-
age’ alarm.
In this case, check the electric connection between the
Lambda probe and the system or replace the Lambda
probe.
Levelling of induction manifold settings
To check this, use a mercury vacuum gauge of the type

shown in the figure. Then, level the vacuum inside the
induction manifolds.
- 63 -
Maintenance
Twist off the plugs that close the vacuum tubes. The
number of the cylinder to which the rubber plug is con-
nected is written on the plug itself (A).
The vacuum tubes are located on the right and left side
B of the vehicle.
Left side: Cylinders 1 and 2

Right side: Cylinders 3 and 4
Connect the measuring device with the rubber pipes.

Each pipe must match the cylinder to which it is con-
nected.
Fit in the Starter key and start the vehicle.

All bypass adjusting screws (1) must first be opened by
turning them 1.5 turns off the ‘all closed’ position.
For this adjustment, it is compulsory to begin with cylin-

der 2 to make sure the EBS valve will work properly.
Cylinder 2 provides the following positions:

min. 0.5 revs – max 3.5 revs
Select the position that offers the best alignment with

the other cylinders.
After finding the right position for cylinder 2, adjust it by

turning the bypass screws of cylinders 1, 3 and 4 until
the vacuums inside the four induction manifolds are
aligned. The mercury columns must have the same
height (see Figure on the side).
Cylinders 1, 3 and 4 too provide the following positions.

min. 0.5 revs – max 3.5 revs
When idling, the revs of the engine must range

between 1100 revs/min and 1200 revs/min.
- 64 -
Maintenance
To align the throttle body, use the diagnostic software.

For the engine to work properly, adjust the throttle body
so that the idling regime control works at “mid-range”.
To do this, after finding the correct alignment, proceed B

as follows:
If the “lead correction” channel is NEGATIVE, close the
bypass valves to take air out, keeping it aligned until
the “Lead correction” setting goes to work within a
range of -4° to +4°.
If the “Lead correction” channel is POSITIVE, open the
bypass valves to add air, keeping it aligned until the
“Lead correction” setting goes to work within a range of
-4° to +4°.
When the adjustment is over, turn off the vehicle,

remove the connection pipe and replace the four pro-
tective plugs.
Adjustment of carbon oxide rate (CO) for vehicles

(BRUTALE 910 S - R - BRUTALE 989 R - 1078 RR
MY 07-08).
CO ADJUSTMENT IS NOT REQUIRED.
The system can correct its (stoichiometric) carburetion
through the Lambda probe control. This does not hap-
pen straightaway but depends on the Lambda probe
switching speed for a water temperature of 85 to 105 °C.
You will notice that, when the Lambda probe % con-
troller work slightly ABOVE ZERO, the ADOFFPL set-
ting WILL INCREASE and will bring the Lambda %
channel back to about 0 ±3%.
You will notice that, when the Lambda probe % con-
troller work slightly BELOW ZERO, the ADOFFPL set-
ting WILL DECREASE and will bring the Lambda %
channel back to about 0 ±3%.
- 65 -
Maintenance
AIR FILTER
Check/substitute Every 6000 kilo-
metres
Certain parts must be removed in sequence before
B acceding to the air filter. See chapter C “Bodywork”:
• Passenger seat
• Rider seat
• Fuel tank
Remove the sealing rubber gasket (1).
Remove the filtering panel from the air box.
- 66 -
Maintenance
Check the condition of the air filter. If it is necessary to

substitute it, proceed as follows:
Prepare a new air filter.
Check that the inside of the air filter compartment is
clean and free from foreign bodies. B
Insert the air filter complying with the correct assembly

direction shown in the figure.
Complete the assembly of the filter into the air filter

compartment sealing the operation opening by the rub-
ber gasket as shown in the figure.
- 67 -
Maintenance
Before proceeding with the assembly of the air filter

compartment onto the motorcycle, apply silicone
grease to the gaskets of the air intake bell chambers.
Proceed with the assembly of the parts listed below
B and according to the procedure described in chapter C
“Bodywork”:
• Fuel tank
• Rider seat
• Passenger seat
- 68 -
Maintenance
BRAKES AND CLUTCH
Check the levels of

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

metres and then every 6000 kilo-
metres
Substitute fluid➝ Every 24000 kilometres or at

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

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

The procedure that is described as follows must be
carried out for the fluid chambers of both the front and
rear brakes and also the clutch fluid chamber.
Place the motorcycle in a vertical position with the han-
dlebars straight.
Check the fluid levels in the brake and clutch fluid
chambers observing the lines for the level marked on
the chambers.
If the level is lower than the lower level line, check the
wear of the brake pads. If the thickness of the pad lin-
ings is correct, add brake fluid complying with the spec-
ification by the manufacturer in according to the follow-
ing procedure:
- Remove the 2 screws from the fluid tank cover;
- Remove the three elements of the cover.
Add brake fluid until the correct level is reached in the

chamber.
Recommended brake fluid: AGIP DOT 4 or

equivalent.
Do not use brake fluid that comes from old

containers, has already been used or does
not come from a sealed container. Do not
use brake fluid that is left over from previous
maintenance or stored for long periods.
Utilise only the recommended brake fluids.
- 69 -
Maintenance
In order to access the back brake fluid tank you should

remove the fuel tank as described in the Chapter C
“Super structures”.
Likewise proceed to the front brake fluid tank.
Before completing the operation, clean and wash accu-

rately the 3 components of the chamber cover using
alcohol and blow to dry them.
Clean the edge of the fluid chamber with a clean cloth.

Close the fluid chamber with the two relative screws.
Imperfect cleaning of these parts could

cause the discharge of small quantities of
brake fluid during riding. Brake fluid has
strong corrosive properties.
- 70 -
Maintenance
Check eventual leaks and blow-bys of brake and clutch

fluid on the unions and tubing.
If any breakages are seen, substitute the damaged
parts as described in chapter H “Brakes”.
B
Brake fluid leakages are dangerous and
immediately discolour painted surfaces.
Before riding, check the tubes and joints of
the brakes for damage and signs of leaks.
Substitution and bleeding of the brake/clutch fluid

The substitution of the brake/clutch fluid and the suc-
cessive bleeding of the circuit are operations that
require particular caution and precision. To carry out
these operations, it is therefore necessary to follow the
procedure described in chapter H “Brakes” of this man-
ual.
- 71 -
Maintenance
BRAKE/CLUTCH/GEARCHANGE COMMANDS CHECK

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

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

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

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

the handgrip.
Whenever the command levers do not func-

tion correctly or have excessive play, con-
sult chapter H “Brakes” for the overhaul of
the same.
- 72 -
Maintenance
Gearchange/rear brake lever adjustment

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

N.m
Operate on both the gearchange and rear brake levers

in the same way.
6 N•m
(Only for Brutale 750 ORO - 910 S - 910 R - 989 R -

1078 RR models)
Footrest adjustment
On some models, the footrests are adjustable. Operate
as follows for the adjustment from the original position:
• Slacken (without removing) the eccentric adjustment

screw (situated at the rear of the footrest support)
using a 12 mm hexagonal spanner.
• Loosen (without remove) the two fixing screws of the

frame board support using a 6 mm setscrew wrench.
• Lay (without tightening) the eccentric adjustment

rear screw. Effectuate the adjustment by utilising the
correct size screwdriver.
Adjust both footrests to the same adjustment

value.
• Tighten the two footrest fixing screws utilising a

torque wrench.
Torque pressure: 24 ÷ 28 N·m
• Tighten the rear eccentric adjustment screw.
24÷28 N•m
- 73 -
Maintenance
BRAKE PADS
Front brake caliper
Check/substitute ➝ At the first 1000 kilo-
metres and then very
6000 kilometres
B
Check the condition and thickness of the brake pads
on the calipers.
Rear brake caliper
Measure the thickness of the pad linings. If the thick-

ness of the linings is equal or less than the wear limit
shown below, replace the pads as described in chapter
H “Brakes”.
Disc
Wear limit: 1 mm.
Pads
If the brake pads are substituted, it is nec-
essary to effectuate a proper running-in
period before reaching an optimal braking
efficiency.
Wear limit 1 mm
ACCELERATOR CONTROL
Accelerator play check➝ At the pre-delivery
check, at the first 1000
kilometres and then
every 6000 kilometres 1
The accelerator control should not be too tight or too

slack (excessive play) in its movement.
It must also be free of play and looseness when turn-
ing it.
For optimum adjustment it is necessary to work on the
two upper nut adjusters (situated on the accelerator
handgrip).
The lack of play on the closure of the accel-

erator (1) can stop the complete closing of
the throttle valve and the accelerator could
remain in the open position, thereby leaving
the engine with a fast tickover. It is the same
for the opening transmission (2).
- 74 -
Maintenance
After making adjustments, check that the throttle

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

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

components, switch on the engine and check that, with
the choke lever activated, the tickover of the engine
does not exceed 2500 r.p.m.
- 75 -
Maintenance
LOCKS
Check ➝ At the pre-delivery, at the first 1000
kilometres and then every 6000 kilo-
metres
B OFF ON
Ignition/steering block switch
This switch has four operating positions.
Do not attach key rings or other objects to

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

trical system and the steering lock. The four control
positions are as follows.
“OFF” position
All electrical circuits are disactivated. The key can be
pulled out.
“ON” position OFF

All electrical circuits are activated, the instruments and
warning lights carry out self-diagnosis and the engine
LOCK
can be switched on. The key cannot be pulled out.
Do not attempt to change the functions of

the ignition switch whilst the motorcycle is
being ridden. It could cause the rider to lose
control of the machine.
Do not leave the key on the ON position for

a long time when the engine is not running,
in order to avoid damage to the electrical
parts of the motorcycle.
“LOCK” position
Turn the handlebar left. Press the key down and rotate Left side Right side
it to the “LOCK” position.
All electrical circuits are disactivated and the steering
is blocked. The key can be pulled out.
“P” position
Rotate the key from the “LOCK” position to the “P”
position.
All electrical circuits are disactivated except for the
sidelights.
The steering is blocked.
The key can be pulled out.
Do not leave the key on the P position for a

long time, in order to avoid discharging the
battery of your motorcycle.
If the ignition switch unit is damaged (it does not allow

the positioning of any one of the four positions), it must
be substituted with a new ignition switch unit following
the sequence of the disassembly as described in chap-
ter G “FRAME”.
- 76 -
Maintenance
Fuel cap lock

Lift up the anti-dust cover.
Insert the key, rotating it in a clockwise direction and lift
up the cap.
After refuelling, press the cap down and rotating the B
key contemporaneously to facilitate the closure. Press
and hold the cap, let the key go free, bring it into a lon-
gitudinal position and pull it out.
If the fuel filler cap does not function (the cap does not
close, the lock blocks, etc.) substitute it with a new one
as described in chapter C “Bodywork”.
Personal compartment lock

Insert the key in the lock.
Turn the key clockwise and at the same time press the
passenger seat slightly.
Lift and take out the passenger seat.
For reassembling the part refer to the following indica-

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

seat, and in any case before using the
motorcycle, ensure that the components are
correctly placed and well fastened to the
supporting structure of the motorcycle.
- 77 -
Maintenance
STEERING
Check and adjust ➝ At the first 1000 kilometres
and then every 12000 kilo-
metres
B
Check the steering components regularly according to
the above-mentioned intervals. A
If it is necessary to carry out adjustments, operate as D
described in chapter F “Suspension and wheels”. B
TRANSMISSION CHAIN D

metres
Substitute ➝ Every 6000 kilometres (Brutale 750
ORO)
Every 12000 kilometres (Brutale 750
S - 910 S - 910 R - 989 R - 1078 RR)
Place the motorcycle on the rear stand.
The chain tension check should be effectuated with the
motorcycle having a static set-up quota equal to the fol-
lowing standard values (see chapter F “Suspension and
wheels”):
BRUTALE 750 ORO - 750 S (MY 03): 190 mm
BRUTALE 750 S (MY 04): 200 mm
BRUTALE 910 S - 910 R - 989 R - 1078 RR: 200 mm
The clearance “h” between the axis of symmetry of the
chain and the chain cover should be equal to the follow-
ing values as shown in the figure.
BRUTALE 750 ORO - 750 S (MY 03): h = 6 mm
BRUTALE 750 S (MY 04): h = 11 mm “h”
BRUTALE 910 S - 910 R - 989 R - 1078 RR: h = 9 mm
Manually rotate the rear wheel and effectuate this check
at different points along the chain.
As the wheel is turned, the play should remain virtual-
ly the same. If, on the other hand, the play on the chain
varies considerably, it means that some of the links are
flattened, jammed or elongated.
Visually check the transmission chain for the following
defects:
Grease
• Slack pins • Excessive use O-ring
• Damaged rollers • Incorrect chain
• Dry and rusty links adjustment
• Bent or seized links • Damaged O-rings
The chain must be substituted if any one of these defects
is found.
When substituting the transmission chain, substitute also
the crown and pinion wheel.
For the substitution of the chain, pinion, crown wheel and
to check the wear of the chain guide, follow the sequence
described in chapter F “Suspension and wheels”.
- 78 -
Maintenance
Adjust➝ At the first 1000 kilometres and then

To adjust the chain tension, proceed as follows:

Slightly loosen the 2 screws of the back wheel hub until B
they can freely turn.
Using the special spanner as indicated in the figure,

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

to the torque pressure indicated as follows.
N.B. Tighten the screws to the specified torque

in several steps and in an alternate pattern.
28÷32 N•m
Rear hub eccentric adjuster screw torque
pressure: 28 ÷ 32 N·m
After tightening the screws of the rear wheel hub,

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

motorcycle set up adjustment must be car-
ried out beforehand. See “Motorcycle set up
adjustment” described in chapter F “SUS-
PENSIONS AND WHEELS”.
- 79 -
Maintenance
Chain lubrication
Lubricate➝ At the first 1000 kilometres and at

6000 kilometres and then at every
B 12000 kilometres
Clean the chain with a clean cloth and/or a jet of air.
The chain is the type with sealing rings (O-

RING); in order to avoid damages you
should not clean the chain using jets of
steam or high pressure water, or using fuel
or cleansing solvents on the market.
Then apply a light and even coating of lubricant on the

whole chain without reaching the surrounding parts, in
particular the tyres.
Use only the lubricant recommended (see

page 11 in this chapter) in order to effec-
tively protect the gearing chain and avoid
from splashing when the motorcycle is run-
ning.
In particular, direct the lubricant jet on the internal links,

in order to lubricate the surface of the O-Rings and
penetrate inside the chain roller.
- 80 -
Maintenance
TYRES
Check pressures➝ At the pre-delivery, at the first
1000 kilometres and then every
6000 kilometres
Check wear ➝ At the first 1000 kilometres and B
then every 6000 kilometres
If the tyre pressures are too high or too low, the ride is
affected and tyre life duration is accentuated.
Therefore maintain the correct tyre pressures to obtain
better roadholding and the maximum wear from the
tyres. The cold tyre pressures are indicated in the
table.
Brand and PIRELLI - Dragon Evo MTR 21 PIRELLI - Dragon Evo MTR 21
type Corsa (Front) / MTR 22 Corsa (Rear) Corsa (Ant.) / MTR 22 Corsa (Post.) PIRELLI - Dragon Supercorsa Pro
MICHELIN - Pilot Sport MICHELIN - Pilot Sport MICHELIN - Pilot Power PIRELLI - Dragon
MICHELIN - Pilot Power MICHELIN - Pilot Power DUNLOP - Sport Max D 208 Supercorsa Pro
DUNLOP - Sport Max D 207 RR DUNLOP - Sport Max D 207 RR Race Replica (**)
DUNLOP - Sport Max D 208 RR (**) DUNLOP - Sport Max D 208 RR (**)
Inflating pressure (*):
Front 2.3 bar (33 psi) 2.3 bar (33 psi) 2.3 bar (33 psi) 2.3 bar (33 psi)
Rear 2.3 bar (33 psi) 2.3 bar (33 psi) 2.3 bar (33 psi) 2.3 bar (33 psi)

Inflating pressure (*):
Front 2.3 bar (33 psi) 2.3 bar (33 psi)
Rear 2.3 bar (33 psi) 2.3 bar (33 psi)
*: when using tyres that have a different brand from those recommended, refer to the tyre pressure marked by the manufacturer on the side of the tyre.
** : Check that the dimensions of the 120/70 front tyre correspond to the dimensions in the motorcycle’s registration booklet. If a 120/70 tyre is used, move the clamp of
the front mudguard next to the upper holes located on the feet of the front suspension’s fork
The use of the motorcycle with excessively worn tyres

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

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

tyre change
Substitute ➝ Every 36000 kilometres 1,5 mm
If excessive play of the front wheel bearings is found

during checks, then substitute them as indicated in
chapter F “Suspension and wheels”.
- 81 -
Maintenance
WHEELS
Visual check ➝ At the first 1000 kilometres and
then every 6000 kilometres (at
least every tyre change)
After having visually checked or following even light

collision damage, it is necessary to check the planari-
ty, the eccentricity and the ovalisation of the wheel.
See the control procedures described in chapter F
“Suspension and wheels”.
- 82 -
Maintenance
REAR WHEEL HUB

Check and lubricate bearings ➝ Every 12000
kilometres
Substitute ➝ Every 12000
kilometres B
To check and overhaul the rear wheel hub unit, it is
necessary to carry out certain preliminary operations
by consulting the relative chapters.
Remove the rear wheel (see chapter F “Suspension
and wheels”).
Lift up the motorcycle by utilising a mechanic’s lift.
Remove the Seeger ring of the fixing nut of the crown
flange (see chapter F “Suspension and wheels”).
Loosen the nut of the wheel pin (see chapter F
“Suspension and wheels”). BRUTALE
Remove the brake caliper (see chap. H “Brakes”) and 910-989-1078
its support flange.
Extract the wheel pin.
Check and overhaul the rear wheel hub unit (see chap-
ter F “Suspension and wheels”).
SWINGARM BEARINGS
Check and lubricate ➝ Every 36000 kilometres
If excessive play is found on the rear fork, due to the

bearings assembled on the central pin of the
fork/frame, substitute them as described in chapter F
REAR SHOCK ABSORBER

Check and adjust ➝ At the first 1000 kilometres
and then every 12000 kilo-
metres
Verify the length in the seat of the back damper spring,

check the absence of leakages or oil blow-by and the
adjusting functionality.
Spring adjustment standard “A”:

A
- Brutale 750 ORO /750 S (MY 03): A= 151 mm

- Brutale 750 S (MY 04): A= 154 mm
- Brutale 910 S (MY 05-06): A= 154 mm
- Brutale 910 R (MY 06): A= 154 mm
- Brutale 910 S (MY 07): A= 153 mm
- Brutale 910 R (MY 07): A= 153 mm
- Brutale 989 R: A= 155 mm
- Brutale 1078 RR: A= 155 mm
The shock absorber contains gas under high

pressure. Do not touch the shock absorber
valve. Do not attempt in any way to remove the
shock absorber.
- 83 -
Maintenance
Compression and extension adjustment (rear suspen-

sion):
CLICK!
(See the Adjustments Table - Chapter “F – SUSPEN- CLICK! CLICK!
CLICK! CLICK!
SION AND WHEELS” - page 38). CLICK!
B
N.B. This operation can be made with the
shock absorber in position on the motor-
cycle.
For further checks on the round joints
where the rear shock absorber is
attached, it is necessary to carry out the
phases of removal described in chapter F
SIDE STAND
Functional check ➝ At the pre-delivery, first 1000
kilometres and then every
6000 kilometres
With the side stand lowered, check that it is not possi-
ble to switch on the engine. Also check that with the
engine switched on, when the side stand is lowered
and a gear is engaged, the engine switches off auto-
matically.
If not, the cause could be a faulty switch mounted on
the side stand. If this is the case, substitute the switch
by carrying out the following procedure.
Disconnect the electrical connectors.
Remove the 2 fixing screws of the switch.
Remove the switch.
After having substituted the switch, tighten the two
screws to the prescribed torque.
Torque pressure: 5 ÷ 7 N·m
Apply Loctite Media 243 5÷7 N•m

Reconnect the electrical connector.
Check that the side stand is not worn.
To remove the side stand, operate as follows:

- After having removed the side stand switch, unhook
the two springs; 1
- remove the nut placed behind the hanger attachment;
- remove the screw (1).
For reassembling perform the operations in reverse
tightening the nut complying with the prescribed torque.
Torque wrench setting of stand plate
screws (2):
25 ÷ 28 N·m
Torque wrench setting of hanger nut:
24 ÷ 28 N·m
Apply Loctite Media 243
2
The substitution of the springs must be car-
ried out utilising the appropriate tool. 25÷28 N•m 24÷28 N•m
Before refastening the springs, verify that
the stand can freely turn (without damages
or frictions).
- 84 -
Maintenance
FRONT FORK
Substitute oil ➝ every 24000 kilometres
The front fork is vitally important for the rideability and

roadholding of the motorcycle. It is therefore necessary B
to substitute the fork oil at the prescribed intervals.
Quantity oil: about 665 cc

Specified oil:
- Brutale 750 ORO / 750 S (MY 03): SAE 5
- Brutale 750 S (MY 04): SAE 7,5
- Brutale 910 S: SAE 7,5
- Brutale 910 R: SAE 7,5
- Brutale 989 R: SAE 7,5
- Brutale 1078 RR: SAE 7,5
To substitute the fork oil and to do a complete overhaul

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

Check and tighten ➝ At the pre-delivery, at the
first 1000 kilometres and
Carry out an accurate check of the tightness of the nuts

and screws on the motorcycle at the intervals pre-
scribed. Consult the table in chapter N “Torque pres-
sures” for the correct values”.
TUBE BAND FASTENERS

Check and tighten ➝ At the pre-delivery, at the
first 1000 kilometres and
Carry out a general check on all tube band fasteners

for their condition and tightness.
Substitute damaged band fasteners by following the
relative procedure delineated in the various sections.
- 85 -
Maintenance
ELECTRICAL SYSTEM
Check the functioning ➝ At the pre-delivery, at the first
1000 kilometres and then
B Carry out a detailed check on the various parts of the
electrical system, the contacts between components and
their good functioning.
Consult chapter E “Electrical system” for these checks.
BATTERY
Check and clean connections ➝ at the first 1000 kilo-
metres and then
every 6000 kilome-
tres
Consult chapter E “Electrical system” for the check on the
battery condition.
If it is necessary to disconnect the battery and remove it
during overhauls carried out on the motorcycle, follow the
procedure in the figure for the correct assembly.
Insert the battery in the proper compartment.
The first charge of the battery must be per-

formed before assembling it on the motorcy-
cle.
Assembly of the battery terminals
Mount the two positive terminal (+) leads onto the rel-
ative pole of the battery, respecting the order indicated
in figure. Pay attention to the colours of the cables in
order to set them in the right way.
- 86 -
Maintenance
Turn the screw of the positive terminals and tighten

them complying with the prescribed torque by using a
torque wrench.
B Torque wrench setting: 7 ÷ 8 Nm B
7 ÷ 8 N•m
When the leads are mounted, replace the protection

cover on the positive pole (see the figure).
Mount the two negative terminal (-) leads on the rela-

tive pole of the battery following the placement shown
in the figure.
- 87 -
Maintenance
Turn the screw of the negative terminals and tighten

them complying with the prescribed torque by using a
torque wrench.
B
Torque wrench setting: 7 ÷ 8 N•m
Before tightening, verify that the cables are

correctly oriented.
7÷8 N•m
At the end of assembly, ensure that the cable

of the positive terminal is placed inside the
structure of the back sub-frame (see the fig-
ure).
POSIZIONAMENTO
PLACEMENT ANDEASSEMBLY
MONTAGGIO OF
DEI TERMINALS
TERMINALI (CAPICORDA) SULLA BATTERIA.
(WIRE TERMINALS) ON THE BATTERY
NEGATIVE WIRE (-)
CAVO NEGATIVO (-)
NEGATIVE POLE (-)

POLO NEGATIVO (-)
NEGATIVE WIRE (-)

CAVO NEGATIVO (-)
CAUTELA:
CAUTION: Prima di effet-
Before
tuare il serraggio, assicu-
tightening, POSITIVE POLE
POLO POSITIVO (+) (+)
rarsi che i caviensure
siano cor-
rettamente orientati
that the wires are(vedi
figura).
correctly oriented
(see the figure)
PROTECTION
CAPPUCCIO COVER
DI PROTEZIONE
POSITIVE WIRE (+)
CAVO POSITIVO (+)
ATTENZIONE: Alla fine dell’ope-
ATTENTION: After having fin-
razione di montaggio, assicurar-
ished
si che il the
cavoassembly,
del terminaleensure
posi- that POSITIVE WIRE
CAVO POSITIVO (+) (+)
tivo
the sia posizionato
positive terminalall’interno
wire is
della struttura del telaietto poste-
placed
riore (vediinside
figura). the rear sub-frame
structure (see the figure)
- 88 -
Maintenance
INSTRUMENTS AND WARNING LIGHTS Luminous warning Luminous warning indication light
Check ➝ At the pre-delivery, at the first 1000 indication light
metres
SET
B
The instrumentation check must be carried out com- button Tachometer
pletely on all its functions as listed in the following list.
If even one of the functions does not function correct-
ly, consult chapter E “Electrical system” for complete
details. Multifunction
display
Turning the ignition key to the “ON” position activates
the instruments and the warning lights. After an initial
check-up (approximately seven seconds) the informa-
tion received correspond to the general condition of the
motorcycle at that moment.
Luminous warning indication lights

1 Main beam warning light (blue)
It lights up only when the main beam is switched on.
2 Dipped beam or sidelights warning lights (green)
It lights up when the dipped beam or sidelights posi- 1 9
tions are activated.

6 8
3 Gears in neutral warning light (green)
It lights up when the gear position is in neutral”. 2
4 Direction indicators warning light (green)
It lights up when the direction indicators are activated.
5 Fuel reserve warning light (orange)
It lights up when the fuel tank contains approximate-
ly four litres of fuel.
6 Engine oil pressure warning light (red)
It lights up when the oil pressure inside the oil lubri-
cation system is insufficient.
3
4 5
If the oil pressure warning light lights up
whilst riding the motorcycle, stop immedi-
ately. Check the oil level and if necessary
top up. If the warning light lights up and
there is a correct level of oil in the engine,
do not continue riding. Contact the nearest
authorised assistance centre.
7 Rev limiter warning light (red)
It starts when the engine exceeds 12,700 rpm
(Brutale 910 S - R: 11300 rpm; Brutale 989 R - 1078
RR: 10800 rpm); the limiting device intervenes at
13,100 rpm (Brutale 910 S - R: 12000 rpm; Brutale
989 R - 1078 RR: 11650 rpm).
8 Side stand warning light (red)
It lights up when the side stand is in the lowered
position.
9 Battery charge warning light (red)
It lights up when the alternator does not supply suf-
ficient current to recharge the battery.
If it lights up whilst riding the motorcycle, go to the
nearest authorised assistance centre.
- 89 -
Maintenance
Multi-function display
10 Speedometer
The speedometer indicates the speed. The value of
the scale can be written in kilometres per hour 10 13
B (k.p.h.) or miles per hour (m.p.h.). The highest
value on the scale is 299 k.p.h. (185 m.p.h.).
11
11 “SET” button
If pressed, the “SET” button can select the figure of
the display to effectuate adjustments. If pressed
again, the figures are confirmed.
12 Total mileometer “TOTAL”

Indicates the total mileage, from 0 to 99999.9 (kilo-
metres or miles).
Partial tripmeter 1 “TRIP 1” 12
Indicates partial mileage, from 0 to 9999.9 kilometres

or miles.
Partial tripmeter 2 “TRIP 2”
Indicates partial mileage, from 0 to 9999.9 kilometres or
miles.
Clock
Indicates the time (0 - 24).
13 Thermometer
Indicates the temperature of the engine coolant.
The value can be in centigrade (°C.) or in
Fahrenheit (°F.).
The temperature field goes from 40°C. to 140°C.
(104°F. to 284°F.).:
- under 40°C. (104°F.) the indication does not
appear. Three flashing lines appear which means
that the temperature signal is very low.;
-between 40° and 49° C (104° and 120° F) the
indication flashes wich means that the tempera-
ture is low;
- between 50°C. and 111°C. (122°F. and 232°F.) the
indication is fixed;
- between 112°C. and 140°C. (234°F. and 284°F.)
the indication flashes which means that the tem-
perature is too high.
Attention: if the temperature is over 120° C

(248° F), stop the motorcycle and check the
coolant level and the fan running on the
right side of the radiator. If it is necessary
to top up the coolant, wait for the cooling of
the engine. Do not open the engine coolant
cap when the engine is hot. If the tempera-
ture indicator continues to mark values
higher than 120° C (248° F) even if the level
is correct and the fan works, not proceed
running and contact an authorized assis-
tance centre.
- 90 -
Maintenance
Modifications to the display functions

Modifications can be made to the clock function, the
tripmeter function and the thermometer function. This
operation must be effectuated with the engine switched
on and the gears in neutral. B
Clock (hours and minutes)
Repeatedly press the starter button until the visualisa-
tion of the hour appears.
Pressing the “SET” button, the first figure of the hour

starts to flash.
Press the starting button to adjust the digit; release

when the desired digit is reached.
NOTE To obtain the quick scrolling of the selected

digit, press and hold the engine starting
button more than two seconds.
Repeat the procedure for the second figure of the hour,

for the first and second figures of the minutes.
Press the “SET” button to confirm the figures and to

interrupt the selection (the flashing).
Speedometer (k.p.h. – m.p.h.)

Repeatedly press the starter button until the visualisa-
tion of the “TOTAL” speedometer function.
Press the “SET” button. The measuring unit of the

speedometer starts to flash.
NOTE The instrumentation has an integral memory

which stores all parameters also when the
engine is off. Except for the clock, which is
set to zero, all parameters are in memory
also in case of battery disconnection.
- 91 -
Maintenance
Press the starter button to pass from kilometres per

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

Press the starter button to pass from °C. to °F. and vice
versa.
Press the “SET” button to confirm the measuring unit.
Display function selection

The selection of the “TOTAL” mileometer, the partial
“TRIP 1” mileometer, the partial “TRIP 2” mileometer
and the clock must be carried out with the engine
switched on.
Repeatedly pressing the starter button, the functions

appear in a cyclic mode.
- 92 -
Maintenance
Resetting of the tripmeters

The values of the “TRIP 1” and “TRIP 2” can be reset
as follows.
Press the starter button to activate the “TRIP 1”. B

Press the starter button for more than four seconds.
The value will start to flash.
Press the starter button for less than four seconds; the
value zeroes. If instead the starter button is pressed for
more than four seconds, the resetting procedure is
interrupted.
Pressing the engine starting button, activate the func-

tion “TRIP 2”.
Press the engine starting button for more than four

seconds; the value starts to blink.
Now pressing the engine starting button for less than

four seconds the value is set to zero.
If you press the engine starting button for more than
four seconds the zero setting is interrupted.
- 93 -
Maintenance
LIGHTS
metres
B
If any of the warning lights or the main lights are burnt
out, replace them as follows.
Dipped headlamp – bulb substitution

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

disconnect the connector (2) placed on the back of the 2
headlamp.
- 94 -
Maintenance
Put the headlamp on a table in order to perform the fol-

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

Remove the protection cover.
Release the check spring.
Extract the bulb of the dipped headlight.
Do not touch the glass of the bulb with your

hands. In case of contact clean using a
degreasing product.
Insert the new bulb.

Refasten the check spring.
Place the protection cover again.
Reconnect the connector of the dipped headlight.
Reassemble the front part of the headlamp from its
support shell.
Retighten the back screw.
Reinsert the connector of the headlamp.
Place the headlamp on its support again and retighten
the two side fixing screws, watching to reinsert the reg-
ister in its seat.
- 95 -
Maintenance
Dipped headlight – Replacing bulb

Turn the bulb of the dipped headlight counterclockwise
and extract it from its seat. 1
Disconnect the connector from the bulb.
B
degreasing product.
Insert the connector in the new bulb.

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

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

degreasing product.

Reinsert the lamp holder in its seat and set it turning
counterclockwise.
Reassemble the headlamp on its support.
Front direction indicators – bulb substitution
Remove the fixing screw.

Remove the glass.
- 96 -
Maintenance
To extract the bulb press it counterclockwise.

Insert the new bulb pressing and turning it clockwise.
Reassemble the glass and retighten the fixing screw.
Rear direction indicators – bulb substitution

Remove the fixing screw.
Remove the glass.
To extract the bulb press it counterclockwise.

Reassemble the glass and retighten the fixing screw.
- 97 -
Maintenance
Rear light/stop light – bulb substitution

Lift the passenger seat.
Extract the bulb holder, rotating it in an anti-clockwise
direction.
B
To extract the bulb, press it down and rotate it in an

anti-clockwise direction.
Reinsert the bulb holder and rotate it in a clockwise
direction.
Number plate light – bulb substitution

Remove the fixing screws of the cable guide.
- 98 -
Maintenance
Following the procedure shown in the figure, lower the

cable guide separating it from the upper supporting
surface.
Extract the lamp holder of the number plate light from

its seat.
Extract the bulb taking it out from the lamp holder.
Reinsert the lamp holder.
Place the cable guide again into contact with the upper
supporting surface.
Retighten the fixing screws of the cable guide.
Fuses – Substitution
The recharge fuse is under the rider seat as shown in
the figure.
Spare fuse
Fuse
- 99 -
Maintenance
The fuses are situated on the right side of the motor-

cycle; to reach them you should disassemble the right
side panel fixed on the tank.
Remove the cover.
Turn the ignition switch on “OFF” before

checking or replacing the fuses in order to
avoid accidental short circuits with conse-
quent risk to damage other electric compo-
nents.
To identify the position and the function of the fuses,

consult the information on the adhesive label and the
electrical system. The reference letters indicated in the
figure correspond to those shown in the electrical dia-
gram.
- 100 -
Maintenance
Replace the burnt fuse and reassemble the cover.

Remember that three spare fuses are available in the
toolkit.
Never use a fuse having an adjustment dif- B

ferent from the instructions in order to avoid
from damaging the electrical system of the
motorcycle with the consequent fire risk.
FRONT HEADLAMP
Check adjustment – At every variation of the motorcy-
cle set-up
Each time a variation to the set-up of the motorcycle is

carried out, it is good practice to carry out the adjust-
ment of the headlamp beam.
The adjustment of the front headlight can be per-

formed operating the screw shown in the side figure.
Clockwise: the headlight leans downward.
Counterclockwise: the headlight leans upwards.
The inclination can be varied for ± 4° in respect of the
standard position.
- 101 -
Maintenance
Adjusting front headlight

Place the motorcycle 10 metres from a vertical wall.
Ensure that the ground is even and that the optical axis of the projector unit is perpendicular to the wall.
The motorcycle must be in a vertical position.. Measure the height of the centre of the beam from the ground and
B mark it with a cross on the wall using a piece of chalk.
Switch on the dipped beam. The upper demarcation limit between the dark zone and the illuminated zone must
be not more than 9/10ths of the height from the ground of the centre of the beam.
- 102 -
Bodywork
SECTION
Revision 2
C
-1-
Bodywork
SUMMARY
FAIRING ASSEMBLY ................................................................................................................................Page 3

DISASSEMBLING FRONT HEADLAMP...............................................................................................Page 4
DISASSEMBLING INSTRUMENTATION PANEL .................................................................................Page 5
C
DISASSEMBLING HANDLEBAR ..........................................................................................................Page 6
DISASSEMBLING HEADLIGHT SUPPORT .........................................................................................Page 7
FUEL TANK.................................................................................................................................................Page 8
FUEL TANK SIDE PANEL REMOVAL .................................................................................................Page 9
FUEL TANK REMOVAL.........................................................................................................................Page 10
AIR FILTER COMPARTMENT....................................................................................................................Page 15
AIR FILTER COMPARTMENT REMOVAL ............................................................................................Page 16
AIRBOX REMOVAL ...............................................................................................................................Page 18
TAIL UNIT....................................................................................................................................................Page 21
TAIL UNIT REMOVAL............................................................................................................................Page 22
UNDER-TAIL ASSEMBLY ..........................................................................................................................Page 25
DISASSEMBLING UNDER TALE UNIT ................................................................................................Page 26
-2-
Bodywork
FAIRING ASSEMBLY
-3-
Bodywork
DISASSEMBLING FRONT HEADLAMP
Disassemble the two fixing screws of the headlamp.
Release the headlamp from the support for the lumi-

nous beam height control.
Disconnect the electric connection (1) and remove the

headlamp.
-4-
Bodywork
DISASSEMBLING INSTRUMENTATION PANEL
Unscrew the fixing screws and remove the instrumen-

tation panel cover by acting in the shown direction.
Loosen the rubber cowl (1) and unhook the connector.

1
Unscrew the fixing screw of the instrumentation panel

and withdraw it from the support.
-5-
Bodywork
DISASSEMBLING HANDLEBAR
Before performing this operation, you should prelimi-

narily carry out the disassembling of the front headlight
and the instrumentation panel as described in the pre-
vious pages.
Disconnect the connectors.

C
If removal of the headlamp is required, unhook the

headlamp support cables.
Disconnect the warning horn.
-6-
Bodywork
Unscrew the four fixing screws of the handlebar U bolt.
Remove the handlebar with the U bolt.

20 N•m
During the reassembly, you should pay
attention to the right positioning of the U
bolt in regard to the handlebar. This is made
using a pin that you have to insert in the
right seating of the handlebar.
Torque wrench of the U bolt handlebar fixing

screws: 20 N•m
DISASSEMBLING HEADLIGHT SUPPORT

Unscrew the three fixing screws and remove the sup- 8÷10 N•m
port.
For reassembling, perform the following operations:

- Apply the breakthread “Loctite 243” on the threaded
part of the three fixing screws.
- Position the headlight support under the steering
base and insert the three fixing screws with the
washers without tightening.
- Gently push the headlamp support towards the rear
of the motorcycle as far as the headlamp support slots
will permit.
- Tighten the fixing screws.
Torque wrench of the headlight
support screws: 8 ÷ 10 Nm
Specific product: LOCTITE 243
-7-
Bodywork
FUEL TANK
-8-
Bodywork
Before removing the fuel tank you should preliminarily

remove passenger and rider seats as described at the
paragraph “Disassembling tale unit” of this chapter.
Remove the ignition commutator protection by

unscrewing the two fixing screws (1).
FUEL TANK SIDE PANEL REMOVAL
Operate on the left side of the motorcycle.

Release the trailing part of the left side panel by relea-
sing the peg (A) from its seat (B) on the rubbered sup-
port, fastened in the rear part of the tank, making it
accomplish the movement shown in the figure.
-9-
Bodywork
Release definitely the side panel by moving it towards

the rear part in order to release it from the special rub-
bered screw (1) fastened to the fuel tank.
C
1
Make the same operations in order to remove the right

side panel.
FUEL TANK REMOVAL
Unscrew and remove the special rear fixing screw (1)

of the fuel tank to the rear sub-frame.
- 10 -
Bodywork
Operate on the right side. Unscrew and remove the

special rubbered screw (1) on the tank support.
Unscrew and remove the two support fixing screws (1)

of the tank support.
Make the same operations on the left side of the

motorcycle in order to remove the tank support.
- 11 -
Bodywork
Lift and lean the fuel tank on a side in order to easily

work on the rapid unions on the fuel pump flange.
N.B. In order to make the unions disengagement

operation from the fuel pump flange easier
it’s recommended the presence of two ope-
rators, one that works on the tank support
and the other on the rapid unions release.
C
Release the rapid unions (1).
Place a protective cloth below the tank as

there may be some fuel spillage.
The release of the fuel tubing occurs when

you press the held seat on the union as you
can see in the figure.
In case of replacement of the rapid clutch

terminals indicated in the figure, apply
Loctite 577 on the threaded part respecting
the terminal phasing when you are tighte-
ning them.
- 12 -
Bodywork
Disconnect the connector of the fuel flange pump (1) of

the main wiring.
Withdraw the fuel breather pipe (1) connected to the

three-way union.
Removing of the fuel tank plug
Insert the motorcycle key in the fuel plug lock, rotate

clockwise and open the plug.
- 13 -
Bodywork
Unscrew and remove the three screws (1) and the

safety screw (2).
1
2
C
During the reassembly of the fuel tank plug make the

same operations in the opposite direction in regard to
disassembling ones by tightening them at the descri-
bed torque and apply the indicated brakethread.
Fuel filler cap fixing screws torque pressure:
- External screws: 5 ÷ 7 N•m
- Fuel tank plug:

Apply Loctite 243 and screw in lightly
5÷7 N•m
- 14 -
Bodywork
AIR FILTER COMPARTMENT
- 15 -
Bodywork
AIR FILTER COMPARTMENT REMOVAL
Before removing the air filter compartment you should

primarily remove the fuel tank as described in the para-
graph “Tank” of this chapter.
Preliminary operations
(Brutale 750 ORO - S / Brutale 910 S-R MY 05-06)
Unscrew and remove the fixing nut (1) of the earth
wiring of the gearcase.
Disconnect the connector (1) of the temperature sen-

sor and the air pressure from the sensor.
1
1
- 16 -
Bodywork
Disconnect the connection to the gearcase from the

main wiring.
Preliminary operations
(Brutale 910 S-R - Brutale 989 R - Brutale 1078 RR
MY2007/08)
After loosening the clamp, disconnect the secondary
air hose from the hose airbox.
Disconnect the temperature sensor connector

(1) and air pressure sensor.
1
- 17 -
Bodywork
AIRBOX REMOVAL
Release the fixing springs (1) of the air filter compart-
ment box to the throttle body.
1 1
Unscrew and remove the two side fixing screws (1) of

the air filter compartment to the frame.
Disconnect the breather piping (1) from the block.
- 18 -
Bodywork
Unscrew and remove the two fixing screws (1) and the
air filter compartment locking support (2).
Remove the air filter compartment from the throttle

body.
During the reassembling make the same operations of

the disassembling paying attention to tighten the fixing
screws (1) of the ignition commutator to the described
torque wrench. 1
Torque wrench of the air filter compartment

fixing screws and locking support: 8 ÷ 10
N•m
Apply Loctite 243
8÷10 N•m
- 19 -
Bodywork
If you had to remove the fixing screws of the throttle

body springs (1), during their reassembling apply the
described brakethread and tighten them to the indica-
ted torque.
1
Torque wrench of the fixing screws of the
throttle body fly springs: 5 ÷ 7 N•m
C
Apply Loctite 243
5÷7 N•m
- 20 -
Bodywork
TAIL UNIT REMOVAL

TAIL UNIT
Insert the ignition lock key in the
opening seat lock on the left side of the motorcycle and
rotate it clockwise.
In the meantime push lightly on the passenger seat.
The lock will be released.

C
Remove the passenger seat.
Release the fixing clip of the rider seat and remove it

from its seat by lifting it.
- 21 -
Bodywork
TAIL UNIT REMOVAL
Insert the ignition lock key in the opening seat lock on

the left side of the motorcycle and rotate it clockwise.
In the meantime push lightly on the passenger seat.
The lock will be released.
Remove the passenger seat.
Release the fixing clip of the rider seat and remove it

from its seat by lifting it.
- 22 -
Bodywork
Unscrew and remove the three upper screws (1) and

the lower fixing screw of the rear fairing panels on both
sides, taking care to recover the nylon washers (2).
1 C
After that remove the side panels.
1 2
Extract the lamp holder of stop and side light from its
seat.
- 23 -
Bodywork
Unscrew the four fixing screws of the rear part tale unit.
Remove the rear part of the tale unit.
Release the electric connector and remove the lamp

holder of the tail and stop light with the wiring.
- 24 -
Bodywork
UNDER-TAIL ASSEMBLY
- 25 -
Bodywork
DISASSEMBLING UNDER TALE UNIT
Disassemble the passenger and rider seats, the side

panels and the rear tail piece as described in the pre-
vious paragraph “Disassembling tale unit”.
Disconnect the connection of the direction indicator

and of the number plate light.
C
Unscrew the three fixing screws of the number plate

holder.
Remove completely the number plate holder.
- 26 -
Bodywork
Unscrew the fixing screws of the battery connections

and remove it from its seat.
Disconnect the negative pole first.
Release the connector from the solenoid starter.
Remove the fixing screw of the starter.
- 27 -
Bodywork
Unscrew the under tale unit fixing screws.
(Brutale 910 S-R - Brutale 989 R - Brutale 1078 RR

MY2007/08)
Unhook the pressure drop sensor connector.
Remove the under tale unit.
- 28 -
Air intake injection system
SECTION
Revision 2
D
-1-
SUMMARY
INJECTION-IGNITION SYSTEM ..............................................................................................................PAGE 3

INJECTION SYSTEM TECHNICAL CHARACTERISTICS .......................................................................PAGE 3
INJECTION TIME (INJECTION VOLUME)................................................................................................PAGE 3
INJECTION TIME COMPENSATION.........................................................................................................PAGE 4
INJECTION ARREST CONTROL ..............................................................................................................PAGE 4
IGNITION SYSTEM....................................................................................................................................PAGE 5
D
POSITIONS OF ENGINE-CONTROL SYSTEM PARTS
(BRUTALE 750 ORO S - 910 S-R MY05-06) ............................................................................................PAGE 6
POSITIONS OF ENGINE-CONTROL SYSTEM PARTS
(BRUTALE 910 S - R MY07 - 989 R - 1078 RR MY08) .....................................................................................PAGE 7
FUEL PUMP CONTROL SYSTEM ............................................................................................................PAGE 8
COMPONENTS ..........................................................................................................................................PAGE 10
SENSORS ..................................................................................................................................................PAGE 12
ENGINE PICK-UP ......................................................................................................................................PAGE 15
TIMING WHEEL GAP ................................................................................................................................PAGE 15
ACTUATORS .............................................................................................................................................PAGE 16
DIAGNOSTICS SYSTEM...........................................................................................................................PAGE 17
INJECTION SYSTEM - ELECTRICAL DIAGRAM ....................................................................................PAGE 18
-2-
INJECTION-IGNITION SYSTEM
The injection-ignition system is of the "alpha/N” type. The motor r.p.m. and the throttle position are used as main
parameters to measure the amount of intake air to find the amount of fuel to be injected.
The amount of intake air for each cycle depends on the density of the air in the intake collector, the single displa-
cement and the volumetric efficiency: this last is determined experimentally on the engine for the entire functio-
ning range (rounds and engine load) and it is stored in the dimensioned plans (maps) inside the EPROM of the
electronic CPU.
The motor r.p.m. and the throttle angle also allow to calculate the ignition advance best suited for any functioning
condition.
The other system sensors (atmospheric pressure sensor, air temperature sensor, water temperature sensor and
trimmer sensor) allow to adjust the basic strategy, in specific functioning conditions.
The injector control is of a semi-sequential type, that is to say, the four injectors are controlled in couples accor- D
ding to the intake sequence.
The ignition is of the static inductive charge type with control of coil charge time integrated into
the power modules inside the CPU.
INJECTION SYSTEM TECHNICAL CHARACTERISTICS
INJECTION TIME (INJECTION VOLUME)

The factors for the determination of the injection time are the basic injection time that is calculated on the basis
of the r.p.m. of the engine, the opening of the accelerator and various compensations that are determined accor-
ding to signals coming from various sensors that reveal the condition of the engine and the riding conditions.
Enginevelocità
Segnale r.p.m. signal
motore
Camshaft positionalbero
Sensore posizione sensor
motore
TEMPO
BASIC
INIEZIONE
INJECTION
Accelerator opening signal DITIME
BASE
Segnale apertura acceleratore
Sensore posizione
Accelerator acceleratore
position sensor
ECU
Various signals
Segnali vari COMPEN-
COMPENSA
Various sensors
Sensori vari SATION
ZIONE
Injection signal TEMPO

FINAL
Segnale iniezione INIEZIONE
INJECTION
Injectors
Iniettori
FINALE
TIME
-3-
INJECTION TIME COMPENSATION
The various sensors allow the injection time (volume) compensations to be carried out on the basis of the following
signals.
SIGNAL DESCRIPTION
When the atmospheric pressure is low, the sensor

ATMOSPHERIC PRESSURE SENSOR SIGNAL
sends a signal to the ECU to reduce the injection
time (volume of the fuel injected) to compensate
the lower presence of oxygen in the atmosphere.
D When the temperature of the engine coolant is low,

ENGINE COOLANT TEMPERATURE SENSOR the injection time (volume) is increased to sustain
SIGNAL the minimum r.p.m. and to compensate the part of
the fuel which condensates along the intake con-
duits.
When the temperature of the intake air is low, the

AIR INTAKE TEMPERATURE SENSOR SIGNAL injection time (volume) is increased to compensate
the higher presence of oxygen.
BATTERY VOLTAGE SIGNAL The battery voltage signal is supplied to the ECU for
the functioning of the ECU and this voltage is revea-
led and utilised as a signal for the compensation of
the injection time (volume). A low voltage determi-
nes a longer injection time for adjustment of the
volume of the injection.
When the engine is switched on, during craking a

STARTER SIGNAL greater volume of fuel is injectedto make starting
easier.
ACCELERATION/DECELERATION SIGNAL During acceleration, the injection time of the fuel

(volume) is increased in proportion to the opening of
the accelerator and the r.p.m. of the engine. During
deceleration, the injection of fuel is diminished in
proportion to the speed of closure of the accelerator
handgrip and of the engine r.p.m.
INJECTION ARREST CONTROL
SIGNAL DESCRIPTION
R.P.M. LIMITER SIGNAL
The functioning of the fuel injectors is interrupted
when the level of engine r.p.m. reaches its limit.
-4-
IGNITION SYSTEM
DESCRIPTION
The system belongs to the family of integrated systems of digital electronic ignition with advance static timing
and electronic fuel injection of the semi-phased intermittent type (injected and ignition simultaneously to cylin-
ders 1-4 and 2-3).
This ignition system consists of an engine crankshaft position sensor (pick-up), an ECU, four ignition coils of
the top plug type and four spark plugs.
The feed of the ignition coil is supplied by the battery via the power relay and is controlled by the ECU with
regards to the position of the switches of the side stand and the gearchange.
The ignition timing is precisely controlled with regards to the engine r.p.m. and the position of the accelera-
tor. Other than this basic condition, also the temperature, intake air pressure and the temperature of the D
engine coolant influence the ignition timing.
N.B.
The ignition interruption circuit is incorporated in the ECU to avoid over-revving the engine. If the motor rea-
ches 12100 r.p.m., this circuit prevents the ignition for all cylinders.
WARNING
The engine could function at more than 12100 r.p.m. without a load or when changing down, even if
the interruption circuit functions and therefore could damage the engine. Never spin the engine at
more than 12100 r.p.m. in any conditions.
-5-
D
POSIZIONE
POSITION OFPARTI SISTEMA CONTROLLO
ENGINE-CONTROL MOTORE
SYSTEM (BRUTALE
PARTS 750 ORO
(BRUTALE 750 S - 910 S-R
ORO-S- (MY
910 05-06)
S-R (MY 05-06)

-6-
A Cruscotto
Instrument panel E E Sensore
Intake airtemperatura-pressione
pressure/tempera- aria I I Centralina
Service unit servizi
Engine
B Sensore temperatura temperature
coolantliquido ture
in sensor
aspirazione L Motor control
L Centralina unit
di controllo motore
sensor
refrigerante Fuel pump
F F Pompa carburante M Starter switch
M Teleruttore avviamento
Ignition
C Bobine coil
di accensione Accelerator
G G Sensore position sensor
posizione acceleratore
D Camshaft
D Sensore position
posizione sensor
albero motore Fuel injectors
H H Iniettori carburante
POSITIONS OF ENGINE-CONTROL SYSTEM PARTS (BRUTALE 910 S-R MY 2007 - BRUTALE 989 R - 1078 RR MY 2008)

-7-
A Instrument panel ture sensor M Starter switch

B Engine coolant temperature F Fuel pump N Phase sensor
sensor G Accelerator position sensor O Secondary airValve
C Ignition coil H Fuel injectors P Fall sensor
D Camshaft position sensor I Service unit Q Lambda Sonde
E Intake air pressure/tempera- L Motor control unit
D
FUEL PUMP CONTROL SYSTEM
When the ignition switch is switched to the "ON" position, the current from the battery reaches the motor of the
fuel pump via the side stand relay and the pump relay thereby switching on the motor.
As the CPU possesses a timer function, the pump motor stops turning three seconds after the ignition switch has
been brought to the "ON" position. If the starter motor turns the electric motor shaft during or after the three
seconds, the motor rotation signal is sent to the CPU that, by controlling the pump relay, makes the pump motor
function continuously. When the ignition switch is switched to the "OFF" position, the control of the pump relay is
interrupted and contemporaneously also the control of the injectors and the ignition coils, thereby causing the
engine to switch off.
SAFETY SWITCH
IGNITION CONTROL
LATCH BATTERY
RELAY
FUSE 09
FUSE 13
NEUTRAL LED
GENERAL SWITCH
FUSE 11 RELAY SOLENOID
FUSE 03 STARTER
POWER
FUSE 15 RELAY
SIDE STAND
PICK UP SWITCH
CLUTCH
SWITCH
GEARCASE 1.5 W
SPARK PLUG COVERS

THROTTLE BODY WITH SUPPRESSOR
-8-
Fuel feed system

The fuel feed system consists of the tank, pump, filter, feed tube, feed tubes (including the fuel injectors), regu-
lator of the pressure and the fuel return tube. The fuel in the tank is pumped into the feed tubing at a controlled
pressure by the relative regulator and maintained at a certain constant value higher than the suction generated
by the motor. The fuel is injected into the air intake conduit when the injector opens, following a law generated by
the ECU. The excess fuel is not consumed and returns to the tank via return fuel tube.
FUEL DISCHARGE
SCARICO TO THE
CARBURANTE GROUND
A TERRA
(TOO FULL)
(TROPPO PIENO)
WATER DISCHARGE
SCARICO TO THE GROUND
ACQUA A TERRA
FUEL FILTER
FILTRO CARBURANTE
FUEL PUMP
POMPA CARBURANTE
TUBO
FUEL MANDATA CARBURANTE
FEED TUBE (WHITE UNION)
(RACCORDO BIANCO)
TUBO
FUEL RITORNO
RETURN CARBURANTE
TUBE (BLACK UNION)
(RACCORDO NERO)
DISCHARGE OF WATER
SCARICO ACQUA E AND
CARBURANTE
FUEL TO THE A TERRA
GROUND
-9-
COMPONENTS
Fuel pump
The electric fuel pump that is situated inside the fuel tank consists of an electric motor, of the rotor, impeller, con-
trol valve and pressure release valve.
The ECU controls the ON/OFF condition as described in the section FUEL PUMP CONTROL SYSTEM.
When electrical energy is supplied to the pump, the motor switches on and the impeller activates. This causes a
difference in pressure on both sides of the impeller because the paddles of the impeller are grooved. The fuel is
therefore sucked towards the output passage. The pump possesses a control valve to maintain a certain pres-
sure in the fuel feed tube even when the pump is stopped and the pressure release valve opens to send fuel back
to the tank when the pressure of the feed fuel increases to 4.5 - 6.5 kg/cm2.
D Absorbed current: 6 – 6.5A at a 13.5V voltage input
When the motor activates the impeller there is a difference in the pressure between the front part of the paddles
and the rear part with the grooves, seen from an angular direction, because of the friction of the fluid. This pro-
cess is continuous, thereby causing the increase in the fuel pressure. The pressurised fuel therefore leaves the
pump chamber and is discharged towards the section of the motor and the control valve.
- 10 -
Fuel pressure regulator

The fuel pressure regulator is a diaphragm pressure release valve that consists of a diaphragm, spring and valve.
It always maintains the pressure of the fuel sent to the injector at 3.0 kg/cm2 (300 kPa).
When the pressure of the fuel rises above 3.0 kg/cm2 (300 kPa) the excess fuel opens the valve of the regulator
and therefore can return to the fuel tank.
- 11 -
SENSORS
Atmospheric air temperature/pressure

The air intake sensor is situated on the right side of
the air filter compartment and indicates both the atmo-
spheric pressure and the air temperature.
Intake air pressure sensor

The sensor reveals the pressure of the intake air and
this pressure is therefore converted into voltage that is
sent to the ECU.
The basic injection time (volume) of the fuel is
D determined according to the voltage of the signal
(output voltage).
The voltage increases when the pressure of the intake
air is high.
Output voltage
(V)
High
Low
Pressure of the intake air

(mmHg)
Low High
- 12 -
Intake air temperature sensor

The temperature of the intake air is found measuring the resistance of the Thermistor. The resistance value read
is proportionate to the voltage read by the ECU.
The volume of fuel injected increases when the intake air temperature is low.
The resistance of the Thermistor increases when the air temperature is low and diminishes when the temperatu-
re is high (NTC type sensor).
Resistance value
(kΩ) D
High
Low
°C
Low High Temperature
AIR TEMPERATURE ‘ D - C
Air temperature sensor characteristics

Temperature (°C) Resistance (kΩ)
-10 9.5
0 6
10 3.8
20 2.5
30 1.6
40 1.1
60 0.6
D
A
AIR PRESSURE ‘ D - A
VOLTAGE FEED TEST C

B
‘ D - B (~ 4,9 ± 0,1 volt)
- 13 -
Throttle body position

The sensor of the throttle position is situated on the
right side of the throttle body.
This sensor is a potentiometer with a resistance which
varies according to the opening angle of the accelera-
tor.
The sensor is supplied by the ECU at a stabilised vol-
tage of 5V and supplies an output voltage proportiona-
te to the throttle angle.
The basic injection time of the fuel (volume) is deter-
mined according to the output voltage of this sensor.
The voltage increases when the accelerator opening is
D increased.
Output voltage
(V)
throttle’s angle
RESISTANCE TEST ‘ A - C
FEED TEST ‘ (~ 4,9 ± 1 volt)
A – – (pin 16)
B – + 5V (pin 14)
C – Signal (pin 30)
- 14 -
ENGINE PICK-UP
The r.p.m./TDC sensor is of an inductive type and is
situated on the left side of the motorcycle.
To check this component it is necessary to identify the

relative connector positioned as shown in the figure,
inside the frame on the right side of the motorcycle.
After having disconnected the pick-up connector, mea-

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

To guarantee the correct functioning of the pick-up it is
necessary to measure the gap between the pick-up
and the timing wheel, that is to say the distance
between the pick-up and the timing wheel by utilising a
feeler gauge as shown in the figure.
GAP width: 0,6 ÷ 0,7 mm
To carry out this check it is necessary to remove the

cover of the timing wheel by consulting the Workshop
Engine Manual.
- 15 -
ACTUATORS
Fuel injector
The fuel injector consists of a solenoid, piston, needle valve and a filter.
The injector is a small electromagnetic injection nozzle that injects fuel into the carburettor according to the signal
coming from the ECU.
When the solenoid is agitated by the ECU, it becomes an electromagnet and attracts the piston. At the same time,
the needle valve incorporated in the piston opens and the injector, under pressure of the fuel, injects the fuel in a
conical dispersion. Given that the opening of the needle valve is constant, the volume of fuel injected at any one
time is dependent on the time that the solenoid is agitated (injection time).
D TECHNICAL DATA: Winding resistance 14.5 Ω
Ignition coils
The ignition coils are of the top plug type (they are assembled directly on the spark plugs. This avoids the use of
the HT leads and enhance the overall system reliability.
ELECTRICAL DIAGRAM
- 16 -
DIAGNOSTICS SYSTEM
Ignition and injection system diagnostics

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

operations:
- reading of engine parameters
- reading of faults and their deletion
- active diagnosis
- 17 -
D
SAFETY SWITCH
IGNITION CONTROL
LATCH BATTERY
RELAY
FUSE 09
FUSE 13
NEUTRAL LED
GENERAL SWITCH
FUSE 11 RELAY
FUSE 03 SOLENOID
STARTER
POWER

FUSE 15 RELAY
SIDE STAND
PICK UP SWITCH
CLUTCH
SWITCH
INJECTION SYSTEM - ELECTRICAL DIAGRAM
GEARCASE 1.8 W
- 18 -
SPARK PLUG COVERS

WITH SUPPRESSOR
THROTTLE BODY
MV Agusta Brutale Oro – S Engine control unit pinout
Pin Description Type of signal

01 cylinders 1-4 coil control power output
02 nc
03 nc
04 Latch relay control digital output
05 Injectors 2-3 control power output
06 nc
07 engine enabling from safety logics digital input
08 aknowledgment of gear not engaged digital input
09 nc
10 K rx line communication line D
11 r.p.m./tdc sensor (pick up) frequency input
12 nc
13 water temperatue sensor signal analogue input
14 sensor reference voltage power output
15 K tx line comunication line
16 sensor gnd power output
17 power gnd power input
18 nc
19 cylinders 2-3 coil control power output
20 fan control
21 nc
22 injectors 1-4 control power output
23 power relay control (fuel pump of coil injectors) digital output
24 revcounter control frequency output
25 nc
26 on key input digital input
27 nc
28 r.p.m./tdc sensor (pick up) frequency input
29 nc
30 throttle potentiometer signal analogue input
31 air temperature sensor signal analogue input
32 air pressure signal analogue input
33 nc
34 power gnd power input
35 enabling from latch relay
- 19 -
- 20 -
Electrical system
SECTION
Revision 3
E
-1-
Electrical system
SUMMARY
CONNECTORS .........................................................................................................................................PAGE 3
COUPLINGS ..............................................................................................................................................PAGE 3
FUSES........................................................................................................................................................PAGE 3
SEMICONDUCTOR PARTS.......................................................................................................................PAGE 4
ELECTRICAL DIAGRAM BRUTALE 750 ORO-S / 910 S-R MY 05/06) .................................................PAGE 5
PARTS LIST .........................................................................................................................................PAGE 6
ELECTRICAL DIAGRAM BRUTALE 910 S – R (MY 2007) 989 R - 1078 RR (MY 2008) .....................PAGE 7
PARTS LIST .........................................................................................................................................PAGE 8
BATTERY ...................................................................................................................................................PAGE 9
INITIAL BATTERY CHARGE ................................................................................................................PAGE 9
E BATTERY ASSEMBLY..........................................................................................................................PAGE 9
CHARGING SYSTEM............................................................................................................................PAGE 14
BATTERY EFFICIENCY CHECK ..........................................................................................................PAGE 22
CPU .......................................................................................................................................................PAGE 24
FUNCTION DIAGRAM...............................................................................................................................PAGE 24
STARTER SYSTEM ...................................................................................................................................PAGE 25
FUSES...................................................................................................................................................PAGE 34
STARTER MOTOR REMOVAL .............................................................................................................PAGE 34
STARTER MOTOR CHECK..................................................................................................................PAGE 35
STARTER MOTOR ASSEMBLY ...........................................................................................................PAGE 35
IGNITION/SIDE STAND SAFETY SYSTEM PARTS CHECK ..............................................................PAGE 37
GEARCHANGE POSITION SWITCH ...................................................................................................PAGE 38
SIDE STAND SWITCH ..........................................................................................................................PAGE 38
SPARK PLUGS .....................................................................................................................................PAGE 39
RUN OFF SAFETY SWITCH ................................................................................................................PAGE 40
INSTRUMENTATION .................................................................................................................................PAGE 42
OIL PRESSURE SENSOR....................................................................................................................PAGE 43
FUEL LEVEL WARNING LIGHT CHECK SWITCH .............................................................................PAGE 43
INSTRUMENT PANEL WATER SENSOR ............................................................................................PAGE 44
KEY IGNITION SWITCH .......................................................................................................................PAGE 44
STARTER RELAY ACTIVATION...........................................................................................................PAGE 44
LEFT DIRECTION INDICATOR ...........................................................................................................PAGE 45
RIGHT DIRECTION INDICATOR ..........................................................................................................PAGE 45
RPM INDICATOR ..................................................................................................................................PAGE 45
SPEED SENSOR .................................................................................................................................PAGE 45
COOLING FAN SYSTEM...........................................................................................................................PAGE 46
HORN .........................................................................................................................................................PAGE 47
SWITCHES.................................................................................................................................................PAGE 48
-2-
Electrical system
CONNECTORS
• When a connector is connected, check that it clicks

into position.
• Check the connector for corrosion, dirt or a broken
cover. CLICK
COUPLINGS
CLICK
• Block couplings – ensure that the block is released
before disconnecting it to push it completely home
when connecting it.
• When disconnecting a coupling, ensure that the body
of the coupling is gripped and do not pull it apart by
the leads.
• Check that the terminals of the couplings are not
slack or bent.
• Check that the terminals are not corroded or dirty.
FUSES
• When a fuse burns out, always investigate why the

fuse has burnt out. Find the cause, repair and then
substitute the fuse.
• Do not utilise a fuse of a different capacity from the
original one.
• Do not utilise wire or any other substitute for the fuse.
-3-
Electrical system
SEMICONDUCTOR PARTS
• Pay special attention to not drop parts incorporating INCORRECT

semiconductors (ECU, instrument panel, CPU).
• When checking these components, carry out the
instruction strictly. The lack of using the correct pro-
cedure can cause grave damage.
-4-
Electrical system
ELECTRICAL DIAGRAM BRUTALE 750 ORO-S / 910 S-R (MY 05/06)
-5-
Electrical system
PARTS LIST
Parts list Parts list Parts list

Ref. Description Ref. Description Ref. Description
1 CPU 16 Solenoidd 32 Instrument panel
2 Number plate light 17-18 33 Air temperature/pressure sensor
Injectors
Iniettori
3 Right indicator 19-20 34 Left indicator
4 Left indicator 21 Butterfly potentiometer 35 Horn
5 Diagnostic connector 22 Water temperature sensor – CPU 36 Water temperature sensor for instrument ther-
6 Rear stop light 23 Oil switch mometer
7 Neutral switch 24 Electric fan 37 Light switch
8-9 Battery 25 Fuses 38 Frame/CPU earth
10 Fuel probe – pump 26 Side stand switch 39 Battery recharge
11 R.p.m. sensor 27 Rear stop switch 40 Clutch switch
12 Coil 28 Ignition switch 41 Starter motor
13 Coil 29 Safety and Front stop switch 42 Frame earth
14 Alternator 30 Right indicator 43 Engine earth
15 Speed sensor 31 Front headlight
E
Wiring colour code Fuses list
Letter(s) Colour Ref. Amps Use
R Red (A)
Y Yellow F1 5 Instrument panel warning light
B Blue F2 5 Side lights
G Green F3 5 Speed sensor
W White F4 5 Right direction indicator
Bk Black
F5 5 Left direction indicator
P Pink
F6 15 Electric cooling fan
V Violet
F7 5 Rear headlight/stop light
Sb Sky blue
F8 15 Latch relay
Gr Grey
F9 7.5 Starter switch
O Orange
F10 15 Dipped beam headlight
Br Brown
F11 5 Instrument panel clock
In combined colors, background and marking colors have been poin- F12 15 Main beam headlight
ted out. E.g. : Br/Bk. F13 15 Injectors-Fuel pump-Coils
F14 40 Battery recharge
F15 40 Spare for battery recharge
-6-
Electrical system
ELECTRICAL DIAGRAM BRUTALE 910 S – R (MY 2007) BRUTALE 989 R - 1078 RR (MY 2008).
5-21W
10W
10W
F13
F14
PUSH
UP
DOWN
FREE
Y
PASSING
G / R Gy/R
HI
R
POS.
TURN
LOCK
PA R K
OFF
ON
HORN
RUN
OFF
F9 F8 F7 F6 F5 F4 F3 F2 F1
S TA R T
10W
PRESS. AIR
10W
55W
60W
F12 F11 F10
5W
-7-
Electrical system
PARTS LIST
Parts list Parts list Parts list
Rif. Description Rif. Description Rif. Description
1 CPU 21 Butterfly potentiometer 37 Light switch
2 Number plate light 22 Water temperature sensor – CPU 38 Frame/CPU earth
3 Right indicator 23 Oil switch 39 Battery recharge
4 Left indicator 24 Electric fan 40 Clutch switch
5 Diagnostic connector 25 Fuses 41 Starter motor
6 Rear stop light 26 Side stand switch 42 Frame earth
7 Neutral switch 27 Rear stop switch 43 Service control unit
8-9 Battery 28 Ignition switch 44 Lambda probe
10 Fuel probe – pump 29 Safety and Front stop switch 45 Anti-theft connector
11 R.p.m. sensor 30 Right indicator 46 LED indicator
12 Coil 31 Front headlight 47 Saddle switch
13 Coil 32 Instrument panel 48 Drop switch
14 Alternator 33 Air temperature/pressure sensor 49 Cam rev sensor
15 Speed sensor 34 Left indicator 50 Battery recharge kit connector
16 Solenoidd 35 Horn
E 17-18
Injectors
36 Water temperature sensor for instrument ther-
19-20 mometer
Wiring colour code Fuses list

Letter(s) Colour Ref. Amps Use
R Red (A)
Y Yellow F1 5 Side lights
B Blue F2 5 Speed sensor
G Green F3 5 Right direction indicator
W White F4 5 Left direction indicator
Bk Black
F5 15 Electric cooling fan
P Pink
F6 5 Rear headlight/stop light
V Violet
F7 15 Latch relay
Sb Sky blue
F8 7,5 Start switch
Gr Grey
F9 15 Dipped beam headlight
O Orange
F10 5 Instrument panel clock
Br Brown
F11 15 Main beam headlight
In combined colors, background and marking colors have been poin- F12 15 Injectors-Fuel pump-Coils
ted out. E.g. : Br/Bk. F13 40 Battery recharge
F14 40 Spare for battery recharge
-8-
Electrical system
BATTERY
The battery mounted on this motorcycle is a sealed

battery therefore no maintenance is required.
The batteries recommended are the following:
- YUASA YTZ10-S (pre-activated).
INITIAL BATTERY CHARGE
Proceed with charging following the method on the

packet that the battery came in or as indicated in the
following table.
Charging method
It is preferable to charge the battery at a constant vol-
tage to not overcharge battery as follows:
Method V C A Load time

(voltage) (temperature) (Load current) (time)
Normal 14,4 20 0,25xC 12-24
Rapid 14,4 20 1xC 6-8
BATTERY ASSEMBLY
Insert the motorcycle key into the rear lock. Turn the
key clockwise while lifting the passenger seat up.
-9-
Electrical system
Remove the passenger seat as shown in the figure.
Rotate the rider seat fastener as shown in the figure.
Lift up the rider seat and remove it.
- 10 -
Electrical system
Insert the battery into the appropriate compartment.
The initial battery charge should be carried

out before mounting it on the motorcycle.
Battery terminal assembly
Assemble the two positive (+) terminal leads on the

relative battery pole, respecting the order shown in the
figure.
Pay attention to the colours of the cable in order to
position them correctly.
Rotate the screw of positive terminal leads and tighten

to the prescribed torque using a torque wrench.
7 ÷ 8 N•m
- 11 -
Electrical system
When the terminals are mounted replace the protec-

tion cover on the positive pole (see figure).
Connect the two negative (-) terminal leads to the rela-

tive pole of the battery respecting the placing shown in
the figure.
Rotate the screw of negative terminal leads and tighten

to the prescribed torque, using a torque wrench.
Before tightening, make sure that

the cables are oriented correctly.
7 ÷ 8 N•m
- 12 -
Electrical system
After the assembly operation, make sure

that the positive terminal cable is positioned
correctly inside the rear frame unit (see figu-
re).
POSIZIONAMENTO
PLACEMENT ANDE ASSEMBLY
MONTAGGIO OF
DEI TERMINALS
TERMINALI (CAPICORDA) SULLA BATTERIA.
(WIRE TERMINALS) ON THE BATTERY
NEGATIVE WIRE (-)
CAVO NEGATIVO (-)
NEGATIVE POLE (-)

POLO NEGATIVO (-)
NEGATIVE WIRE (-)

CAVO NEGATIVO (-)
CAUTELA: Prima di effet- POSITIVE POLE (+)
CAUTION:
tuare Before
il serraggio, assicu- POLO POSITIVO (+)
tightening,
rarsi che i caviensure
siano cor-
rettamente
that the orientati
wires are(vedi
figura).
correctly oriented
(see the figure)
PROTECTION COVER
CAPPUCCIO DI PROTEZIONE
POSITIVE WIRE (+)
CAVO POSITIVO (+)
ATTENZIONE:
ATTENTION:Alla fine having
After dell’ope- fini-
razione di montaggio, assicurar-
shed
si che ilthe
cavoassembly,
del terminale ensure
posi- that POSITIVE WIRE (+)
CAVO POSITIVO (+)
the positive
tivo terminal
sia posizionato wire is pla-
all’interno
della struttura del telaietto poste-
ced inside the
riore (vedi figura). rear sub-frame
structure (see the figure)
- 13 -
Electrical system
CHARGING SYSTEM
The system of the charging circuit illustrated as follows is substantially composed of a generator and a
rectifier/regulator, enclosed in one component.
The alternating current (AC) is transformed into direct current (DC) by the rectifier, regulated and therefore utilised
for charging the battery.
Ignition
IG Switch
E Stator coil B IG
S S
R
F
Battery
L L Charge
Load
M.IC Lamp
Tr1
Tr3
Rotor coil
P
F
IC Regulator
Warning function
• Disconnection of the coil

• Disconnection of the regulator
• Disconnection of terminal B (voltage at terminal S is
less than 13 volts)
Any one of these abnormalities switches on the warning
light on the instrument panel.
As shown in the figure, the temperature influences the

characteristics of the regulator with steps of variation of
the regulated voltage.
- 14 -
Electrical system
In the preceding diagram is illustrated the complete charging circuit. The input circuit of the regulator includes the
integrated M-IC that, being complex in its various functions will be simply indicated as M-IC.
(1) Ignition switch “ON” with engine off.
Ignition
Switch
IG
E
Stator coil B IG
S S
R
F
Battery
L L Charge
Load
M.IC Lamp
Tr1
Tr3
Rotor coil
P
F
IC Regulator
The M-IC reveals the battery voltage applied to the IG terminal and activates Tr1. The initial current passes via
the rotor coil (to reduce the battery charge to the minimum when it is in this condition), Tr1 passes from “ON” to
“OFF” intermittently thereby reducing the absorption of the system to 0.17A.
During this period the generator is not functioning and does not generate any voltage. The voltage at point P is
0V and M-IC revealing this value, activates Tr3 which switches on the warning light.
- 15 -
Electrical system
(2) Recharging (voltage less than the regulated voltage).
Ignition
E IG Switch
Stator coil B IG
S S
R
F
Battery
L L Charge
Load
M.IC Lamp
Tr1
Tr3
Rotor coil
P
F
IC Regulator
Once the engine is switched on, the M-IC makes the Tr1 pass from an intermittent “ON” and “OFF” condition to
a stabilised “ON” condition to guarantee an abundant flow of current and a rapid recharge.
At this point, the M-IC disactivates also Tr3 that switches off the warning light.
When the voltage at terminal B exceeds the battery voltage, then the battery starts recharging.
- 16 -
Electrical system
(3) Recharge (voltage more than the regulated voltage).
Charge Current
B
Ignition
IG Switch E
Stator coil B IG
S S
R
F
Battery
L L Charge
Load
M.IC Lamp
Tr1
Tr3
Rotor coil
P
F
IC Regulator
The moment in which the Tr1 is stabilised in the “ON” position the voltage at terminal B increases and when the
voltage at terminal S exceeds the regulated voltage (approximately 14.5V at 25°), the I-MC realises it and puts
the Tr1 in the “OFF” position. This condition is maintained until the voltage at terminal S does not become less
than the regulated voltage.
- 17 -
Electrical system
(4) Rotor coil disconnected.
Charge Current
B
Ignition
E IG Switch
Stator coil B IG
S S
R
F
Battery
L L Charge
Load
M.IC Lamp
Tr1
Tr3
Rotor coil
P
F
IC Regulator
If the rotor coil is disconnected whilst the generator is functioning, the generator interrupts the current and the vol-
tage at terminal P goes to zero.
The M-IC reveals this condition and through the Tr3 switches on the warning light.
- 18 -
Electrical system
(5) Disconnection of terminal S of the regulator.
Charge Current
B
Ignition
Switch
IG
E
Stator coil B IG
S S
R
F
Battery
L L Charge
Load
M.IC Lamp
Tr1
Tr3
Rotor coil
P
F
IC Regulator
If a reference voltage does not arrive at terminal S whilst the alternator is functioning, the M-IC reveals it and
through Tr3 switches on the warning light.
At this point the M-IC, to maintain the voltage at terminal B between 13.3V and 16.3V activates and disactivates
Tr1.
- 19 -
Electrical system
(6) Terminal B disconnected.
Charge Current
B
Ignition
Switch
E 2 IG
Stator coil B IG
S 1 S
R
F
Battery
L 4 L Charge
Load
M.IC Lamp
Tr1
Tr3
Rotor coil
P
F
IC Regulator
4Connettore a 4 vie
ways connector
If terminal B is disconnected whilst the alternator is functioning, the voltage of the battery gradually drops until it
starts discharging. As long as the voltage at terminal S is more than 13V the M-IC maintains the voltage at ter-
minal B at 20V, protecting the alternator and the rectifier in the moment in which the voltage at terminal S drops
under 13V. The M-IC reveals it through Tr3 and activates the warning light.
- 20 -
Electrical system
A list of possible problems that could occur when the warning light is switched on.
Incorrect contact at terminal B or the 4- YES Repair the fault.

way coupling; interruption of the system
The light still remains on.
including the fuses or short circuit.
NO
YES
NO OK
E
There is a short circuit between terminal YES

Repair the fault.
L and earth.
NO
With the engine switched on at approxi-

mately 2000 r.p.m. check the voltage of
the battery (all utilities must be switched
NO, the vol- Check the earthing of the engine and
off and the regulator at 25°C.); the voltage
tage is lower. increase the r.p.m.
must be 14.5V ± 0.6.
N.B. At different temperatures the voltage
can be between 13V and 15.5V.
NO
YES
Substitute the alternator.
Check that there is a good connection of

the charging leads and the charging fuse.
- 21 -
Electrical system
BATTERY EFFICIENCY CHECK
Battery current loss check

• Remove the tail unit as described in chapter C
“Bodywork”.
• Turn the ignition switch to the “OFF” position.
• Disconnect the cable from the negative (-) pole of the
battery.
• Connect the multi-tester between the negative (-) ter-
minal and the negative (-) cable of the battery.
Losses are indicated if the tester measures more than
2-2.5mA.
Battery current loss: less than 1mA
E First of all when using an ampmeter, utilise a high

range of the multi-tester because the current los-
ses in the case of malfunctioning could be eleva-
ted.
If losses are found, search for the part where the tester
measures less than 2-2.5mA by removing couplings
and connectors one at a time.
Black lead Red lead
- 22 -
Electrical system
Charge feed check

• Remove the tail unit
• Switch on the engine and run it at 2000 r.p.m. with
the light switch in the “ON” position and the selector
on main beam Hl.
Measure the voltage between the positive (+) and

negative (-) terminals of the battery with a multi-tester.
If the tester indicates less than 12.6V or more than
14.3V the cause will be found in the generator.
Battery
N.B. When carrying out this check, ensure that
the battery is fully charged.
Standard recharge voltage: Tester

12.6 - 14.3V at 2000 r.p.m. (VCC)
- 23 -
Electrical system
CPU
The CPU includes a group of functions previously performed by other components of the motorcycle. This allowed
to simplify wiring and to reduce connections. The general reliability of the unit is enhanced and overall weight is
reduced.
FUNCTION DIAGRAM
ELECTRICAL SYSTEM
BAT
IGNITION SWITCH
FUEL-INJECTOR-COIL PUMP
E ON/OFF RIGHT CONTROL ENGINE CONTROL GEARCASE PIN 23

DIRECT POSITIVE FOR INSTRUMENT PANEL
ALTERNATOR – TAIL LIGHTS
RIGHT CONTROL – KLAXON POSITIVE 02
ALTERNATOR – SPEED SENSOR –INSTRUMENT PANEL – RESERVE
PROBE POSITIVE 03
STOP LIGHTS POSITIVE 04
INTERMITTENCE LED
RIGHT IND. CONTROL
LEFT IND. CONTROL
RIGHT TURN INDICATORS
LEFT TURN INDICATORS
DRIVING BEAM
DRIVING BEAM CONTROL
LOWER BEAM
LOWER BEAM CONTROL
ENGINE CONTROL GEARCASE PIN 35
ENGINE CONTROL GEARCASE PIN 4
ELECTRIC FAN
ELECTRIC FAN CONTROL FROM ENGINE CONTROL
GEARCASE
CLUTCH SWITCH REMOTE CONTROL SWITCH COIL
ENGINE CONTROL GERCASE

PIN 7
CLUTCH SWITCH
STAND SWITCH
NEUTRAL SWITCH
A – with neutral engaged, the contact is closed.

B – for ECU with “Pull up” input to battery voltage or for
negative coil ignition feed relay.
C – side stand switch.
D – Neutral warning light.
E – Side stand lowered warning light position.
F – Clutch switch.
G – 1N5404 diode.
H – Engine start switch.
- 24 -
Electrical system
STARTER SYSTEM
The diagram below represents the starter system.
SISTEMA
IGNITION -INJECTION
ACCENSIONE KILL
INTERRUTTORE
SYSTEM
INIEZIONE SWITCH
SPEGNIMENTO
15A
D
7.5A
N
POSITIVE
POSITIVOTER-
MINAL – BAT-
BATT.
TERY
2 A N.O.
E
E
C
G G
1 B
IN CENTRALINA
ECU 1.6 M
1.6M
F N.O.
3 H
BATT
++BATTERY
BATTERIA STARTER
MOTORINO
MOTOR
B M
RICARICA
RECHARGE
IN EFFECT
START SWITCH ENGINE
GEAR POSITION STAND POSITION CLUTCH LEVER POSITION
DISABLED LOCKED OFF
1 I I I NO NO
2 I O I NO NO
3 I I O NO NO
4 I O O NO NO
5 O O I NO NO
6 O I I SI SI
7 O I O SI SI
8 O O O SI NO
GEAR I: neutral condition

O: not neutral condition
STAND I: down
O: up
CLUTCH LEVER I: pulled lever

O: leaved lever
ELECTRIC START Start switch disabled

LOCKED DISABLED
ENGINE LOCKED
Engine forced off
OFF
- 25 -
E
Ignition key in the “OFF”
position SAFETY SWITCH
IGNITION CONTROL
LATCH BATTERY
RELAY
FUSE 09
FUSE 13
NEUTRAL LED
SWITCH
GENERAL
FUSE 03
STARTER
POWER
FUSE 15 RELAY

SIDE STAND
PICK UP SWITCH
CLUTCH
SWITCH
GEARCASE 1.8 W
- 26 -
Electrical system
SPARK PLUG COVERS

WITH SUPPRESSOR
THROTTLE BODY
Ignition key in the “ON” posi-
tion SAFETY SWITCH
Safety switch in the “RUN”
IGNITION CONTROL
position
LATCH BATTERY
Start activated FUSE 09 RELAY
Side stand lowered
Gear engaged
Clutch not pulled in FUSE 13 NEUTRAL LED
Engine not switched on SWITCH
GENERAL
FUSE 03 FUSE 11 RELAY SOLENOID
STARTER

FUSE 15 POWER
RELAY
SIDE STAND
PICK UP SWITCH
CLUTCH
SWITCH
GEARCASE 1.8 W
- 27 -
Electrical system
SPARK PLUG COVERS

WITH SUPPRESSOR
THROTTLE BODY
E
E
Ignition key in the “ON” Position
Safety switch in the “OFF” Position SAFETY SWITCH
IGNITION CONTROL
BATTERY
LATCH
RELAY
FUSE 09
FUSE 13
NEUTRAL LED
SWITCH
FUSE 11 GENERAL
STARTER
POWER
FUSE 15 RELAY

SIDE STAND
PICK UP SWITCH
CLUTCH
SWITCH
GEARCASE 1.8 W
- 28 -
Electrical system
SPARK PLUG COVERS

WITH SUPPRESSOR
THROTTLE BODY
Ignition key in the “ON” position
Safety switch in the “RUN” position SAFETY SWITCH
Start disactivated
IGNITION CONTROL
Side stand lowered BATTERY
LATCH
Gear engaged FUSE 09 RELAY
Clutch not pulled in
Engine not switched on
FUSE 13
NEUTRAL LED
SWITCH
GENERAL
FUSE 03
STARTER

POWER
FUSE 15 RELAY
SIDE STAND
PICK UP SWITCH
CLUTCH
SWITCH
GEARCASE 1.8 W
- 29 -
Electrical system
SPARK PLUG COVERS

WITH SUPPRESSOR
THROTTLE BODY
E
E
Ignition key in the “ON” position SAFETY SWITCH
Safety switch in the “RUN” Position
Start activated IGNITION CONTROL
Side stand raised LATCH BATTERY

RELAY
Gear engaged FUSE 09
Clutch released
Engine switched on
FUSE 13
NEUTRAL LED
SWITCH
GENERAL
FUSE 03
STARTER
POWER
FUSE 15 RELAY

SIDE STAND
PICK UP SWITCH
CLUTCH
SWITCH
GEARCASE 1.8 W
- 30 -
Electrical system
SPARK PLUG COVERS

WITH SUPPRESSOR
THROTTLE BODY
Start activated
IGNITION CONTROL
Side stand raised BATTERY
LATCH
Gear engaged FUSE 09 RELAY
Clutch pulled in
Engine switches on
FUSE 13
NEUTRAL LED
SWITCH
GENERAL
FUSE 11 RELAY
FUSE 03 SOLENOID
STARTER

POWER
FUSE 15 RELAY
SIDE STAND
PICK UP SWITCH
CLUTCH
SWITCH
GEARCASE 1.8 W
- 31 -
Electrical system
SPARK PLUG COVERS

WITH SUPPRESSOR
THROTTLE BODY
E
E
Safety switch on the “RUN” position SAFETY SWITCH
Start activated IGNITION CONTROL
LATCH
Gear engaged RELAY
FUSE 09
Clutch pulled in
Engine does not switch on
FUSE 13
NEUTRAL LED
SWITCH
FUSE 11 GENERAL
STARTER
POWER
FUSE 15 RELAY

SIDE STAND
PICK UP SWITCH
CLUTCH
SWITCH
GEARCASE 1.8 W
- 32 -
Electrical system
SPARK PLUG COVERS

WITH SUPPRESSOR
THROTTLE BODY
Start activated
IGNITION CONTROL
LATCH
Gear not engaged RELAY
FUSE 09
Clutch not pulled in
Engine switched on
FUSE 13
NEUTRAL LED
SWITCH
GENERAL
FUSE 11 RELAY
FUSE 03 SOLENOID
STARTER

FUSE 15 POWER
RELAY
SIDE STAND
PICK UP SWITCH
CLUTCH
SWITCH
GEARCASE 1.8 W
- 33 -
Electrical system
SPARK PLUG COVERS

THROTTLE BODY WITH SUPPRESSOR
E
Electrical system
FUSES
The fuses are situated on the right side of the motorcy-

cle.
To reach them it is necessary to remove the tank side
panel and the cover.
Substitute the burnt fuse and replace the cover (find

the electrical fault before replacing the fuse).
To identify the position and the function of the fuses,
consult the information written on the adhesive and in
the electrical diagram. The reference letters indicated
in the figure correspond to those shown in the diagram.
STARTER MOTOR REMOVAL
• Remove the fuel tank (see chapter C “Bodywork”).

• Drain off the engine coolant, completely emptying the
cylinder passageways via the two screws situated
on the front part of the cylinders.
• Remove the coils from the frame support.
• Remove the blow-by cover.
• Disconnect the cable of the pick-up.
• Disconnect the alternator connector.
• Remove the coolant liquid pump by disconnecting
the rubber union from the conduit that brings the
coolant liquid to the cylinders.
• Remove the conduit of the cylinder cooling system.
• Disconnect the cable of the starter motor.
• Remove the two fixing screws of the starter motor.
• Remove the starter motor by extracting it as indica-
ted in the figure.
- 34 -
Electrical system
STARTER MOTOR CHECK
If a fault has been diagnosed in the starter motor, it is

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

removal. Pay attention to the following points:
Substitute the O-ring with a new one to avoid

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

- Apply a small quantity of MOLYKOTE to the rotor
shaft.
- Apply a small quantity of LOCTITE 243 to the bolts of
the starter motor.
- 35 -
Electrical system
Starter relay check
Remove the rider seat, disconnect the battery.

Unhook the connector from the starter relay.
Unscrew the fixing screw of the relay.
Disconnect the cables of the starter motor and the

positive cable of the battery from the relay.
- 36 -
Electrical system
Apply 12 volts to the terminals (1) and (2) of the relay

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

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

circuit or if a resistance is present. The winding is in
good condition if the value of the resistance revealed is
as indicated.
Starter relay resistance

Standard: 3-6 ohm
IGNITION/SIDE STAND SAFETY SYSTEM PARTS

CHECK
The safety system of the motorcycle is included into

the CPU.
Terminals 3, 4 and 5 of the 36-way coupling of CPU
are those involved.
Using a multi-tester, measure the voltage between the

terminals as indicated in the following table:
3 4 5
3
4
5 0,4-0,6 0,4-0,6
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
- 37 -
Electrical system
GEARCHANGE POSITION SWITCH
The connector of the gearchange position switch is

placed in the proximity of the side stand and motorcy-
cle speed sensor connectors.
The connector of the gearchange position switch dif-
fers from the side stand connector since it is identified
by an S marked on the electric system sheathing.
Disconnect the connector of the gearchange position
switch and utilising a multi-tester, check the continuity
between the black lead and earth with the gears in
neutral.
Black Engine earth

ON (Neutral)
E OFF (Neutral exluded)
When the connector of the gearchange posi-

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

on a support under the pinion wheel transmission
casing on the left side of the motorcycle.
- Disconnect the connector of the side stand switch.
Utilising a multi-tester, check the continuity as indica-
ted in the table.
Green Brown Black

ON (Raised)
OFF (Lowered)
- 38 -
Electrical system
If it is necessary to substitute the switch proceed by

unscrewing the two fixing screws.
SPARK PLUGS
To accede to the ignition spark plugs, it is necessary to

remove the following components:
• Tail unit
• Left side panel
• Right side panel
• Fuel tank
Remove the coil connectors.

To carry out this operation, free the secondary lock
(yellow "tongue") removing it from its seat, then press
the black "tongue" and unhook the connector.
Unscrew the earth connection from the cylinder head

cover and free the coil wiring from the frame removing
the two fixing band fasteners; then slide the wiring out
from the right side.
- 39 -
Electrical system
Unscrew the fixing screws of the coil plates and remo-

ve them. MY 2007-2008
Remove the coils from their seats.
When reassembling the coils, take care to

connect the map connector correctly. If not
connected or if connected incorrectly, it could
cause damages to the coils themselves.
Check the resistance between the electrode and the

screw cap of the spark plug as shown in the figure.
Permitted resistance: 4.5 ÷ 5.5 K
Carry out the test on all the spark plugs.
RUN OFF SAFETY SWITCH
Remove the instrument panel cover unscrewing the

two fixing screws on the sides.
- 40 -
Electrical system
Remove the relative connector to the right hand control

group as indicated in the figure.
Remove the plug part of the connector.
With the switch in the “RUN” position, check the conti-

nuity between pins (1) and (2).
- 41 -
Electrical system
INSTRUMENTATION
If faults are found in the instrumentation, it is necessary

to check the main wiring and the various components
related to the instrumentation.
To carry out the various checks, remove the instrument
panel cover, then move aside the rubber cap and the
connector situated behind the instrumentation.
Consult the diagram below to identify the contacts of

the various components:
1 Side stand 11 Starter relay output

2 Oil press 12 Engine starter switch
3 High beam 13 Turn-L
4 Lights 14 Turn-R
5 Neutral 15 Open
6 Low fuel 16 Ta pulse
7 CHG 17 Open
8 Temp sensor 18 Sp pulse
9 IGN 19 Open
10 Battery 20 GND
- 42 -
Electrical system
OIL PRESSURE SENSOR
With the engine switched off, it is necessary to find

continuity between the terminal of the sensor and the
earth of the motorcycle (as shown in the figure).
With the engine switched on, the contact must be
open.
FUEL LEVEL WARNING LIGHT CHECK SWITCH
After verified the fault in the fuel level warning system,

check in the fuse box on the right side of the motorcy-
cle the good condition of the relative fuse.
Having ascertained the good condition of the fuses in

question, proceed as follows:
With the fuel tank removed from the motorcycle and
empty of fuel, connect a small circuit composed of 12V
battery and a light bulb of 12V – 1.7W to the connector
of the fuel level indicator as shown in the diagram.
If the switch is in a good condition, the light bulb should
light up after several seconds.
Pour some fuel into the fuel tank and confirm that the
light bulb switches off after having poured more fuel
into the tank than the maximum required for the reser-
ve.
- 43 -
Electrical system
INSTRUMENT PANEL WATER SENSOR

Connect a resistance between the two connections of
the connector as shown in the table. Turn the ignition
key to the "ON" position.
At this point the display should indicate the
Temperature relative to the resistance applied.
It is sufficient to carry out the test at 50° C and at 100°
C with the respective resistances of 1.150 kOhm. and
0.204 kOhm.
TEMP. °C RESIST. kΩ TEMP. °C RESIST. kΩ

- 40 100.950 + 40 1.598
- 30 53.100 + 50 1.150
- 20 29.121 + 60 0.746
- 10 16.599 + 70 0.565
0 9.750 + 80 0.377
E + 10 5.970 + 90 0.275
+ 20 3.747 + 100 0.204
+ 25 3.000 + 110 0.153
+ 30 2.547 + 125 0.102
KEY IGNITION SWITCH
If there is no 12V input between pin (9) and (20) of the

instrument panel connector with ignition switch in the
“ON” position, the cause can be identified by a fault in
fuses 13 or 3.
If the fuses are in good condition, check the continuity
between the pin (9) of the instrument panel and the pin
(15) of the fuse box connector and between the pin
(10) of the instrument panel and the pin (12) of the fuse
box connector.
STARTER RELAY ACTIVATION

- Check that there is a 12V input between pin (11) and (20)
with the safety switch in the “RUN” position and the starter
button pressed.
- If there is no voltage, check the presence of voltage input
between pin (12) and (20).
- If there is no voltage input between pin (12) and (20),
check the condition of fuse E5 after which check the right
hand control as follows:
1) Disconnect the connector of the right hand control;
2) Check the continuity between the contacts (1) and (3)
with the safety switch in the “RUN” Position and the starter
button pressed.
3) Having verified the good functioning of the right hand
control, the cause can be identified as damage to the
instrument panel.
- 44 -
Electrical system
LEFT DIRECTION INDICATOR

If the left direction indicator warning light does not func-
tion, there must be the presence of voltage input inter-
mittently between pin (13) and pin (20).
If the presence of input voltage is verified, the conti-
nuity between pin (13) of the instrument panel and pin
(5) of the left hand control connector must be checked.
RIGHT DIRECTION INDICATOR

If the right direction indicator warning light does not
function, there must be the presence of voltage input
intermittently between pin (14) and pin (20).
If the presence of input voltage is verified, the conti-
nuity between pin (14) of the instrument panel and pin
(7) of the right hand control connector must be
checked. E
RPM INDICATOR
If the r.p.m. of the engine is not signalled on the instru-
ment panel with the engine switched on, check:
. The continuity between pin (16) of the instrument
panel and pin (20) of the CPU.
. If the cause is verified, the fault will be found in the
CPU.
N.B. In the case of substitution of the CPU: with

the ignition key in the “OFF” position wait
approximately fifteen seconds before
disconnecting the same.
SPEED SENSOR
If the speed of the motorcycle is not indicated on the

instrument panel, proceed as follows:
• Check the condition of the fuse 3.
- 45 -
Electrical system
If the fuse in question is in good condition, proceed

with the check of the speed sensor as follows:
1) Remove the sensor from the motorcycle as descri-
bed in the “F4 workshop engine manual (Code
8000A1592).
2) Disconnect the connector, check that there 10 kΩ is
measured between terminals (1) and (2) of the con-
nector.
COOLING FAN SYSTEM
If there is a fault in the functioning of the cooling fan,

proceed with the following check:
• Check the condition of fuse 7;
• If the fuse is in good condition, check the cooling fan
relay mounted on the right side of the motorcycle as
indicated in page 38.
If the relay is in good condition but does not become

excited, disconnect the connector of the temperature
sensor marked by an M on the lead. Make a bridge
between the two contacts as shown in the figure.
• With the ignition switch in the “ON” position the fan
should operate and the voltage at the Yellow-
Black/White lead of the fan relay connector should be
12V.
• Check the continuity of the system.
• Check the condition of the thermal switch on the
radiator. The functioning interval is as described in
chapter “Cooling system”.
100° C
97° C
- 46 -
Electrical system
HORN
A fault in the horn system should be checked at various

points:
• Check the condition of fuse 11 in the fuse box on the
right side of the motorcycle.
• If the fuse is in good condition, disconnect the con-
nector of the left control and check the continuity
between contact 34 of the control with the horn button
pressed as in the following page under “Switches”.
• Check the continuity of the winding of the horn.
- 47 -
Electrical system
SWITCHES
Check the continuity of each switch with a tester. If there is any anomaly, substitute the respective switch unit with
a new one.
- 48 -
Suspension and wheels
SECTION
Revision 4
F
-1-
SUMMARY
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

FRONT WHEEL REMOVAL (BRUTALE 750 ORO - 750 S - 910 S) . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 5
FRONT WHEEL REMOVAL (BRUTALE 910 R - 989 R - 1078 RR) . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 6
FRONT WHEEL ASSEMBLY (BRUTALE 750 ORO - 750 S - 910 S) . . . . . . . . . . . . . . . . . . . . . . . .PAGE 12
FRONT WHEEL ASSEMBLY (BRUTALE 910 R - 989 R - 1078 RR) . . . . . . . . . . . . . . . . . . . . . . . .PAGE 12
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 15
FRONT FORK OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 16
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 29
STEERING ASSEMBLY OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 30
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 35
REAR WHEEL HUB AND SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 43
REAR WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 44
F SWINGARM REMOVAL AND OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 51
CHAIN REMOVAL (MY 2007 and previous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 56
CHAIN REASSEMBLING (MY 2007 and previous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 57
CHAIN REMOVAL (MY 2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 59
CHAIN REASSEMBLING (MY 2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 60
MOTORCYCLE SET-UP ADJUSTEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 75
WHEEL BALANCE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 78
-2-
FRONT WHEEL
A B C D E F G H J K L M
N·m 20 ÷ 22 40 ÷ 44 38 ÷ 42 60 ÷ 65 42 ÷ 46 12 ÷ 14 5÷7
Torque
pressure Kg·m
ft·lb
Operation
FRONT WHEEL
Dimensions 3,50” x 17” 3,50” x 17” 3,50” x 17” 3,50” x 17”
FRONT TYRE
Dimensions 120/65-ZR 17 (56 W) or 120/65-ZR 17 (56 W) or
120/70-ZR 17 (58 W)
120/70-ZR 17 (56 W-58 W) (**) 120/70-ZR 17 (56 W-58 W) (**)
Brand and type PIRELLI - Dragon Evo
MTR21 Corsa PIRELLI - Dragon
MICHELIN - Pilot Sport Supercorsa Pro PIRELLI - Dragon
MICHELIN - Pilot Power MICHELIN - Pilot Power Supercorsa Pro
DUNLOP-Sport Max D 207 RR DUNLOP - Sport Max
DUNLOP - Sport Max D 208 D 208 Race Replica (**)
Race Replica (**)
Front tyre pressure (*) 2.3 bar (33 psi) 2.3 bar (33 psi) 2.3 bar (33 psi)
*: When using tyres of a brand which is different from the recommended type, refer to the tyre pressure marked by the manufacturer on the side of the tyre.
**: Check that the dimensions of the 120/70 front tyre correspond to the dimensions in the motorcycle’s registration booklet. If a 120/70 tyre is used, move
the clamp of the front mudguard next to the upper holes located on the feet of the front suspension’s fork.
-3-
FRONT WHEEL
A B C D E F G H J K L M
N·m 20 ÷ 22 40 ÷ 44 38 ÷ 42 60 ÷ 65 42 ÷ 46 12 ÷ 14 5÷7
Torque
pressure Kg·m
ft·lb
Operation

FRONT WHEEL
Dimensions 3.50” x 17” 3.50” x 17”
FRONT TYRE
DimensionS 120/70-ZR 17 (58 W) 120/70-ZR 17 (58 W)
Front tyre pressure (*) 2.3 bar (33 psi) 2.3 bar (33 psi)
*: When using tyres of a brand which is different from the recommended type, refer to the tyre pressure marked by the manufacturer on the side of the tyre.
**: Check that the dimensions of the 120/70 front tyre correspond to the dimensions in the motorcycle’s registration booklet. If a 120/70 tyre is used, move
the clamp of the front mudguard next to the upper holes located on the feet of the front suspension’s fork.
-4-
Before proceeding with the removal and overhaul of

the components relative to the front suspension, it is
advisable to remove beforehand the front mudguard as
described in detail in chapter H “Brakes”.
Special tool: N. 800092642
FRONT WHEEL REMOVAL

(BRUTALE 750 ORO - 750 S - 910 S) F
Unscrew the two fixing screws (1) of both front calipers
and remove the calipers. 1
N.B. Position the removed calipers so that they

do not hamper subsequent operations.
Protect the disassembled calipers with pro-

tective material thereby avoiding possible
damage to the wheel rim. Hold the calipers
appropriately, to not charge the brake tubes.
Pay attention to not bend the brake tubes to
avoid any damages.
Lift the motorcycle up at the front end.

Mount the special tool that is supplied with a pin on the
lower part of the steering base as shown in the figure.
Lift the motorcycle up.
Special tool N. 800095807 and N. 800095808
N.B. To facilitate the removal of the wheel it is

advisable to tape the brake tubing to the
special tool.
-5-
Before proceeding with the removal and overhaul of

the components relative to the front suspension, it is
advisable to remove beforehand the front mudguard as
described in detail in chapter H “Brakes”.
Place the motorcycle on the rear stand. 1
Special tool: N. 800092642
F
1
FRONT WHEEL REMOVAL

(BRUTALE 910 R- 989 R- 1078 RR)
Unscrew the two fixing screws (1) of both front calipers
and remove the calipers.
Position the removed calipers so that they

N.B.
do not hamper subsequent operations.
B4 910 R B4 989 R - 1078 RR
Protect the disassembled calipers with
N.B.
protective material thereby avoiding possi-
ble damage to the wheel rim. Hold the cali-
pers appropriately, to not charge the brake
tubes.
Pay attention to not bend the brake tubes to
avoid any damages.
Lift the motorcycle up at the front end.

Mount the special tool that is supplied with a pin on the
lower part of the steering base as shown in the figure.
Lift the motorcycle up.
Special tool N. 800095807 and N. 800095808
N.B. To facilitate the removal of the wheel it is

advisable to tape the brake tubing to the
special tool.
-6-
Remove the screw (1) on both front wheel/fork attach-

ments.
During this operation, it is necessary to sup-

port the wheel.
Loosen the two screws (2) on the fork foot on the left
side of the vehicle. Leave the screws partly tightened F
to facilitate the removal and the subsequent refitting of 2
the axle.
Loosen the pin (3) with the Ø 26 bushing and remove

the wheel spindle (4).
3 4
-7-
Front wheel bearing check
Only for the B4 910 R - 989 R - 1078 RR models, the

following preliminary operations must be performed:
- Fit the axle on the front wheel.
- Turn in and bring the threaded bushing (Part Code B
8000A3469) into contact with the wheel spindle, tighte- A
ning it by hand.
With the wheel spindle still mounted to the wheel, rota-

te the wheel to check that the bearings are not pitted
and rotate with a smooth action. Check also for axial
(A) and/or radial (B) movement. If either condition is
verified, substitute the bearings.
Front wheel bearing substitution

F
Brutale 750 ORO - 750 S - 910 S:
Remove the wheel spindle utilising the special tool as
Special tool N.800092872
Brutale 910 R:
Remove the threaded bushing, the wheel spindle and
the left and right spacers from the wheel rim.
Utilise the special tool to extract the bearings. To

assemble the tool, it is necessary to remove the screw
(1) and extract the wheel spindle (2); remove the nut 1
(3) and the flange (4). 2
Before substituting the bearings as indica- 3

ted above it is advisable to remove the brake
discs as indicated in chapter “Brakes” to 4
avoid damaging them.
Special tool N. 800092862
-8-
Introduce the extractor until the internal ring of the bea-

ring is hooked up. Introduce the wheel spindle and
screw and manually block them.
Mount the flange, spacer ring and nut utilising a 14 mm

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

seats of the bearings on the wheels are not scored or
marked.
-9-
Reassembly – front wheel bearings

Before proceeding with the reassembly, accurately
clean the bearing seats in the wheel hub.
Lubricate the outer race of both bearings with special
grease.
Mount a bearing onto the special tool.
Recommended product: AGIP GREASE 30
Introduce the stem of the tool into the wheel hub as

F shown in the figure and insert the aluminium spacer.
Assemble the other bearing and the guide.
- 10 -
Insert the guide spacer and utilising a press, squeeze

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

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

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

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

tricity in the central part does not exceed
0.05 mm.
- 11 -
FRONT WHEEL ASSEMBLY

(BRUTALE 750 ORO - 750 S - 910 S)
If the front tyre is substituted, before assem-
bling the wheel it is necessary to balance the
wheel following the indications in page 78.
After having carried out the check on the parts of the front
wheel, accurately clean the wheel spindle and assemble it
from right to left. Tighten the screw ring of the wheel spind-
le to the torque prescribed utilising the special tool. Ensure
that when the wheel is mounted into place, the screw ring
of the wheel spindle must be on the left side of the
motorcycle.
Screw ring of the frontal wheel spindle - Torque

40÷44 N•m
pressure: 40 ÷ 44 N•m

Mount the wheel, complete with wheel spindle onto the
F wheel attachments of the front forks.
20÷22 N•m
Ensure that the attachments do not sit on
the external face of the hexagon. 1
Tighten the two screws to the torque pressure prescri-

bed.
Mount the two brake calipers as described in chapter H
“Brakes”.
Tightening torque of the fork attachment

fixing screws: 20 ÷ 22 N•m
During this phase it is necessary to support

the front wheel to avoid snagging the two
screws.
FRONT WHEEL ASSEMBLY

(BRUTALE 910 R - 989 R- 1078 RR)
If the front tyre is substituted, before assem-
bling the wheel it is necessary to balance the
wheel following the indications in page 78.
If the bearings have been replaced, refit the bearings,

the inner spacer, the two left and right outer spacers
and the brake discs on the wheel using the reverse pro-
cedure to the removal.
- 12 -
Position the wheel and insert the axle (1) from the right
side of the vehicle.
1 2
N.B. Ensure that the bushing on the left fork
foot is in place and in contact with the foot,
with the fixing screws slightly tightened in
order to prevent them from coming out
while inserting the axle.
Tighten the axle to the prescribed torque.
Grease only the first threads and the cylin-

drical parts of the axle.
Torque pressure: 60 ÷ 65 Nm
Fitting the front brake calipers

(Brutale 910 R - 989 R - 1078 RR) F
1
Fit the front brake calipers to the fork feet and place the
fixing screws (1) without tightening.
Grease only the first screw threads.
B4 910 R B4 989 R - 1078 RR
Insert the brake lines in the clips (2) and (3) on the front
mudguard.
2 3
- 13 -
Remove the front stand and rest the front wheel on the
ground.
While pulling the front brake lever, push down on the

front suspension two or three times to allow the right-
hand fork rod to position itself properly.
Tighten the right (4) and left (5) fork foot screws.
F 4 5
N.B. Tighten the screws to the specified torque
in several steps and in an alternate pattern.
12 ÷ 14 N•m
Keep the brake lever pulled back with a clamp as

shown in the figure on the left.
Tighten the front brake caliper fixing screws to the pre-

scribed torque.
After completing the fitting operations, disengage the

front brake lever from the clamp.
42 ÷ 46 N•m
- 14 -
FRONT FORK
A B C D E F G H I L M N O P
N·m 40 20 20 8 ÷ 10 8 ÷ 9 16 ÷ 18 22 ÷ 24 20÷22 12÷14
Torque
pressure Kg·m
ft·lb
Operation
Description Brutale 750 ORO Brutale 750 S Brutale 910 S Brutale 910 R
FRONT SUSPENSION
Type Hydraulic telescopic forks with the stems positioned upside down, equipped with an
external adjustment system for extension, compression and spring preload
Ø stems (mm) 50 with Titanium Nitride 50 50 50 with carbonitriding
Telescopic movement 135 135 (MY 03) / 133 (MY 04) 133 129
- 15 -
FRONT FORK
A B C D E F G H I L M N O P
N·m 40 20 20 8 ÷ 10 8 ÷ 9 16 ÷ 18 22 ÷ 24 20÷22 12÷14
Torque
pressure Kg·m
ft·lb
Operation
Descrption Brutale 989 R Brutale 1078 RR

FRONT SUSPENSION
Type Hydraulic telescopic forks with the stems positioned upside down, equipped with an
external adjustment system for extension, compression and spring preload
Ø stems (mm) 50 50
Telescopic movement 130 130
- 16 -
FRONT FORK OVERHAUL

Remove the front wheel as described in the paragraph
”Front wheel removal” of this Chapter. 1 2
N.B. Only for the Brutale 910 R - 989 R - 1078 RR

models:
Before continuing with the other operations, loosen the

two screws (1) on the fork on the left side of the vehi-
cle and remove the bushing (2).
Stem removal
1 F
Slacken the screw (1) of the steering head and the
three screws (2) of the steering base.
During this phase, support the stem.
Slide out the stem, supporting it with both hands and
operating with caution so as not to drop it.
Proceed with the same operation for both stems.
Fork overhaul
Place the stem in a vice paying attention to protect
the surfaces to not damage them.
- 17 -
Slacken the fork cap (1).
Completely unscrew the cap and lower the sleeve as

F shown in the figure. This operation must be carried out
keeping the stem in a vertical position.
Unscrew the cap. Using the key, adjust the spring pre-
load adjuster while blocking the rotation of the nut pla-
ced on the pump rod.
- 18 -
Remove the spring-push spacer (1) and the relative

spacer ring.
Slide out the spring complete with the spacer.

F
Remove the internal rod for the extension adjustment.
- 19 -
Turn the stem upside down and completely pour out

the oil into a suitable container.
Recover the oil in an appropriate container.

Do not dispose of the used oil in the envi-
ronment.
Unscrew the lower central screw that fixes the pump

F unit. Collect the seal washer underneath. 40 N•m
When reassembling tighten to 40 N•m.
Extract the pump unit.

Check that the sealing ring on the pump is still in its
seat (only for bikes from MY 04 to MY 07).
Only for MY 08 vehicles: Take care not to reverse the

pumping elements on the fork while fitting it back in,
and configure as follows:
- Brake-pressing pumping element: fit on left fork.
- Brake-releasing pumping element: fit on right fork.
- 20 -
Lower the anti-dust seal (1) taking care to not damage

the seat on the sleeve.
Remove the retaining ring (1) with a screwdriver, taking

care to not scratch the stem. F
Extract the sleeve from the stem by repeated blows at

the end.
- 21 -
Only for MY 2007 model and previous: Unscrew the

hydraulic braking adjuster under compression.
Fork assembly check

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

stem and check the condition of the chroming.
Check the spring length against the following

minimum levels permitted:
- BRUTALE 750 ORO / 750 S / 910 S: 265 mm
- BRUTALE 910 R / 989 R / 1078 RR: 260 mm.
Manually widen the upper bush and extract it.

Remove the lower bush, the washer, the oil seal and
the anti-dust seal (see figure).
- 22 -
Assembly oil seal and anti-dust seal

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

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

into their seats with the respective washers. Utilise the
special tool.
Using the same technique, assemble the oil seal and its
stop ring and then manually assemble the anti-dust seal.
Special tool N. 8000A1039
Stop
Oil seal Stop ring Anti-dust seal
washer
- 23 -
Only for MY 2007 model and previous: Reassemble

the hydraulic brake adjuster under compression into its
seat by utilising a new O-ring seal.
Torque pressure of the compression hydrau-

lic brake adjuster : 20 N•m
20 N•m
Insert the internal rod.

F Insert the spring spacer.
Maintain the sleeve in a vertical position. Introduce the

following amount of oil:
- BRUTALE 750 ORO / 750 S (MY 03): 646 cc

- BRUTALE 750 S (MY 04): 665 cc
- BRUTALE 910 S: 665 cc
- BRUTALE 910 R: 718 cc
- BRUTALE 989 R: 690 cc
- BRUTALE 1078 RR: 715 cc
Press the pump rod up and down until a perfect fluidity

of movement is obtained.
Recommended oil:
- BRUTALE 750 ORO / 750 S (MY 03): SAE 5
- BRUTALE 750 S (MY 04): SAE 7,5
- BRUTALE 910 S: SAE 7,5
- BRUTALE 910 R: SAE 7,5
- BRUTALE 989 R - 1078 RR: SAE 7,5
- 24 -
Check that the oil level is at an “X” value from the

upper edge of the sleeve, including the upper edge as
well.
- BRUTALE 750 ORO / 750 S (MY 03): X = 90 mm

- BRUTALE 750 S (MY 04): X = 85 mm
- BRUTALE 910 S: X = 85 mm
- BRUTALE 910 R: X = 74 mm
- BRUTALE 989 R - 1078 RR: X = 75 mm
N.B.: Measurement taken with the inside rod

and the spacer in place.
It is important to respect the quotes indicated.

Ensure that the inside rod has reached the
limit stop.
Manually screw in the locknut until it reaches the end

of the thread. F
The locknut has a special assembly direc-
tion. Pay attention to keep the two support
bases facing upwards (see the figure below).
Introduce the spring.
Insert the key on the pump nut (1) slightly pressing

down the spring.
- 25 -
Place the spring-push spacer (1) and the relative

washer. 20 N•m
Reassemble the complete cap with a new O-ring.
Tighten the cap to the prescribed torque pressure.
Stem cap torque pressure: 20 N•m
Fork stem assembly

F
Assemble the left stem in its seat. To position the stem
correctly, refer to the diagram in the figure on the side.
Pay attention to respect the “X” assembly dimension,
which is reported below:
- BRUTALE 750 ORO / 750 S (MY 03-04)

(up to engine registration number 10760):X = 165 - 165,5 mm
- BRUTALE 750 S (MY 04)
(from engine registration number 10761): X = 167,5 - 168 mm
- BRUTALE 910 S: X = 167,5 - 168 mm
- BRUTALE 910 R: X = 192,5 - 193 mm
- BRUTALE 989 R: X = 192,5 - 193 mm
- BRUTALE 1078 RR: X = 192,5 - 193 mm
Screw in and tighten the three screws (1) at the base

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

or inexact assembly could compromise the 1
stability and steering of the motorcycle.
Assemble the right stem, in the same way as described

for the left stem.
- 26 -
Tighten the three screws (1) at the base of the stee-

ring; perform the operation several times until the pre-
scribed torque pressure is reached.
This operation must be carried for both stems.
1
Torque pressure of the screws at the base
of the steering: 8 ÷ 9 N•m
8 ÷ 9 N•m
Slacken the central screw (3) of the steering head.

Check that the steering stem ring nut is perfectly set 16÷18 N•m 22÷24 N•m F
against the steering head.
Tighten the two screws (2) of the steering head to the
prescribed torque pressure and successively tighten the
central screw (3).
Torque pressure of the external screws (2):

16 ÷ 18 N•m
2
Torque pressure central screw (3):
22 ÷ 24 N•m
3
This check is necessary for the correct posi-
tioning of the stems even if the steering
head has not been removed.
Set up the front wheel by following the procedure

shown on page 11 of this chapter.
- 27 -
Front suspension adjustment

After having correctly reassembled the entire fork
assembly, it is necessary to re-establish the adjust-
ments shown in the table to guarantee the best set-up
of the motorcycle. Carry out the same adjustment on
both fork stems.
It is necessary that the adjusters on both fork
stems are adjusted to the same position.
Type of set-up
Brutale 750 ORO
Soft Standard Hard
Spring preload 0 turns 2 turns 4 turns Extension braking
Spring preload
Rebound damping 13 clicks 10 clicks 7 clicks hydraulic device
Compression damping 11 clicks 8 clicks 5 clicks
Type of set-up
Brutale 750 S (MY 03)
Soft Standard Hard
F Spring preload 2 turns 4 turns 6 turns
Rebound damping 13 clicks 10 clicks 7 clicks
Compression damping 11 clicks 8 clicks 5 clicks
Type of set-up
Brutale 750 S (MY 04)
Soft Standard Hard
Spring preload 1 turns 2 turns 3 turns
Rebound damping 12 clicks 10 clicks 7 clicks Compression braking Compression braking
hydraulic device hydraulic device
Compression damping 12 clicks 10 clicks 7 clicks (MY 07 and previous) (MY 2008)
Type of set-up Type of set-up

Brutale 910 S (MY 05/06) Brutale 989 R
Soft Standard Hard On road
Spring preload 1 turns 2 turns 3 turns Spring preload 3 turns
Rebound damping 16 clicks 14 clicks 11 clicks Rebound damping 18 clicks
Compression damping 12 clicks 10 clicks 7 clicks Compression damping 18 clicks
Type of set-up Type of set-up

Brutale 910 S (MY 07) Brutale 1078 RR
On road On race track On road
Spring preload 2 turns 6 turns Spring preload 3 turns
Rebound damping 14 clicks 10 clicks Rebound damping 18 clicks
Compression damping 8 clicks 6 clicks Compression damping 18 clicks
Type of set-up
Brutale 910 R
On road On race track
Spring preload 4 turns 6 turns
Rebound damping 14 clicks 10 clicks
Compression damping 8 clicks 6 clicks
- 28 -
STEERING ASSEMBLY
E
F
D
B
A B C D E
95÷100 (B4 750 ORO-S)
N·m 18 ÷ 20 In contact + 10°
120÷125 (B4 910-989-1078)
Torque
Kg·m
pressure
ft·lb
Operation
- 29 -
STEERING ASSEMBLY OVERHAUL

To operate on the steering assembly, it is necessary to
remove the fork stems as described in this chapter, in
the paragraph “Front fork overhaul”.
Then remove the components according to

the following order:
- front headlight;
- instrument panel;
- handlebars;
- headlight support;
Steering head removal

F Slacken the fixing screw (1) of the steering head and 1
remove it from the steering pin.
Steering base removal

Utilising the special tool, slacken the screw ring of the
steering pin.
Support the motorcycle sufficiently enough so that the
front stand can be removed. Ensure that the brake pin-
cers are securely placed.
- 30 -
Remove the screw ring previously slackened and

remove the steering base complete with the pin.
Remove the anti-dust seal, the internal bearing ring
and the ball bearing ring.
Eccentric steering head removal

With the special tool remove the fixing screw ring of F
the eccentric steering head.
During this operation press the tool with the

palm of the hand along the axis of rotation
and at the same time support the motorcycle.
Disassembly of the frame head steering sleeve

Remove the adjustment screw of the frame head stee-
ring sleeve, sustaining the frame head steering sleeve
at the lower part.
- 31 -
Reassembly of the frame head steering sleeve

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

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

the slot on the frame head steering sleeve with the
threaded hole on the frame head (see figure).
Align the slot to the hole and tighten the screw (1) to
the prescribed tightening torque.
Tightening torque: 18 ÷ 20 N•m
18÷20 N•m
- 32 -
Screw ring assembly

After having accurately cleaned the screw ring and the
seat of the steering head on the frame, apply the pre-
scribed grease both on the threading and on the coni-
cal part of the screw ring, then screw it manually onto
the relative seat.
Utilising the special tool, tighten the screw ring (1) to

the prescribed torque pressure. B4 750 : F
95÷100 N•m
B4 910-989-1078:
Torque pressure of the frame head steering 120÷125 N•m
sleeve screw ring:
Brutale 750 ORO - 750 S 95 ÷ 100 N•m
Brutale 910 S - R - 989 R - 1078 RR 120 ÷ 125 N•m
During this tightening operation, press down with force 1

along the axis of rotation of the tool (see figure).
Assembly steering base

Accurately clean all the parts and check the general
condition.
Before reassembly, grease the internal ring of the bea-
ring and the ball bearing ring on the steering pin with
Agip Grease 30.
- 33 -
Assemble the steering base to the eccentric steering

head.
Assemble the upper ball bearing ring already greased.
Assemble the internal ring of the bearing, the anti-dust
sealand the screw ring of the steering pin.
Steering pin tightening

F Screw down, without tightening, the screw ring of the
steering pin.
This operation must be done manually.
Ensure that the steering base is at the end of stroke,
completely steered to the right.
Utilising the special tool, tighten the screw ring (1) by
rotating it 10° (see figure), calculable as one-third
distance between the two holes of the steering head
screw ring (2).
Steering head assembly

Position the steering head in its seat.
Reposition the fork stems as described previously in
this chapter.
Tighten the three screws of the steering head as
described previously.
N.B. Check the exact position of the fork

stems.
- 34 -
REAR SUSPENSION
A B C D E F G H I L
N·m 40 ÷ 44 40 ÷ 44 40 ÷ 44 50 ÷ 55
Torque
pressure Kg·m
ft·lb
Operation 243
REAR SUSPENSION
Type Progressive with mono-arm fork and mono-shock absorber
adjustable for extension, compression and spring preload
Swingarm Magnesium alloy Aluminium alloy Aluminium alloy Aluminium alloy
Wheel travel (mm) 120 120 120 120

REAR SUSPENSION
Type Progressive with mono-arm fork and mono-shock absorber
adjustable for extension, compression and spring preload
Swingarm Aluminium alloy Aluminium alloy
Wheel travel (mm) 120 120
During the disassembly and check of the rear suspension assembly, it is advisable to disassemble the fuel tank,
- 35 -
Rear shock absorber disassembly

Remove the fuel tank as described in chapter C
“Bodywork”.
Lift up the rear part of the motorcycle (utilising a lift and

safety straps) high enough to take the load off the
shock absorber.
1
Slacken the upper screw of the shock absorber (1).
Slacken the central screw (2) of the rear wheel com-

F pensator assembly.
Slacken the lower screw of the shock absorber (3).

21 3
1
Raise up or lower the motorcycle utilising the lift so that

the previously slackened screws are freed.
Remove the pin (4) of the compensator assembly,
remove the upper screw of the shock absorber.
41
- 36 -
Slacken the central fixing pin of the engine (5).

Slacken the rear fork pin (6).
These operations are necessary to free the compen-
sator assembly.
Lift up the compensator assembly. 5
1 6
2
Remove the upper screw of the shock absorber that
was previously slackened.
Extract the complete rear shock absorber upwards.
Rear shock absorber test

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

- BRUTALE 750 ORO / 750 S (MY 03): A= 151 mm
- BRUTALE 750 S (MY 04): A= 154 mm
- BRUTALE 910 S (MY 05-06): A= 154 mm
- BRUTALE 910 R (MY 06): A= 154 mm
- BRUTALE 910 S (MY 07): A= 153 mm
- BRUTALE 910 R (MY 07): A= 153 mm
- BRUTALE 989 R - 1078 RR (MY 08) A= 155 mm
Check the functioning of the adjusters.
The shock absorber contains high-pressure

gas. Do not touch the valve of the shock
absorber tank. Do not try to disassemble the
shock absorber.
- 37 -
Rear suspension adjustment
N.B. The following operations can be also car-

ried out with the rear shock absorber
assembled to the motorcycle.
BRUTALE 750 ORO Type of set-up (only rider)
BRUTALE 750 S (MY 03) Soft Standard Hard
Compression damping
0 clicks 6 clicks 12 clicks
(high speed)
Compression damping
(low speed) 18 clicks 15 clicks 12 clicks
BRUTALE 750 ORO Type of set-up (with passenger)
BRUTALE 750 S (MY 03) Soft Standard Hard
Rebound damping 21 scatti 17 scatti 13 scatti
Compression damping
(high speed)
Compression damping
(low speed) 18 clicks 15 clicks 12 clicks Hydraulic rebound damping device
BRUTALE 750 S Type of set-up (only rider)

(MY 04) Soft Standard Hard
F Compression damping
(high speed)
Compression damping
BRUTALE 750 S Type of set-up (with passenger) *
Compression damping
(high speed) 18 clicks 18 clicks 18 clicks
Compression damping
BRUTALE 910 S Type of set-up (only rider)

Compression damping
(high speed) 0 clicks 6 clicks 12 clicks Hydraulic compression damping device in low speed (MY
Compression damping
03) (A) – high speed (MY 03) (B)
(low speed)
BRUTALE 910 S Type of set-up (with passenger) *
Compression damping
(high speed) 18 clicks 18 clicks 18 clicks
Compression damping
BRUTALE 910 R Type of set-up (only rider)

(MY 06) Su strada In pista
Rebound damping 8 clicks 7 clicks
Compression damping
(high speed) 6 clicks 12 clicks
C D
Compression damping
(low speed) 12 clicks 8 clicks
BRUTALE 910 R Type of set-up (with passenger) *
(MY 06) On road On race track
Rebound damping 8 clicks –
Compression damping
(high speed) 18 clicks –
Compression damping Hydraulic compression damping device in high speed (C)
(low speed) 12 clicks –
- low speed (D) (B4 750 MY 04 - B4 910 MY 05 / 06)
N.B. (*): Only for Brutale 750 S MY 2004 - Brutale 910 S MY 2005/2006 - Brutale 910 R MY 2006: when using
the vehicle with a passenger, increase the rear shock absorber’s spring-preloading by 2 turns in
respect to the standard setup (see suspension setup adjustment - page 75).
- 38 -
BRUTALE 910 S Type of set-up (only rider) BRUTALE 910 R Type of set-up (only rider)
(MY 07) On road On race track (MY 07) Su strada In pista
Rebound damping 14 clicks 10 clicks Rebound damping 14 clicks 10 clicks
Compression damping Compression damping
(high speed) 0 clicks 12 clicks (high speed) 0 clicks 12 clicks
(low speed) 14 clicks 10 clicks (low speed) 14 clicks 10 clicks
BRUTALE 910 S Type of set-up (with passenger) ** BRUTALE 910 R Type of set-up (with passenger) **
(MY 07) On road On race track (MY 07) On road On race track
Rebound damping 14 clicks – Rebound damping 14 clicks –
(high speed) 18 clicks – (high speed) 18 clicks –
(low speed) 14 clicks – (low speed) 14 clicks –
N.B. (**): For Brutale 910 S MY 2007 - Brutale 910 R MY 2007 only: For use of the vehicle with a
passenger, increasing the rear shock absorber preload by 2 revs is recommended with
respect to the normal setup (see setup adjustment – page 75).
BRUTALE 989 R Type of set-up (only rider) BRUTALE 1078 RR Type of set-up (only rider)
(MY 08) On road (MY 08) On road
Rebound damping 26 clicks Rebound damping 26 clicks
(high speed)
0 clicks
(high speed) 0 clicks F
(low speed) 23 clicks (low speed) 23 clicks
BRUTALE 989 R Type of set-up (with passenger) BRUTALE 1078 RR Type of set-up (with passenger)
(MY 08) On road (MY 08) On road
Rebound damping 26 clicks Rebound damping 26 clicks
(high speed) 0 clicks (high speed) 0 clicks
(low speed) 23 clicks (low speed) 23 clicks
Rocker arm assembly removal

Remove the special screw (1) that fixes the rocker arm 1
assembly of the rear suspension to the mono-arm fork.
Extract the complete rocker arm assembly.
- 39 -
Rocker arm assembly overhaul

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

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

Remove the three screws (1) indicated in the figure 1
and remove the support plate (2).
- 40 -
When reassembling, it is necessary to apply a special

product to the three screws. Lightly screw them in. 40÷44 N•m
Tighten the central screw first and then the other two to
the prescribed torque pressure.
Special product Loctite 243
Reassembly rocker arm assembly

Reassemble the rocker arm assembly after having F
cleaned and greased the seat of the special screw
situated on the swingarm.
Screw in the screw without tightening it.
Recommended grease : Agip Grease 30
Assembly rear shock absorber

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

the lift and safety straps.
This operation is necessary to recover the
play between the shock absorber/rocker arm
assembly/swingarm.
- 41 -
Tighten up the whole assembly:

Tighten the screws of the connecting rod. 40÷44 N•m 50÷55 N•m
Tighten the lower and upper screw of the shock absorber.
3
Tighten the frame pin (1).
Tighten the swingarm pin (2).
55÷60 N•m
Tighten the screw of the rocker arm assembly (3). 1
Apply Agip Grease 30 only to the threads of
the screws.
Connecting rod torque pressure: 40 ÷ 44 N•m

Shock absorber torque pressure 40 ÷ 44 N•m
Rocker arm assembly
torque pressure 50 ÷ 55 N•m
Frame pin torque pressure 55 ÷ 60 N•m 2
Swingarm torque pressure 70 ÷ 75 N•m
70÷75 N•m
- 42 -
REAR WHEEL HUB AND SWINGARM
B4 910-989-1078
A B C D E F G H I L M N O P Q R
N·m 30÷35 20÷22 45÷50 200÷220 28÷32 220÷240 140 25 8 25 70÷75 30÷35 18 18÷20 5÷7
Torque
pressure Kg·m
ft·lb
Operation 243 270 243 243 243 270
REAR WHEEL
Material Aluminium alloy Aluminium alloy Aluminium alloy Forged aluminium alloy
Dimensions 6,00” x 17” 6,00” x 17” 6,00” x 17” 6,00” x 17”
REAR TYRE
Dimensions 190/50-ZR 17 (73 W) 190/50-ZR 17 (73 W)
190/55-ZR 17 (75 W)
o 180/55-ZR 17 (73 W) o 190/55-ZR 17 (75 W)
Rear tyre
2.3 bar (33 psi) 2.3 bar (33 psi) 2.3 bar (33 psi)
pressure (*)

REAR WHEEL
Material Aluminium alloy Forged aluminium alloy
Dimensions 6.00” x 17” 6.00” x 17”
REAR TYRE
Dimensions 190/55-ZR 17 (75 W) 190/55-ZR 17 (75 W)
Rear tyre
pressure (*) 2.3 bar (33 psi) 2.3 bar (33 psi)
*: In the event of different make tyres being used as opposed to those advised, refer to the pressure values marked on the side of
the tyre by the manufacturer.
- 43 -
REAR WHEEL REMOVAL
Before checking and overhauling the rear wheel hub

assembly it is necessary to carry out the following pre-
liminary operations:
Remove the fixing screws of the lower silencer.
Remove the exhaust protection.

F
Turn the lower silencer outwards slightly.

If this movement is difficult due to residue in the com-
pensator connection area, clean the part by applying
lubricant/penetrating spray.
Rotate the silencer in a clockwise or anti-clockwise
direction alternatively to allow the lubricant to seep
through.
- 44 -
Remove the retaining ring (1) of the wheel nut.

Remove the rear wheel by removing the polygonal nut, 1
using the following tools:
Torque wrench
55 mm polygonal spanner
Utilising a torque wrench, slacken the

rear wheel nut.
The polygonal fixing nut of the rear wheel

has a left hand thread. To slacken the nut
it is therefore necessary to turn the
torque wrench in a clockwise direction.
Remove the rear wheel nut.

F
N.B. When reassembling, tighten the rear wheel
nut to the prescribed torque pressure.
Rear wheel nut torque pressure: 220 ÷ 240

N•m
220÷240 N•m
Remove the rear wheel taking care to not hit the silen-
cer connecting plate.
N.B. If this operation is too difficult to carry out,

remove the silencer connecting plate com-
pletely before removing the wheel.
- 45 -
After having effectuated the rear wheel removal, sup-

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

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

clockwise direction as shown in the figure. Utilise the
following tools:
• Torque wrench
• 55 mm polygonal spanner
- 46 -
Slacken the fixings (1) of the wheel hub.

1
Remove the screw complete with bushing.

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

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

necessary to carry out the motorcycle
set up adjustment. See “Motorcycle set up
adjustment” in this chapter.
- 47 -
Rear sprocket assembly removal

Brutale 750 ORO - S
Remove the wheel spindle nut (2) previously slacke- 3
ned and the spacer ring (4) underneath.
Remove the rear sprocket assembly (3) by manually
pulling the assembly outwards.
Make sure that a spacer ring is present

between the flange and the hub.
Do not hit the rear sprocket with metal 4

objects.
Brutale 910 S - 910 R - 989 R - 1078 RR

F Remove the previously loosened polygonal nut (2) and
the washer underneath (4).
2
Remove the rear sprocket unit (3) and the spacer ring
(5) underneath. 3
- 48 -
Slacken the two screws (6) and remove the brake cali-
per (7).
Disassembly of the wheel pin

Remove the wheel spindle complete with the brake F
disc, extracting it from the right side of the motorcycle
as shown in the figure.
Brake caliper support flange removal

Remove the Seeger retaining ring (1), the spacer ring
(2), the flange (3) and the spacer ring underneath.
3
2
- 49 -
Wheel hub disassembly

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

complete unit. Never substitute one bearing
only.
For normal maintenance, remove the two internal spa-

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

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

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

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

243
Caliper holder pin torque pressure:

30 ÷ 35 N•m
- 50 -
SWINGARM REMOVAL AND OVERHAUL

Before removing and overhauling the swingarm, it is
necessary to execute the following preliminary opera-
tions:
- Remove the rear shock absorber and connecting rod
as described in the paragraph “Disassembly rear
shock absorber” and “rocker arm assembly removal” of
this chapter.
Silencers removal
Unhook the two connecting springs between the silen- F
cers and the exhaust group.
Remove the plate connecting the two silencers.
- 51 -
Unscrew the screw fixing the silencers to the support.
Remove the upper silencer first, then the lower one.

F
Remove the other components of the rear wheel

assembly as shown in the operations previously
described from page 41.
Exhaust group removal (Brutale 750 ORO-S /

Brutale 910 S-R MY 05/06)
Unhook the two connecting springs between the silen-

cers and the exhaust collectors.
- 52 -
Unscrew the screw fixing the compensator to the

frame.
Unscrew the pin from the left side of the frame, then
remove the exhaust compensator. F
Exhaust group removal

(910 S - R MY 2007 - 989 R - 1078 RR)
cabling and pull outwards, on the right side of the vehicle.
- 53 -
Unscrew the lower fixing screws of the oil radiator guard,

positioned at the lower base of the water radiator.
Remove the oil radiator guard.
Move the radiators slightly towards the front of the

F motorcycle, then remove the flange fixing the exhaust 20÷22 N•m
manifolds to the cylinder unit by unscrewing the nut.
During this operation, take care not to touch

the exhaust pipes in order to avoid burns.
Special tool N. 8000B2051
When reassembling, it is necessary to apply a special

product to the three screws. Lightly screw them in.
Tighten the central screw first and then the other two to
the prescribed torque pressure.

243
- 54 -

Lower chain guide removal

Remove the three screws of the chain guide. F
Remove the chain guide (1) complete with the two rear
brake tube guide plates.
- 55 -
CHAIN REMOVAL (MY 2007 and previous)

Remove the chain utilising the special tool.
Special tool N. 800095389.
Identify the connecting link.

The core section of the tool should act on the internal
part of the chain.
N.B. The tool has three functions:

• As a chain cutter: with a punch mounted
aligned at A.
• Press fitting of connecting link plate:
with a raised punch aligned at A.
• As an anvil: with a raised punch aligned
at B.
Pre-assemble the tool as shown in the figure.

F Align a pin with the central hole of the tool.
Mount the tool onto the chain as shown in the figure

and align the punch on «A». A
Operate as shown in the figure, removing both pins
B
from the connecting link.
- 56 -
CHAIN REASSEMBLING (MY 2007 and previous)
Before reassembling the chain, grease the connecting

pins and the O-Rings as shown in the figure, by using
the special grease supplied with the chain kit.
Utilise only new links.
Connect both ends of the chain with the connecting

link, and press the connecting plate into the connecting F
pins by hand.
Fit the punch and the plate holder on the tool as shown
in the figure.
- 57 -
Mount the tool onto the chain as shown in the figure

and align the punch on «A». 30÷35 N•m A
Manually tighten the screws until contact is felt with the

backing plate.
Tighten at the specified torque.
Connecting link plate press fitting torque

pressure:
30 ÷ 35 N•m
Riveting of pin (MY 2007 and previous)

F Pull out the plate holder from the tool, keeping the 45÷50 N•m B
punch in the position used in the previous operation.
Mount the tool onto one of the pins of the connecting

link as shown in the figure and align the punch on «B».
Turn the pin holder by hand until the punch contacts
with the pin. Check that the punch and the pin are cor-
rectly aligned.
Tighten at the specified torque.

Pin riveting torque pressure:
45 ÷ 50 N•m
Repeat the above operations for the second pin of the

connecting link.
After the riveting of the pin, check that the head dia-
meter of both pins is equal to the following value:
- Pin head diameter after riveting:

d = Ø 5.5 mm
- 58 -
CHAIN REMOVAL (MY 2008)
Cut the chain utilising the special tool. 2
Unscrew bolt (1) so that the tip is retracted into the hex
nut.
N.B. This tool coud be applied in any point of

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

phase the chain with the tool. 1
Screw the bolt (1) until the pin is out of the chain plate
on the wheel side.
- 59 -
CHAIN REASSEMBLING (MY 2008)

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

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

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

on the lower strand of the chain where there is more
room to work.
- 60 -
Closing the rivet link (MY 2008)

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

tering pin between the chain rollers, in order to fit with
the rivet link.
Thread the bolt (1) with the fingers in until the outer
plate is placed on the rivet link fork pins. 1
With a wrench fully thread in the bolt (1) until the pin
ends reach the bottom the slots in the link plate carrier
(2). Avoid to force too much. This places the outer plate
at the correct position on the fork.
Slowly unscrew the bolt (1) and remove the tool from 1
the chain.
Riveting (MY 2008)

Use the professional rivet tool. F
Pull the plate (4) to open the positioning rods (3), insert
the chain into the tool in correspondance of the first pin
to rivet an release the plate (4). The chain should be
correctly inserted into the tool and kept in place by rods
(3).
Slide punch (5) to contact the head of the pin to be rive-

ted.
Using a hammer, give a sharp blow to punch (5) to 4

deform the head of the pin.
Rotate punch (5) approx. 90° and repeat operation. 5
- 61 -
Release the chain by retracting plate to open the posi-

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

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

F head of both pins is between the following range:
- Pin head diameter after riveting:
d = Ø 5.60 ÷ 5.80 mm
If the diameter is out of the specified range repeat the

riveting operation.
- 62 -
Swingarm pin removal

Remove the screw (1) on the right side of the motorcy-
cle.
Remove the washer and push out the pin manually.
Support the swingarm so that it does not drop to the
ground.
Now the swingarm can be extracted.
Upper chain guide removal

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

seat is situated in the swingarm.
- 63 -
Slide out in a forward position as shown in the figure.

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

are removed.
Utilising the special tool press on both ball bearings

and extract them.
Operate in the same way for the bearings on the left
side.
Special tool N. 800092860 RIGHT SIDE
- 64 -
Extract the spacer from the right side.
Check the condition of both bearing seats and the seat

of the spacer. F
If the spacer is in good condition, reinsert it onto the
fork from the right side.
Assembly of the roller bearings and the roller bea-

ring units
Pre-assemble the two roller bearing units on the left
side and the two ball bearings on the right hand side
utilising the special tool N. 800092866 as shown in the
figure.
Utilising a press fit the bearings and the roller bearing

units (see figure).
At the end of the overhaul operations, reassemble the

following components on the motorcycle:
- Swingarm
- Swingarm pin
When reassembling the pin, apply special grease on

the first threads of the swingarm pin screw.
Swingarm pin screw torque pressure:

70 ÷ 75 N•m
- 65 -
Wheel spindle unit check

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

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

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

wear (A).
A A
- 66 -
Utilising a press with an adequate punch for both the

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

270
Brake disc carrier plate screw torque pres-

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

(Brutale 750 ORO - S) F
Evaluate the wear condition of the crown wheel. If it is

badly worn, effectuate a substitution with a new part.
Slacken the five Silentblocks and if necessary substi-

tute them.
When reassembling, grease the area that comes into

contact between the flange and the crown. 45÷50 N•m
Grease used: AGIP GR SM
Do not apply grease to the threads of the

pins.
Tighten the five nuts to 45 ÷ 50 N•m as shown in the

figure.
- 67 -
Crown wheel assembly check

(Brutale 910 S - 910 R - 989 R - 1078 RR)
Evaluate the wear condition of the crown wheel. If it is

badly worn, effectuate a substitution with a new part.
Push the crown support of the flange unit (1) out from
the crown unit (2).
Check the condition of the 5 silentblocks (3). 3 1
If the silentblocks need replacing, proceed as follows:

F 1
Remove the 5 nuts (1) and replace the worn parts.
Follow the steps in reverse to reassemble the silent-

blocks.
Remove the 5 nuts (3) to free the crown (1) from the
crown flange (2). 2 1
Replace the crown.
Remount the new crown on the crown flange, making

sure the pins (4) enter the holes.
- 68 -
When reassembling the crown unit to the crown sup-

port flange unit, grease the coupling areas.
Grease used: AGIP GR SM
Do not apply grease to the threads of the

pins.
Reassembly wheel hub

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

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

ve seats on the flange.
Assemble the rear spacer ring in contact with the hub,
then the brake caliper-carrying flange (1), the second
spacer ring and the Seeger retaining ring (1).
It is important to ensure that the Seeger retaining ring
is inserted around the whole circumference of the seat.
- 69 -
Introduce the first spacer.

Grease and insert the roller bearing unit.
Assemble the second spacer (the ground one).
The grease used must have the following

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

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

screws (2) at the specified torque. 18 N•m
Special product: Loctite 243

2
Torque pressure: 18 N•m
- 70 -
Insert the spacer ring illustrated in the figure onto the

wheel pin.
Insert the crown wheel assembly, the second spacer
ring and the wheel pin fixing nut.
Reassemble the chain as described at pages 57÷60 of

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

in the figure. 45÷50 N•m F
Tightening torque: 45 ÷ 50 N·m
Tighten the 5 nuts to block the crown on the flange as

Apply grease only on the threaded part
25 N•m
Tighten the wheel pin fixing nut by rotating it clockwise

as shown in the figure, by using the following tools:
• Torque wrench
• 55 mm polygonal socket wrench
Slip flange nut coupling torque:

200-220 Nm
Apply grease only on the threaded part
Assemble the retaining ring.
Reassemble the lower chain pad, the upper chain

guard and the central exhaust manifolds respectively.
200÷220 N•m
- 71 -
Rear wheel assembly
In the case of substitution of the rear tyre it

will be necessary to effectuate the balancing
of the wheel before assembling it. Follow the
instructions indicated in page 78.
Insert 1st gear.

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

220 ÷ 240 N•m
Apply grease only on the threaded part 220÷240 N•m
Pay attention not to apply grease on the

conical part of the nut.
F Insert the retaining ring.
Reassemble the exhaust silencers.

1
Perform the chain tension adjustment as described in
the chapter B “MAINTENANCE”.
Pinion wheel removal

Pull out the pin contact holder (1) from the engine
guard support plate.
Remove the screw (1) of the clutch control cylinder and

the three screws (2) of the pinion wheel cover.
- 72 -
Remove the cover being careful to not extract the clut-

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

hammer. F
Unscrew the pinion wheel retaining nut.
Be careful to not hit the timing wheel situa-

ted on the extremity of the pinion shaft
during this operation.
Slacken the chain (see page 47), bring it forward and

slide it off the pinion wheel.
Effectuate this operation only if the pinion wheel has to
be substituted.
If the pinion wheel and crown wheel assembly have to
be substituted, it is advisable to operate by cutting the
chain (see page 56÷59), to facilitate the operation.
- 73 -
For reassembly, insert the pinion wheel with the chain

already attached.
Insert a new washer on to the threaded cam shaft, tigh-
ten the nut and strongly tighten the prescribed coupling
using an average-strength threadlock fluid.
Hammer the new washer down onto the two opposite
faces of the hexagon.
Chain pinion wheel nut torque pressure:

140 N•m
Recommended thread-locking fluid:

Loctite 243
140 N•m
Reassemble the pinion wheel cover after having clea-

F ned the support base.
Screw in the four screws lightly and proceed with the
tightening, screwing down respectively on the three
screws M8 (1) and on the screw M6 (2).
Replace the rubber bands and reinsert the electrical
connector. 1 25 N•m
Torque pressure (M8 Screws): 25 N•m

Torque pressure (M6 Screws): 8 N•m 2
8 N•m
- 74 -
MOTORCYCLE SET-UP ADJUSTMENT
Special tool N. 800092642 A
WARNING: The following adjustments must

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

(special tool) in its appropriate seats as shown in the
figure.
Raise the rear part of the motorcycle by using the

handle and the passenger footrest, until the full exten- F
sion of the rear shock absorber is reached; contempo-
raneously measure the distance X1 between the upper
extremity of the rear stand and the point on the setting-
up arm.
N.B. Two persons must carry out this opera-
tion.
Check that the dimension X1 is equal to:
− BRUTALE 750 ORO / 750 S (MY 03): X1 = 212 mm

− BRUTALE 750 S (MY 04): X1 = 225 mm
− BRUTALE 910 S: X1 = 225 mm
− BRUTALE 910 R: X1 = 225 mm
− BRUTALE 989 R - 1078 RR: X1 = 225 mm
If the dimension X1 differs from the indicated value,

slacken the fixing screws (1) of the semi-connecting
rods of the rear suspension.
- 75 -
Using a ring spanner, adjust the half connecting rod

distancing by regulator (1) until the required X1 level is
reached.
Tighten the fixing screws of the semi-connecting rods

F to the prescribed torque pressure.
Torque pressure: 8÷10 N•m
8÷10 N•m
Press down on the seat so that the shock absorber is

compressed and then let it go back into its resting posi-
tion.
- 76 -
Measure the distance X2 between the upper extremity

of the rear stand tube and the point on the setting-up
arm indicated by the arrow in the figure.
Calculate the static slack Δ according to this formula:
Δ = X1 – X2
The value of the static slack should be equal to:
− BRUTALE 750 ORO / 750 S (MY 03): Δ = 22 mm
− BRUTALE 750 S (MY 04): Δ = 25 mm
− BRUTALE 910 S: Δ = 25 mm
− BRUTALE 910 R: Δ = 25 mm
− BRUTALE 989 R / 1078 RR: Δ = 20 mm
If the static slack value Δ is different from the indicated

value, it is necessary to effectuate the following adjust- F
ment to the shock absorber spring.
Slacken the upper lock ring of the rear shock absorber,

rotating it in the direction indicated in the figure by uti-
lising a 75 mm key spanner.
Rotate the lower lock ring as shown in the figure, either

in a clockwise or anti-clockwise direction, according to
the static slack Δ value calculated.
− BRUTALE 750 ORO / 750 S (MY 03): Δ < 25 mm Δ > 25 mm
Δ < 22 mm: Rotate in an anti-clockwise direction 750 S (MY 04) 750 S (MY 04)
Δ > 22 mm: Rotate in a clockwise direction
Δ < 25 mm Δ > 25 mm
− BRUTALE 750 S (MY 04): 910 S - 910 R 910 S - 910 R
Δ < 25 mm: Rotate in an anti-clockwise direction
− BRUTALE 910 S:
Δ < 25 mm: Rotate in an anti-clockwise direction
− BRUTALE 910 R:
Δ < 25 mm: Rotate in an anti-clockwise direction Δ < 20 mm Δ > 20 mm
989 R - 1078 RR 989 R - 1078 RR
− BRUTALE 989 R / 1078 RR: Δ < 22 mm Δ > 22 mm
Δ < 20 mm: Rotate in an anti-clockwise direction 750 ORO-S (MY 03) 750 ORO-S (MY 03)
- 77 -
At the end of the spring adjustment operation, tighten

the upper lock ring as shown in the figure.
After having completed the adjustment of the motorcy-

cle set-up, it is necessary to adjust the tension of the
chain.
Check also the orientation of the front headlight and if

necessary effectuate the necessary adjustments. Both
these operations are described in chapter B
“Maintenance”.
WHEEL BALANCE CHECK

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

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

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

makes of tyres, it is necessary to refer to the
yellow mark (1) present on the side of the tyre
as shown in the figure. It indicates the lighte-
st point of balancing and must be situated 1 A
close to the tyre valve when the tyre is moun-
ted onto the wheel rim.
N.B. On the side:

- Figure A: Brutale 750 S / 910 S / 910 R
/ 989 R / 1078 RR version
- Figure B: Brutale 750 Oro version
B
1
- 78 -
Rear wheel balancing
Before mounting the rear wheel on the appropriate

tool, insert the balancing tool into the central hole of the
wheel.
Insert the polygonal nut of the balancing tool from the

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

that shown in the figure, utilising a ground pin of 35
mm diameter. Check the wheel utilising a micrometer
gauge and check the following tolerances:
Ovalization and maximum eccentricity

must not exceed 0.5 mm.
- 79 -
Place the dial gauge as shown in the figure, and check

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

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

- Figure A: Brutale 750 S / 910 S / 910 R /
989 R / 1078 RR version
- Figure B: Brutale 750 Oro version
B
1
- 80 -
Frame
SECTION
Revision 3
G
-1-
Frame
SUMMARY
FRAME REMOVAL PRELIMINARY OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

THROTTLE BODY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 7
COIL DISMANTLING (BRUTALE 750 ORO - S / BRUTALE 910 S-R MY 05-06) . . . . . . . . . . . . . . . . .PAGE 9
COIL DISMANTLING (BRUTALE 910 S-R / BRUTALE 989 R-1078 RR MY 07-08) . . . . . . . . . . . . . . .PAGE 9
SECONDARY AIR SYSTEM DISMANTLING (BRUTALE 910 S-R / BRUTALE 989 R-1078 RR MY 07-08) PAGE 11
FRAME DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 14
FRAME CONTROL REFERENCE MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 18
ASSEMBLY FRAME TO THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 20
REAR SUB-FRAME REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 24
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 27
-2-
Frame
FRAME REMOVAL PRELIMINARY OPERATIONS
Place the motorcycle on the rear stand no. 800092642.
Operating on the right side, remove the sealing cover

by unscrewing the two fixing nuts.
Operate in the same way to remove the left sealing

cover.
G
Remove the components in the following sequence:

- Passenger and rider seat;
- Fuel tank;
- Air filter compartment;
the reassembly procedures of the components indicat-

ed are described in chapter C “Bodywork”.
-3-
Frame
Utilising the lift no. 800095807 equipped with the pin

no. 800095808, lift up the front part of the motorcycle.
Remove the components in the following sequence:

- Front mudguard;
- Front brake calipers;
- Front wheel;
- Water radiator;
G
the procedure for removing the components indicated
are described in chapter F “Suspensions and wheels”,
chapter H “Brakes” and chapter L “Cooling and lubri-
cating system.
Insert the support no. 800097867, under the engine

assembly taking care to position it as indicated in the
figures.
Lower the motorcycle and remove the lift no.
800095807.
-4-
Frame
Remove the two fixing screws (1) of the front headlight

on the sides. 2
Take care to slide the adjuster out of its seat when the 1
headlight is removed from the support.
Before removing the front headlight, disconnect the
connector (2) placed in the rear part of the headlight.
Then remove the headlight support and the instrument
panel as described in chapter C “Bodywork”.
Proceed removing the front brake pump and the clutch

control pump as described in chapter H “Brakes”.
Free the clutch control hose (1) from the relative rub-
ber bands on the frame. 1
G
Operating on the right side, free the wiring from the

bands fixing it to the frame.
-5-
Frame
Protect the area around the fluid chamber with a cloth

or paper.
Remove the union and discharge the clutch fluid from
the system into an appropriate container.
Remove the steering assembly and the relative com-

ponents of the front suspension as described in chap-
ter F “Suspensions and wheels”.
Remove the ignition switch and the cooling system

complete with the expansion tank as described in
chapter L “Cooling and lubricating system”.
1
-6-
Frame
THROTTLE BODY REMOVAL
Slacken the nut (1) fixing the accelerator control wiring

to the support plate of the throttle body.
Fleet the accelerator control wiring and extract the

pawl (A) of the opening wiring. A
Carry out the same operation on the pawl of the clos-
ing wiring.
Disconnect the connector (1) of the control of the throt-

tle body potentiometer from the main wiring.
1
-7-
Frame
Slacken the bands (1) fixing the throttle body to the air
intake of each cylinder.
Disconnect the connections relative to the injectors of

each cylinder.
Remove the complete throttle body assembly.
-8-
Frame
Extract the connectors from the coils.

To carry out this operation, free the secondary lock
(yellow "tongue") by extracting it from its seat, then
press the black "tongue" and unhook the connector.
Unscrew the earth connection on the engine head

cover and free the coil wiring from the frame by remov-
ing the two fixing bands; then slide it out on the right
side.
COIL DISMANTLING (BRUTALE 910 S-R / BRU-

TALE 989 R / 1078 RR MY 07-08) 1
Disconnect the coil connectors (1) from the
control unit support.
-9-
Frame
Unscrew and remove the coil backing plate fixing

screws (1).
Remove the coils from their housings.
Operating on the right side of the motorcycle unscrew

and remove the two fixing screws of the rear sealing
protection, then free the protection.
Operate on the left side to remove the left rear sealing

G protection.
Operating alternatively on both sides of the motorcycle

remove the supports of the tubing for checking the suc-
tion by unscrewing the screw fixing the support to the
frame.
- 10 -
Frame
SECONDARY AIR SYSTEM DISMANTLING

(BRUTALE 910 S-R / BRUTALE 989 R / 1078 RR MY 07-08)
Disconnect the connector (1) from the secondary air 1

unit.
Disconnect the secondary air hoses (1) and (2) to the

cylinders by loosening the clamps.
1
Disconnect the airbox connector hose (1).
- 11 -
Frame
Unscrew the screws (1) and remove the fixing

plate (2).
2 1
Remove the two CLIC R 96105 clamps using

special pliers.
Remove the two rubber bands so to free the wiring

from the frame.
- 12 -
Frame
Slide the CPU out from the fixing support fixed to the
frame.
Slide out the main wiring and fold it backwards on the

rear sub-frame.
Fix the main wiring to the sub-frame with an elastic

band.
- 13 -
Frame
FRAME DISASSEMBLY
Operating in the same way on both sides of the motor-

cycle unscrew and remove the front screw fixing the
engine cylinder head to the frame and collect the
eccentric washer.
Operating on the right side unscrew and remove the

rear nut fixing the engine assembly to the frame.
Operating on the left side extract the pin (1).
- 14 -
Frame
Remove the screws fixing the frame tothe union plates

from both sides.
Remove the frame rotating the steering head housing

upwards.
Frame check
Accurately clean the conical seats of the steering head
housing.
- 15 -
Frame
Check that there are no marks or signs on all surfaces.

Check that the area shown in the figure is not
deformed (as a consequence of accident damage).
Check that there are marks of evident breakages along

the frame tubes.
If damage is found, substitute the frame.
Clean and examine the contacts between the frame

and the engine and also between the frame and union
plates.
- 16 -
Frame
- 17 -
Frame
FRAME CONTROL REFERENCE MEASUREMENTS

To carry out a detailed check of the frame, herewith
below are the reference measurements that are of fun-
damental importance for the correct condition of the
frame.
- 18 -
Frame
Steering head housing check

Check the diameter and eventual ovalisation of the 5 mm
steering head housing, 5 mm from the lip of the bevel-
ling as shown in the figure.
Measure the ovalisation in diverse points as shown in

the figure.
- 19 -
Frame
ASSEMBLY FRAME TO THE MOTORCYCLE

If it is necessary to substitute the frame, it is possible
to recuperate various components from the old frame,
such as the CPU support plate, anti-vibration rubbers
and the rubber protection. These components can be
mounted onto the new frame after having effectuated a
thorough check on their condition.
For the stamping and the homologation labels of the
new frame, contact the MV AGUSTA service centre.
Thoroughly clean the matching surfaces of the frame-

engine cylinder head and frame-union plates.
- 20 -
Frame
With regards to the positioning of the cables, fasteners

and various wiring consult the various tables shown in
the F4 Brutale 750 ORO - 750 S Spare Parts
Catalogue (Code 800099359) - 910 S - 910 R Spare
Parts Catalogue (Code 8000A5273) - 989 RR / 1078
RR (Code 8000B1321).
.
- 21 -
Frame
Carry out the sequence of operations of assembly in

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

N·m Kgm
1 800084869 Front engine mounting screw M12x1.25 55/60 5.5/6.0
2 800084866 Upper engine mounting screw M12x1.25 55/60 5.5/6.0
G 3 800084865 Lower engine mounting screw M12x1.25 55/60 5.5/6.0
4 800084867 Plate – frame screw M12x1.25 55/60 5.5/6.0
5 800086395 Front fork pin screw M15x1.25 70/75 7.0/7.5
6 800084863 Rear suspension compensator screw M10x1.25 50/55 5.0/5.5
7 8J0090426 Plate- upper sub-frame fixing screw M8x1.25 24/28 2.4/2.8
8 8J0090426 Plate- lower sub-frame fixing screw M8x1.25 24/28 2.4/2.8
The tightening of the engine mounting screws and the

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

carried out by letting the sub-frame drop into position
by its own weight.
Utilise “AGIP GREASE 30” for the screws.
- 22 -
Frame
- 23 -
Frame
REAR SUB-FRAME REMOVAL
After having carried out the removal of all the neces-

sary components described in the previous paragraph,
remove the connector (1) on the generator.
1
Unscrew and remove the nut fixing the generator

wiring to the system.
Unscrew and remove the nut fixing the starter motor

wiring to the starter switch.
- 24 -
Frame
Unscrew and remove the screw fixing the engine earth

cable to the fixing support of the rear brake fluid tank.
Once the wiring has been freed and collected as

shown in the figure, it is possible to remove the rear
sub-frame.
Unscrew and remove on both sides the two lower

screws fixing the rear sub-frame to the union plates
taking care to recuperate the nuts.
Unscrew and remove the two upper fixing screws tak-

ing care, in this case also, to support the sub-frame
and recuperate the nuts.
- 25 -
Frame
At this point it is possible to remove the complete

sub-frame assembly from the motorcycle.
Rear frame unit assembly
Carry out the operation of reassembling the rear sub-

frame on the motorcycle in the reverse order of
removal, taking care to tighten the fixing screws to the
G prescribed torque pressure.
Rear sub-frame fixing screw torque pres-

sure: 24÷28 N•m
24÷28 N•m
- 26 -
Frame
ENGINE REMOVAL
Side stand removal

Operating on the left side of the motorcycle, unscrew
and remove the two fixing screws of the side stand
switch.
Disconnect the connector of the side stand switch from

the main wiring.
Disconnect the connector of the speed sensor (1) from

the main wiring.
1
- 27 -
Frame
Remove the side stand assembly by unscrewing the

three fixing screws (1).
1
Slide the terminals of the connections out of fixing sup-

port.
Gearchange lever removal

Unscrew the fixing screw (1) and slide out the
gearchange lever (2). 1 2
- 28 -
Frame
Operating on the right side of the motorcycle, remove

the fixing support of the rear brake fluid tank by
unscrewing the fixing screw (1).
Remove the rear brake pump and the relative protec-

tion as described in chapter H “Brakes”.
N.B. The figures show the collectors when

removed, but the operation is still possible
with the exhaust collectors assembled. G
Disconnect the connector of the rear brake stop light

from the main wiring.
- 29 -
Frame
EXHAUST GROUP REMOVAL (BRUTALE 750 ORO-

S / BRUTALE 910 S-R MY 05/06)
Remove the exhaust collectors fixing flanges of the
cylinders 1-2-3-4 by unscrewing the fixing nuts.
Unhook the union spring between the compensator

and the collector of cylinders 3-4.
Remove the collector of cylinders 3-4 by sliding it out

of the primary compensator.
- 30 -
Frame
Unhook the union spring between the compensator

and the collector of cylinders 1-2 and remove the col-
lector by sliding it out of the primary compensator.
Unhook the two connecting springs between the

exhaust group and the silencers.
Remove the connecting plate between the two

silencers.
- 31 -
Frame
Unscrew the screw fixing the silencers to the support.
Remove the upper silencer first, then the lower one.
Unscrew the screw fixing the compensator to the

frame.
- 32 -
Frame
Remove the exhaust compensator by removing it from

the pin on the left side of the frame.
Exhaust group removal

(BRUTALE 910 S-R / BRUTALE 989 R / 1078 RR MY 07-08)
cabling and pull outwards, on the right side of the vehicle.
Unscrew the lower fixing screws of the oil radiator

guard, positioned at the lower base of the water radia-
tor.
Remove the oil radiator guard.
- 33 -
Frame

motorcycle, then remove the flange fixing the exhaust
During this operation, take care near the discharge
hoses in order to avoid scalding.
Special tool: code 8000B2051
G At the time of the assembly, apply the recommended

thread locking adhesive to the threads of the screws
and tighten them at the required torque.
Recommended thread-locking fluid: Loctite 243
- 34 -
Frame

Remove the chain as described in chapter F

“Suspensions and wheels”.
Position an appropriate lift to support the rear suspen-

sion/fork assembly as shown in the figure.
- 35 -
Frame
Slacken the fixing screw of the front fork pin by 1 turn.
Slacken the nut on the rear suspension compensator

pin.
Remove the engine support lower pin fixing nut.
- 36 -
Frame
Operating on the left side extract the engine support

pin.
Extract the bush shown in the figure from the union

plates of the frame from both sides.
Remove the engine assembly from the union plates by

dragging it forwards.
- 37 -
Frame
Operating on the right side, remove the fork pin fixing

screw (1) taking care to recuperate the washer (2).
1 2
Recuperate the spacer.
N.B. The spacer is present on the Brutale ORO

model only.
G Remove the right union plate.
Remove the rear suspension pin fixing nut and slide

out the pin from the left side.
- 38 -
Frame
Remove the fork pin (1) and the spacer (2).
N.B. The spacer is present on the Brutale ORO

model only.
1
Remove the left union plate.
2
When reassembling proceed in the reverse order of
removal, taking care to apply the prescribed grease
and to tighten every fixing to the torque pressure indi-
cated on page 20 of this chapter.
If it is necessary to remove the rider footrests, remove

them by unscrewing the two fixing (1) screws.
N.B. When reassembling tighten the footrest

fixing screws to the prescribed torque 1
pressure. G
Torque pressure of the screws fixing the
footrests to the label: 24 ÷28 N •m.
24÷28 N•m
- 39 -
Frame
- 40 -
Brakes
SECTION
Revision 3
H
-1-
Brakes
SUMMARY
FRONT BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

FRONT MUDGUARD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 4
FRONT BRAKE PADS SUBSTITUTION (BRUTALE 750 ORO - 750 S - 910 S) . . . . . . . . . . . . . . . .PAGE 4
FRONT BRAKE PADS SUBSTITUTION (BRUTALE 910 R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 6
FRONT BRAKE PADS SUBSTITUTION (BRUTALE 989 R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 8
FRONT BRAKE PADS SUBSTITUTION (BRUTALE 1078 RR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 10
SUBSTITUTION AND BLEEDING OF THE FRONT BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 14
FRONT BRAKE CALIPERS SUBSTITUTION (BRUTALE 750 ORO - 750 S - 910 S) . . . . . . . . . . . .PAGE 18
FRONT BRAKE CALIPERS SUBSTITUTION (BRUTALE 910 R - 989 R - 1078 RR MY 2007-08) . .PAGE 19
FRONT BRAKE PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 19
FRONT BRAKE LEVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 21
CLUTCH LEVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 22
FRONT BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 23
FRONT BRAKE DISCS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 24
REAR BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 26
REAR BRAKE PADS SUBSTITUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 27
SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 30
REAR BRAKE CALIPER SUBSTITUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 32
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 34
REAR BRAKE DISC REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 35
H
-2-
Brakes
FRONT BRAKE SYSTEM
A B C D E F G H I J K
N•m 15 ÷ 20 8 23 ÷ 25 38 ÷ 42 16 ÷ 18 16 ÷ 18 8 ÷ 10 2 6 23 ÷ 26 42 ÷ 46
Torque Kg•m
pressure
ft•lb
243
Operation
FRONT BRAKE
Type Semi-floating double disc with the braking area in steel
Ø disc (mm) 310 310 310 320
Disc flanges Aluminium Steel Steel Aluminium
Calipers (pistons mm) 6 pistons Ø 22.65; Ø 25.4; Ø 30.23 6 pistons Ø 34
Front disc thickness (mm) 4,8 4,8 4,8 4,5
Min. pad thickness (mm) 1 1 1 1

FRONT BRAKE
Type Semi-floating double disc with the braking area in steel Semi-floating double disc with the braking area in steel
Ø disc (mm) 310 320
Disc flanges Steel Aluminium
Calipers (pistons mm) Radial with 4 pistons (Ø 32) Monobloc radial with 4 pistons (Ø 34)
Front disc thickness (mm) 4,8 5
Min. pad thickness (mm) 1 1
-3-
Brakes
FRONT MUDGUARD REMOVAL

Remove the four screws of the rear attachment of the
front mudguard as shown in the figure (the two lower
screws are mounted with a bush).
Remove the front brake tubing from the clip mounted
on the attachment.
Widen the attachment and slide it out of its seat.
Remove the two right and left screws with their bushes
from the mudguard.
The front fork has two regulator slots.

During reassembly of the front mud guard,
tighten the screws into the upper threaded
holes if the vehicle is fitted with 120/70
tyres.
FRONT BRAKE PADS SUBSTITUTION

(BRUTALE 750 ORO - 750 S - 910 S)
Widen the pads with a pincer so that the pistons are

pushed back into their seats (as shown in the figure).
The movement towards the outside of the

brake pads makes the pistons go back into
their seats, with the consequent increase in
the level of the brake fluid in the brake fluid
chamber.
-4-
Brakes
Unscrew the pad support pin as indicated in the figure.
Compress the spring and extract the pin.
Remove the pads.
Every 6000 kilometres, check the wear of the pads.

Front brake caliper
The pad thickness must not be less than 1 mm. If the
pads are excessively worn, substitute them.
Disc
Pads
Wear limit 1 mm
-5-
Brakes
To effectuate the assembly of the new pads, align the

holes of the pads with the holes in the caliper.
After having visually checked the condition of the pad
plates, check that they offer sufficient pressure to the
pad during the assembly phase.
Check the condition of the pad-retaining threaded pin.
It must be perfect.
Check that there are not signs of brake fluid on the
brake/tube union and on the bleeder valve.
Check the pad plate direction proceeding as shown in
the figure.
Ensure the correct assembly of the pad pla-

tes.
Tighten the pin to the prescribed torque pressure.

15÷20N•m
Front brake pad pin torque pressure: 15 ÷ 20
N• m
FRONT BRAKE PADS SUBSTITUTION

(BRUTALE 910 R)
Widen the pads with a pincer so that the pistons are

pushed back into their seats (as shown in the figure).
The movement towards the outside of the

brake pads makes the pistons go back into
their seats, with the consequent increase in
the level of the brake fluid in the brake fluid
chamber.
-6-
Brakes
Compress the spring and extract the pin.
Remove the two springs, the two pins and the four
pads.

Front brake caliper
Disc
Pads
Wear limit 1 mm
-7-
Brakes
When refitting, push the pads all the way in.

Insert the spring and, while pressing it down, insert the
pin.
Ensure that the spring is properly seated by

pulling it outwards as shown in the figure.
FRONT BRAKE PAD REPLACEMENT

(BRUTALE 989 R)
Using calipers, position the pin in such a way as to faci-

litate Sieger removal.
-8-
Brakes
Remove the two Siegers, one for each pin.
Remove the two pins and remove the pad cover.
NOTE: Re-assemble the pad cover with the stamp

of the arrow turned upwards.
Remove the two pads from the caliper.

Repeat the same disassembling procedure for the
other caliper.
-9-
Brakes

Front brake caliper
Disc
Pads
Wear limit 1 mm
For setting up front brake pads, carry out the opera-

tions described above in reverse order.
FRONT BRAKE PAD REPLACEMENT

(BRUTALE 1078 RR)
To replace front brake pads, first of all, it is necessary

to remove the brake callipers from the motorbike, as
- 10 -
Brakes
Loose the pads with a screwdriver.
Push one of the two pads towards the central part of

the caliper.
Release the pad and remove it.
- 11 -
Brakes
Remove the second pad by carrying out the same ope-

rations as described above.

Front brake caliper
Disc
H
Pads
Wear limit 1 mm
Before setting up the pads, make sure the sheet-steel

is correctly located in its seat.
- 12 -
Brakes
Introduce the first pad by hooking it on the upper part,

and inserting the lower part in the middle of the caliper.
Make sure to hold the sheet-steel in its seat during the

operation.
Take the pad in touch with the pistons.
- 13 -
Brakes
Introduce the second pad by carrying out the same

operations as described above. (In this case, it is not
necessary to hold the sheet-steel pressed, since it is
already held in its seat by the first pad).
After inserting the newly supplied pad, assemble the

front brake calipers on the motorbike and insert the
relating fixing screws. Tighten the screws at the sche-
duled torque.
Screw tightening torque of front brake cali-

per screws: 42 ÷ 46 N• m
SUBSTITUTION AND BLEEDING OF THE FRONT

BRAKE FLUID
Place the motorcycle on a horizontal surface with the

steering in a straight line.
Protect the area with a cloth.
Remove the two front brake fluid chamber cover.
Brake fluid has a strong corrosive power.

Be careful to not spill the fluid on surroun-
ding parts.
If the fluid is spilt clean immediately with
industrial alcohol and dry with compressed
air.
- 14 -
Brakes
Remove the protection cap

of the bleed valve of the
front right caliper.
Apply a rubber tube to the
bleed valve (the valve is
placed on the summit of
the brake caliper).
Put the other end of the
rubber tube in a suitable
container.
B4 750 ORO - S B4 910 R - B4 989 R B4 1078 RR

B4 910 S
Pull the brake lever without releasing it.

Slacken the bleed valve and empty the brake system.
Tighten again the bleeding screw.
Fill the system by pulling the brake lever 3-4 times (see
figure).
Repeat the above operations until the fluid reaches the

minimum level in the reservoir. Top-up with new brake
fluid and continue the operation until brake fluid of a
different colour comes out.
The quantity of brake fluid necessary for this operation

is approximately 250 cc.
N.B. Repeat this operation on both calipers.
Recommended brake fluid :

AGIP Brake Fluid DOT 4
Utilise only the prescribed brake fluid from

sealed containers. NEVER use old or used
brake fluid.
- 15 -
Brakes
Tighten the bleed screw, remove the rubber tube, care-

fully clean the screw with alcohol, blow it dry and put
the protective cap back on.
Bleed screw tightening torque:

- B4 750 ORO / 750 S / 910 S: 8 Nm
- B4 910 R: 6 Nm
- B4 989 R - 1078 RR: 6Nm
Only for MY 2007 model and previous: Using circlip

pliers, slowly widen the brake pads in their respective
seats so that it avoids the emulsion of the brake fluid
whilst passing through the various connecting holes.
Carry out this operation on both calipers. B4 750 ORO - S B4 910 R
B4 910 S
Slowly squeeze the brake lever to bring the pads in

contact with the disc and also checking that there is no
sponginess in the action of the lever. Air bubbles
ahould not rise in the chamber.
If the bleeding has been done correctly, the movement
of the lever is short and without any elastic effect.
Repeat the bleeding operation if there is still spongi-

ness at the lever.
H
Pour new brake fluid into the chamber until it reaches

the maximum level.
Recommended brake fluid :

Utilise only the prescribed brake fluid from

sealed containers. NEVER use old or used
brake fluid.
- 16 -
Brakes
Top-up the level of the fluid until it reaches the maxi-

mum mark.
Carefully clean around the edge of the brake fluid

chamber utilising a clean cloth.
Imperfect cleaning of this component could

cause the loss of small quantities of brake
fluid whilst riding.
Accurately clean the three elements of the brake fluid

chamber cap with alcohol and dry with compressed air.
- 17 -
Brakes
Place the cap on the brake fluid chamber and tighten

the two lateral fixing screws.
FRONT BRAKE CALIPERS SUBSTITUTION

(BRUTALE 750 ORO - 750 S - 910 S)
• It is advisable to remove the brake pads to facilitate
the operation.
• Slightly move the front brake lever towards the right
handgrip and hold it in position with a strap to limit
the outflow of brake fluid during subsequent opera-
tions.
• Taking care not to spill any remains of the brake fluid
H that may remain inside the brake tubing, remove the
union as indicated in the figure.
Brake liquid can corrode painted surfaces. Clean

immediately any spilt brake liquid using indu-
strial alcohol and drying with compressed air.
• Remove the two caliper fixing screws (1) indicated in

the figure.
• Remove the brake caliper.
N.B. The removal operation for both the right
and left front calipers is identical. 38÷42 N•m 16÷18 N•m
• To reassemble the front brake calipers proceed in the
reverse order to removal.
• Tighten the relative fixing screws to the prescribed torques.
Torque pressure of the fixing screws of the
front brake calipers: 38÷42 N•m 1
Only grease the first threads of the brake cali-
per fixing screws.
Caliper union torque pressure: 16÷18 N•m
• Carry out the reassembly of the brake pads checking
the minimum pad thickness.
• Proceed with the bleeding of the system as described in
page 14.
- 18 -
Brakes
FRONT BRAKE CALIPERS SUBSTITUTION

(BRUTALE 910 R - 989 R - 1078 RR MY 07-08)
• It is advisable to remove the brake pads to facilitate
the operation (only for B4 910 R / 989 R model).
• Slightly move the front brake lever towards the right
handgrip and hold it in position with a strap to limit
the outflow of brake fluid during subsequent opera-
tions.
• Taking care not to spill any remains of the brake fluid
that may remain inside the brake tubing, remove the
union as indicated in the figure.
Brake liquid can corrode painted surfaces. Clean
immediately any spilt brake liquid using indu-
strial alcohol and drying with compressed air.
• Remove the two caliper fixing screws (1) indicated in
the figure.
• Remove the brake caliper.
N.B. The removal operation for both the right
and left front calipers is identical.
23÷26 N•m 42÷46 N•m
To fit the front brake calipers, follow these steps:
• Insert the caliper fixing screws and turn them in until
they make contact.
Only grease the first threads of the brake cali-
per fixing screws.
• Replace the brake pads (only for B4 910 R/989 R model). H
• Refit the caliper union after replacing the sealing
1
washers.
Caliper union torque pressure: 23÷26 Nm
• Fill the system with brake fluid.
• Bleed the system as described in page 14.
• Keep the brake lever pulled back with a strap and
tighten the brake caliper fixing screws.
Caliper fixing screws torque pressure:
42÷46 Nm
FRONT BRAKE PUMP REMOVAL
Remove the cap from the front brake fluid reservoir

and drain the reservoir with a syringe.
Brake fluid is extremely corrosive.

Avoid contact with the eyes, skin and nose.
Wash abundantly with water and call a doc-
tor if accidental contact occurs.
During the following operations, avoid con-

tact with painted surfaces.
- 19 -
Brakes
Remove the union indicated in the figure.
Remove the connectors of the electrical system.
Remove the fixing screw that fixes the pump to the

handlebar.
Open the clamp.
Push down to remove the pump from the reference pin.
- 20 -
Brakes
To substitute the front brake switch remove the screw

After having carried out the overhaul of the

front brake pump assembly, carefully wash
and bleed the front brake system as previou-
sly described in this chapter.
FRONT BRAKE LEVER REMOVAL
Unscrew the blocking nut.
Unscrew the pin and remove it; then remove the brake
lever.
- 21 -
Brakes
When reassembling take care to insert the

lever into its seat. 8÷10 N•m
Grease the pin with the specified product.
Insert the pin into the seat and screw it in until the beat
is reached, then tighten the nut by using a screwdriver.
Front brake lever nut torque pressure:

8 ÷ 10 N • m
CLUTCH LEVER REMOVAL

Remove the nut shown in the figure.
Unscrew the pin and extract it.

Remove the clutch lever.
- 22 -
Brakes
When reassembling, be careful to insert the

pin of the pump piston into the seat situated
on the lever (see figure).
Grease the pin with the specified product.
For the reassembly of the lever tighten the pin.

Keeping the pin still, tighten the nut with a screwdriver.
Clutch lever nut torque pressure:

8 ÷ 10 N • m
8÷10 N•m
FRONT BRAKE DISCS
Check the thickness of the front discs utilising a micro-

meter gauge. Carry out the measurement at least at
three points with 120 ° between them, as shown in the
figure.
Utilise a micrometer gauge for this check.
- Minimum thickness:
- B4 750 / B4 910 S / B4 989 R: 4,5 mm
- B4 910 R: 4,0 mm
- B4 1078 RR: 4,5 mm
This operation just be carried out on both front discs.
If the measurements are below the mini-

mum, substitute the component with a new
one.
- 23 -
Brakes
FRONT BRAKE DISC REMOVAL

Remove the front wheel from the motorcycle (see
paragraph “Front brake caliper removal”).
Remove the front wheel pin utilising two special tools
(see chapter F “Suspensions and wheels”).
Special tool 800092872
Place the wheel in a horizontal position on a work

plane and remove the five screws of each disc procee-
ding in a star-like mode for the removal.
Visually check the discs for lines or score marks.
Place the milled side of the brake disc flange on a level

surface with the milled side face down and utilising a
micrometer gauge check that the maximum oscillation
of the disc reached during a rotation of 360° does not
exceed 0,3 mm.
If the oscillation is higher than 0.3 mm, sub-

stitute the disc with a new one.
This operation must be carried out on both front discs.
- 24 -
Brakes
Front disc assembly

Thoroughly clean the contact surfaces of the discs and
the wheel.
Accurately grease all relative surfaces of the disc befo-
re reassembling.
Apply thread-locking fluid to the five fixing screws of

the disc.
Recommended thread-locking fluid:

Loctite 243
Screw in the screws lightly, proceeding in a star-like

mode. 23÷25 N•m
Continuing in a star-like mode, tighten the screws to
the prescribed torque pressures.
Front brake disc screw torque pressure:

23 ÷ 25 N•m
Be careful to reassemble the discs in the original posi-

tions (it is advisable to mark them by applying an adhe-
sive label).
This operation is important so that a good

contact between the brake discs and the
relative pads.
Reassemble the wheel pin and the wheel as described

in chapter F “Suspensions and wheels”.
- 25 -
Brakes
REAR BRAKE SYSTEM
A B C D E F
N•m 220 ÷ 240 15 ÷ 20 16 ÷ 18 16 ÷ 18 18 18 ÷ 20
Torque
pressure Kg•m
ft•lb
Operation 243 270
REAR BRAKE
Type Steel disc
Ø disc (mm) 210 210 210 210
Caliper (Ø piston mm) 4 pistons Ø 25,4
Disc thickness (mm) 6 6 6 6
Minimum pad thickness (mm) 1 1 1 1

REAR BRAKE
Type Steel disc
Ø disc (mm) 210 210
Caliper (Ø piston mm) 4 pistons Ø 25,4
Disc thickness (mm) 6 6
Minimum pad thickness (mm 1 1
- 26 -
Brakes
REAR BRAKE PADS SUBSTITUTION
Remove the fixing screws of the lower silencer.
Remove the exhaust protection.
Turn the lower silencer outwards slightly.

If this movement is difficult due to residue in the com-
pensator connection area, clean the part by applying
lubricant/penetrating spray.
Rotate the silencer in a clockwise or anti-clockwise
direction alternatively to allow the lubricant to seep
through.
- 27 -
Brakes
Remove the retaining ring of the wheel nut.

Remove the rear wheel by removing the polygonal nut,
using the following tools:
Torque wrench
55 mm polygonal spanner
Utilising a torque wrench, slacken the rear wheel nut.
The rear wheel blocking nut has a left-hand

thread, so to loosen the rear wheel blocking
nut it must be turned clockwise.
Remove the rear wheel nut.

220÷240 N•m
N.B. When reassembling, tighten the rear wheel
nut to the prescribed torque pressure.
Rear wheel nut torque pressure: 220 ÷ 240

N•m
H Grease only the threaded section.
Take care not to apply grease to the tapered

section of the nut.
Remove the rear wheel taking care to not hit the silen-
cer connecting plate.
N.B. If this operation is too difficult to carry out,

remove the silencer connecting plate
completely before removing the wheel.
- 28 -
Brakes
Utilising circlip pincers as shown in the figure, widen

the pads so that the pistons are pushed back into their
seats.
The outward movement of the brake pads

provocates the retraction of the pistons in
their relative seats, with a consequent
increase in the level of the brake fluid in the
brake fluid chamber.
Remove the pad support pin and the relative spring.
Remove the pad by letting it drop down.
Rear brake pads

Rear brake caliper
Wear/substitution check:
the first time after 1000 kilometres; then every 6000
kilometres.
Check the wear condition and the thickness of the

brake pads on the calipers.
Disc
Pads
Wear limit 1 mm
- 29 -
Brakes
Analyse the condition of the rear brake system and its

components.
Proceed with the reassembly in the reverse order of
removal.
Tighten the pin to the prescribed torque pressure.
Rear brake caliper pin torque pressure: 15 ÷

20 N•m
15÷20 N•m
SUBSTITUTION AND BLEEDING OF THE REAR

BRAKE FLUID
The operation described herewith must be

carried out with the engine cold: the position
of the brake fluid tank could cause grave
burns.
To carry out this operation it is necessary to remove

the passenger seat, the rider seat and the fuel tank,
to accede to the brake fluid tank as described in chap-
ter C “Bodywork”.
- 30 -
Brakes
Open the cover of the rear brake fluid reservoir by

removing the two screws.
To substitute the brake fluid, connect a rubber tube to

the bleed valve, then empty the system in an appro-
priate container by slackening the bleed screw as
shown in the figure while keeping the brake lever
pushed.
Tighten the bleed screw.
Push the brake lever 3-4 times in order to fill the

braking system.
Repeat the above operations until the fluid reaches the H

minimum level in the reservoir. Top-up with new brake
fluid and continue the operation until brake fluid of a
different colour comes out.
Tighten the bleed screw.
Fill the rear brake fluid reservoir until the fluid reaches
the maximum level.
Recommended brake fluid:

Utilise exclusively the prescribed brake

fluid. Use only new brake fluid from sealed
containers. NEVER utilise old or used brake
fluid.
Be careful to not spill the fluid from the

reservoir during these operations.
Brake fluid is extremely corrosive.
Avoid contract with the eyes, skin and nose.
Wash abundantly with water if contact is
accidentally made and consult a doctor.
During the successive operations, avoid
spilling the fluid onto painted surfaces.
- 31 -
Brakes
Before closing the fluid reservoir, check the condition

of the components.
REAR BRAKE CALIPER SUBSTITUTION

To facilitate the operation, remove the brake pads as
described previously.
Remove the crown wheel as described in chapter F
“SUSPENSIONS AND WHEELS”.
Empty the system of brake fluid as described in para-

graph “Substitution and bleeding of the rear brake
H fluid”.
Remove the tubing by unscrewing the union indicated
in the figure.
Be careful of the residue fluid that remains inside the

pincer unit.
Remove the two screws indicated in the figure.

Substitute the caliper. 18 N•m
For reassembly, tighten the two screws to the prescri-
bed torque pressure.
Rear brake caliper screw torque pressure:

18 N•m
Apply Loctite 243
- 32 -
Brakes
Assemble the union tightening to the prescribed tor-

que. 16÷18 N•m
Torque pressure: 16 ÷18 N•m
N.B. Substitute the washers with new ones.
If the brake pads have been removed, reassemble

them.
Proceed with the filling and bleeding of the rear brake

system (see page 24).
Rear brake pump removal

Carry out the emptying of the brake system as pre-
viously described in paragraph “Substitution and blee-
ding of the rear brake fluid”.
Remove the clips complete with the fixing pin of the

rear brake lever and the pump control fork by rotating
and successively pushing inward as shown in the figu-
re.
H
Unscrew the union indicated by the arrow in the figure,

thereby freeing the pump the brake tubing.
- 33 -
Brakes
Unscrew the two fixing screws of the brake pump to its

relative support.
Remove the pump.
After having carried out a check on all components and

substituted those used, damaged or defective proceed
with the assembly by following the procedure in rever- 8÷10 N•m 16÷18 N•m
se order of removal.
N.B. Substitute the gaskets of the pump/caliper

hoses.
Tighten the fixings to the prescribed torque pressure.
Torque pressure pump union:

H 16÷18 N•m
Torque pressure of the screws fixing the

brake pump to the support:
Screws M6: 8÷10 N•m - Screws M8: 23÷25

N•m 23÷25 N•m
Conclude the operations by filling the system with
brake fluid and successively bleeding the system (see
page 24).
REAR BRAKE DISC
Check the thickness of the rear brake disc.

Substitute the disc if the measurements are less than
the minimum value allowed. Effectuate the substitution
as hereby described.
- Minimum thickness allowed: 5.7 mm
- 34 -
Brakes
REAR BRAKE DISC REMOVAL

Before proceeding with the removal of the rear brake
disc, it is necessary to carry out certain operations
described previously in this chapter:
Remove the rear wheel.
Remove the rear brake disc from its support.
Remove the four nuts fixing the disc to the flange spli-
ned to the wheel pin.
Remove the four nuts previously freed by extracting

them from the rear part of the motorcycle and rotating
the disc to facilitate the removal of the nuts.
Check the rear brake disk level using a comparator

and resting the disk on a levelling table. Use the same
procedure for the front brake disks.
The planarity value must not exceed 0.3 mm.
Utilise a micrometer gauge with support to

carry out this check.
H
Check the thickness of the rear brake disc by utilising

a micrometer gauge. Carry out the measurement at
least at three points with 120 ° between them.
The minimum thickness of the disc must not be less

than 5.7 mm.
- 35 -
Brakes
Before reassembling the rear brake disc, check the

condition of the four pins and four special nuts.
Proceed with tightening of the nuts. 18÷20 N•m
The screws must be assembled with the

nuts screwed in lightly and brought into con-
tact with the disc surface.
After this operation, tighten the four nuts in
a cross-like mode.
Rear brake disc nut torque pressure: 18÷20

N•m.
Apply Loctite 270
Conclude the reassembly operations of the various

components by following the procedures previously
described in these paragraphs in reverse order.
- 36 -
Cooling system and lubrication system
SECTION
Revision 4
L
-1-
SUMMARY
COMPLETE COOLING SYSTEM ASSEMBLY AND LUBRICATION SYSTEM...........................................PAGE 3

COOLING SYSTEM LEAKAGE CHECK ..................................................................................................PAGE 4
EXPANSION TANK CAP CHECK .............................................................................................................PAGE 4
ENGINE COOLANT EXTRACTION...........................................................................................................PAGE 5
EXPANSION TANK REMOVAL .................................................................................................................PAGE 5
DISASSEMBLING WATER RADIATOR ....................................................................................................PAGE 8
COOLING FAN DISMANTLING (BRUTALE 750 ORO - S / 910 S - R MY 05/06) ................................PAGE 12
COOLING FAN DISMANTLING (BRUTALE 910 S-R / 989 R / 1078 RR MY 07/08) .............................PAGE 13
CHECKING COOLING FAN STARTER.....................................................................................................PAGE 15
COOLING FAN REASSEMBLY (BRUTALE 750 ORO - S / 910 S - R MY 05/06) ...................................PAGE 15
COOLING FAN REASSEMBLY (BRUTALE 910 S-R / 989 R / 1078 RR MY 07/08) ..............................PAGE 15
COOLANT TEMPERATURE SENSOR (BRUTALE 750 ORO - S / 910 S - R MY 05/06)........................PAGE 19
REMOVING THERMOSTAT VALVE ..........................................................................................................PAGE 20
REASSEMBLING THERMOSTAT VALVE.................................................................................................PAGE 22
REASSEMBLING EXPANSION TANK ......................................................................................................PAGE 25
ASSEMBLING WATER RADIATOR ..........................................................................................................PAGE 27
REMOVING OIL RADIATOR .....................................................................................................................PAGE 33
REASSEMBLING OIL RADIATOR ............................................................................................................PAGE 38
-2-
COMPLETE COOLING SYSTEM ASSEMBLY AND LUBRICATION SYSTEM
Before checking, disposing of, or overhauling any component relevant to the cooling and lubrication perform some
preliminary operations system:
1) Let the engine cool down.
2) Remove the passenger and pilot seat, right and left side panel, ignition switch cover, fuel tank and air filter com-
partment as described in the chapter C “Superstructures”.
-3-
COOLING SYSTEM LEAKAGE CHECK
Before removing the radiator and discharging the engi-

ne coolant, check that the cooling system does not
have leakages.
Remove the expansion tank cap and connect the
tester (of the type shown in the diagram) to the filler
hole.
Do not open the cap of the expansion vessel

when the engine is hot.
Apply a pressure of approximately 120 kPa (1.2

kg/cm2) and check that the system maintains the pres-
sure for at least 10 seconds.
If the pressure diminishes within ten seconds means

that there is a leak in the system.
If so, check the entire system and substitute the defec-

tive/damaged parts.
When removing the tester from the filler

hole, wrap a cloth around the filler hole to
avoid spurts of engine coolant.
Do not exceed the recommended pressure

to avoid damaging the radiator.
EXPANSION TANK CAP CHECK

Check the release pressure of the radiator cap by utili-
sing the appropriate tester as follows:
Apply the cap to the tester as indicated and slowly
create a pressure by activating the tester.
Ensure that the pressure increase is stopped at 110 ±
15 kPA (1.1±0.15 kg/cm2) and check that with the
tester held steady, the pressure is maintained for at
least ten seconds. Substitute the cap if the pressure is
not maintained for ten seconds.
Radiator cap release pressure:

110±15 kPa (1.1±0.15 kg/cm2)
-4-
ENGINE COOLANT EXTRACTION
Remove the ignition commutator cover unscrewing the

two fixing screws (1).
Open the cap of the expansion tank (2). 2
Empty the cooling system of the coolant as follows:
• Place under the engine a container to collect the

discharged coolant; 2
• Remove the discharge screw (1) situated on the water
pump (2);
• Make sure the coolant flows into the container. 1
Wait until all the engine coolant has dripped out of the
cooling system.
Recover the coolant in an appropriate vessel.

Do not drain liquid into the environment.
EXPANSION TANK REMOVAL
After emptying the cooling system as described in the

previous paragraph, the passenger saddle, driver
saddle, tank side panels, fuel tank and airbox must be
removed prior to the expansion chamber as described
in Chapter C “Superstructures”.
Remove the ignition switch and the fuel tank support

bracket unscrewing the two fixing screws (1).
-5-
Disconnect the connector (1) of the ignition switch and

remove the relative rubber clamp (2) by working on the 2
right side of the vehicle.
On the right side of the motorcycle remove the clamp

(1) connecting water radiator breather pipe to the
expansion tank using specific pliers CLIC R 205 and its
rubber clamp (2).
Specific tool CLIC R 205
L 1
Disconnect the overflow pipe (1) from the expansion

tank.
Check the diameter of the tube that has just been
removed.
If the external diameter = Ø 10.5 mm and the internal 1
diameter = Ø 6.5 mm the tube can be reused for the
successive assembly.
If the dimensions of the tube are different from those
indicated it must be substituted for a new one.
If so, proceed with its complete removal.
-6-
In order to extract the pipe you should release it from

the fixing point shown by the arrow in the figure on the
side.
Remove the ignition switch support unscrewing the

four screws (1). 1
On the left side of the motorcycle remove the clamp (1)

connecting the water radiator charging pipe to the
expansion tank using a specific pliers CLIC R 205 and 2
its rubber clamp placed near the fluid supply tank.
Specific tool CLIC R 205 1
Disconnect the water radiator charging pipe (2).
Remove the expansion tank (1) releasing it from its

seat on the frame and lifting it in the rearward of the
motorcycle.
1
-7-
DISASSEMBLING WATER RADIATOR
Remove the upper (1) and side (2) protections of the 2

water radiator unscrewing the respective fixing screws 1
on both sides of the radiator.
Remove the oil radiator protective guard (1) by

unscrewing the two fixing screws.
1
L
Remove the upper plastic protection (1) unscrewing

the two fixing screws.
-8-
Remove the protective grid (1) taking it out from its

seat. 1
Disconnect the connector (1) of the water radiator elec-

tric fan on the right side of the motorcycle.
Only for Brutale 910 S - 910 R - 989 R - 1078 RR

(MY2007/08) models:
Disconnect the two water radiator cooling fan
connectors (1) located on the right side of the
vehicle.
-9-
Disconnect the connector (1) of the water temperature

sensor at the instrument panel on the left side of the
vehicle. 1
Remove the clamp (1) on the water suction pipe cou-

pling from the pump to the radiator using the specific
pliers CLIC R 205.
Specific tool - pliers CLIC R 205
L 1
Remove the clamp (1) on the water inlet pipe coupling

to the radiator from the thermostat valve using the spe-
cific pliers CLIC R 205.

1
- 10 -
Disconnect the fixing link rod on the right side of the

water radiator.
Move the radiator towards the front side of the

motorcycle in order to the release the water suction
pipe coupling (1) from the pump to the radiator.
1
Release the water inlet pipe coupling to the radiator (1)

to the radiator from the thermostat valve.
- 11 -
Remove the radiator fixing screws on the left side of

the motorcycle.
Remove the radiator moving it right in order to release

it from the peg (A) on the frame support.
A
COOLING FAN DISMANTLING (BRUTALE 750 ORO

- S / 910 S-R MY 05/06) 1
Unscrew the three screws (1) and remove the comple-

te fan support.
- 12 -
For replacing fan you should remove the three nuts (1)
for fixing fan (2) and protecting (3) the support (4).
3 1 4
COOLING FAN DISMANTLING (BRUTALE 910 S-R /

989 R / 1078 RR MY 07/08)
Remove the rubber clamp and free the cabling from

the right and left sides of the fan units.
Unhook the right fan unit cable connector from the spe-
cial plate on the right fan support.
- 13 -
Unscrew the three screws (1) and remove both the fan
unit and support.
Remove the clamp connecting the cooling fan to the

support.
Before replacing the fan it is important to remove the

three blocking nuts (1) from the fan (2) and the guard
(3) attached to the support (4).
3
After dismantling the right engine fan unit, proceed in
the same way for the left unit.
- 14 -
CHECKING COOLING FAN STARTER

In order to verify the efficiency of the electric fan star-
Motorino
Fan motor Ampmeter
ter, this starter must be connected as shown in the figu- elettroventola Amperometro
re by using voltmeter and amperometer.
During the test the starter must be powered.
This test can be carried out on a work surface (con- A
necting a 12V – 9Ah battery) or on board the motorcy-
cle.
The voltmeter is to check that the battery feeds the
motor at 12V. When the fan turns at maximum speed Battery
Batteria V Voltmeter
Voltmetro
the ampmeter should indicate not more than 5 ampe-
re.
If the motor does not turn, substitute the fan motor unit
with a new one.
N.B. To carry out the above-indicated test it is

not necessary to remove the fan motors
from the engine.
COOLING FAN REASSEMBLY (BRUTALE 750 ORO-

S / 910 S-R MY 05/06) 5÷6 N•m
Insert the electric fan (2) on its support (4).
Tighten the three fixing nuts (1) putting the electric fan
between support and protection (3).
Torque wrench setting of electric fan nuts: 2

5 ÷ 6 N•m
L
3 1 4
Position the previously assembled electric cooling fan

onto the radiator. 5÷6 N•m 1
Tighten the screws (1) to the prescribed torque wren-
ch.
Torque wrench setting of electric fan sup-

port fixing screws: 5 ÷ 6 N•m
- 15 -
Ensure that the protective sheath (2) is inserted on the

fan wiring.
Position the wiring of the upper electric cooling fan as
Insert the electrical connector into its tongue support in
the area indicated of the fan frame and fix the cable
using the appropriate tear clamps (1) as shown in the
figure. 1
To avoid possible contact between the elec-

tric lead and the exhaust tube, ensure that 2
the lead is correctly positioned.
COOLING FAN REASSEMBLY (BRUTALE 910 S-R /

989 R / 1078 RR MY 07/08)
Reassemble the cooling fan unit by commencing with
3
the left fan.
Fit the cooling fan (2) into its support (4).

Tighten the three blocking nuts (1), setting the cooling
fan between the support and guard (3). 4
Cooling fan nut coupling torque

4.5-6 Nm
L 2
Position the reassembled cooling fan on to the radiator.

Attach the left fan unit to the radiator without tightening.
- 16 -
Measure the minimum span between the fan and

radiator pack using a feeler gauge as illustrated in the
diagram.
Perform the measurement several times in the mini-
mum span area around the entire fan.
The minimum distance “d” must be in the following
dimensional range: 1.5 < d < 4.5 mm.
Tighten the three screws (1) to the prescribed coupling

torque.
Cooling fan support screws coupling torque

7-10 Nm 1
Proceed in a similar manner for the left cooling fan unit.
1
L
Fit the left fan unit cable connector to the special plate
on the right fan support.
- 17 -
Fit the left fan unit cabling to the related support using
a pull clamp.
Fit the right fan unit cable connector to the special plate
on the right fan support.
Position the right fan unit cabling as shown in the dia-

gram and fit to the related support using a pull clamp.
- 18 -
Fit the right and left fan unit cabling using rubber clamps.
FLUID TEMPERATURE SENSOR (BRUTALE 750

ORO-S / 910 S-R MY 05/06)
If necessary, check the efficiency of the liquid tempe-

rature sensor by removing it from the radiator.
Remove the temperature sensor of the cooling liquid

using a 19 mm wrench.
Checking water temperature sensor

Check that the resistance of the coolant temperature sen-
sor varies with the temperature as shown.
Carry out the check as follows:
Connect the coolant temperature sensor to an ohm-meter
and immerse it into heated oil as indicated.
Heat the oil to slowly raise the temperature and observe
the thermometer and the ohm-meter. If the resistance of
the coolant temperature sensor does not change as indi-
cated in the table, then the sensor must be substituted.
Special tool 09900-25008: Multi-tester
- 19 -
Temperature Average resistance

20 °C Approx. 3,747 Kohm
If the resistance is infinite or quite different from those

indicated, the coolant temperature sensor must be
substituted.
Assembling water temperature sensor

Before assembling, apply the thread-locking fluid on 14 N•m
the threaded section of the sensor.
Thread-locking fluid used: Loctite 577
Screw and fasten the temperature sensor of the coo-

ling liquid to the specified tightening torque.
Coolant temperature sensor torque pressu-

re: 14 N•m
After the first tightening, furtherly tighten the sensor

L until the rear connector reaches either the nearest hori-
zontal or vertical position.
Be careful when inserting the coolant tem-

perature sensor. It could be damaged if it is
knocked.
REMOVING THERMOSTAT VALVE

Remove the fixing screws (1) of the thermostat valve
cover.
N.B. The figure shows an engine assembly

removed from the frame, but you can
perform the operation also when the engi-
ne unit is assembled.
- 20 -
Remove the cover of the thermostat (1).

Remove the thermostat (2).
Checking thermostat valve

Check to see if the thermostat pad is damaged.
Check the functioning of the thermostat as follows:
• Suspend the thermostat by a piece of string threa-

ded through the flange as indicated in the figure.
• Immerse the thermostat in water contained in a labo-
ratory glass as indicated in the figure. Ensure that
the thermostat is maintained in suspension. Heat the
water with a heat source and observe the increase
in temperature of the thermometer.
• Observe the temperature at the moment of opening
of the thermostat. The temperature at which the
thermostat commences to open should be between
L
the indicated values.
Standard
Thermostat opening temperature:
74.5 - 78.5°C
• Continue to heat the water to increase the tempera-
ture.
• When the temperature of the water reaches the spe-
cified value, the thermostat should be raised up by
at least 7 mm.
Standard
Raising up of the thermostat:
More than 7.0 mm at 90°C
• If the thermostat does not satisfy only one of the

requisites (opening temperature and raising up of
the thermostat), it must be substituted.
- 21 -
REASSEMBLING THERMOSTAT VALVE
Insert the O-ring (1) in its appropriate seat on the cover 1

of the thermostat.
Check the condition of the O-ring previously utilised.
If the O-ring is not in good condition, substi-

tute it with a new one.
Apply a thin layer of silicone grease.
Recommended grease: Silicone Grease
Insert the thermostat (1) into its seat within the cover.
During the assembly of the thermostat ensure that the

hole (2) on the external flange of the thermostat is ali-
gned with the curved working (3) on the cover. 2 3
- 22 -
Insert the cover of the thermostat, complete with ther-

mostat onto the engine. 10 N•m
Tighten the three fixing screws (1) to the prescribed
torque pressure.
Torque pressure: 10 N•m
If the water temperature sensor connector was remo-

ved previously, the following action must be taken.
Tighten the H2O sensor (1) for gearcase, ensuring that

the connector is in horizontal or standing position.
1
For Brutale 750 ORO-S / Brutale 910 S-R MY 05/06

models only:
Connect the connector (1) to the sensor.
- 23 -
For Brutale 910 S - 910 R (MY2007) - 989 R - 1078

RR models only:
Connect the water temperature sensor electrical cable
(1) to the control unit.
Block the water temperature sensor electrical cable

with an elastic clamp as illustrated in the diagram.
- 24 -
REASSEMBLING EXPANSION TANK
Position the tube in respect of the expansion tank as

Position the expansion tank on the frame; if the opera-

tion is difficult, slightly turn the tank clockwise.
Insert the radiator water breather pipe (1) and the over-
flow pipe (2) inside the seats on the plastic clip (3). 8÷10 N•m
Reassemble and fix the ignition switch fixing support
(4) using the four screws (5). 4
Screw tightening torque (5): 8 ÷ 10 N•m

5
5
2 1
- 25 -
If the “overflow” tube was previously removed, reposi-

tion it and fasten with the three rubber clamps (1) as
Ensure that the placement follows the figure and inclu-

1
des also the clutch control piping (2).
Put the overflow pipe (1) on the nozzle of the expan-

sion tank cap (2) again, until it reaches the reference
limit shown in the figure.
Assemble the ignition switch (1) securing it on the

fixing support using the two screws (2). 8÷10 N•m
Screw tightening torque (2): 8 ÷ 10 N•m
- 26 -
On the left side of the motorcycle, insert the water

radiator connecting pipe (2) to the expansion tank.
Secure it using a clamp (1) CLIC R 205 with relevant 2
specific pliers.
Specific tool CLIC R 205 1
Reconnect the connector (1) with the main wiring con-

nection.
2
Secure the ignition switch wiring to the radiator
breather pipe using the rubber clamp (2).
ASSEMBLING WATER RADIATOR

A
On the right side of the motorcycle insert the radiator
right support equipped with rubber bulb in the frame
peg (A).
- 27 -
On the left side of the motorcycle insert the radiator

fixing screw and tighten it to the prescribed torque 10 N•m
wrench.
Torque wrench setting of the radiator fixing

screw: 10 N•m
Insert the delivery pipe coupling that connects the ther-

mostat valve with the radiator.
Secure it using a clamp CLIC R 96 300 (white).
Insert the return pipe coupling that connects the radia-

tor with the water pump.
Secure it using a clamp CLIC R 96 315 (white).
- 28 -
On the right side of the motorcycle connect the electric

fan connector (1) with the main wiring.
For Brutale 910 S - 910 R (MY2007) - 989 R - 1078

RR models only:
On the right side of the vehicle, connect the cooling fan
connectors (1) to the main cabling connection.
1
L
Always on the right side of the motorcycle insert the

breather pipe (1) on the radiator nozzle.
Secure it using a clamp CLIC R 96 120 (black).
Connect the tubes and wires of the electric fan using a
rubber clamp (2).
Reconnect the lower connecting rod.
- 29 -
Insert the protective grid (1) working from the bottom

upwards. 1
Assemble the plastic upper protection (1) and secure it

using the two fixing screws.
Assemble the side (2) and upper (1) protections secu-

ring them on the radiator using the respective fixing
screws. 2
1
- 30 -
Perform the same operation for assembling the oil

radiator protection.
Fill the system using the appropriate fluid.
Fill until a level slightly over the notch indicating the

MIN level is reached.
Tighten the sealing cap of the expansion tank.
- 31 -
For assembling repeat the same phases described for

disassembling the components, but reversing the
order.
Reassemble the following components in order:

- Air filter compartment
- Fuel tank
Start the engine for a few seconds. Let it cool and

then re-check the level of the cooling liquid inside the
expansion tank.
It must reach the line shown in the figure, keeping sli-
ghtly over the MIN reference.
If the level is lower than the line shown, reset it adding

new liquid from the filling cap; restart the engine until
the temperature is reached and wait for the fan comes
into operation at least twice. Shut off the engine and
wait for the temperature falls; finally perform the defini-
tive check of the coolant level.
Complete the motorcycle assembly.
- 32 -
REMOVING OIL RADIATOR
Before removing the oil radiator you should completely

drain the lubrication system.
Put an appropriate vessel under the engine.
Remove the oil drain plug (1).
Recover the coolant in an appropriate vessel.

Do not drain liquid into the environment.
Remove the filling cap (1) on the right side of the

motorcycle in order to facilitate the oil spill.

model: Remove the filler cap (1) using the supplied 10
mm hexagon bar attached to a wrench.
BRUTALE 910 S - R -
Wait for the complete draining of the lubrication 989 R - 1078 RR
system.
Remove the oil radiator protection unscrewing the two

fixing screws.
- 33 -
For Brutale 750 ORO-S / Brutale 910 S-R MY 05/06

models only:
Remove the exhaust manifolds of the cylinders 1-2-3-
4 unscrewing the fixing nuts of the fixing flange (1) from
1
the cylinders.
During this operation pay attention to the

exhaust pipes in order to avoid scorching if
the engine is still hot.
Release the junction spring (1) between compensator

and manifold of cylinders 3 and 4.
Release the junction spring (1) between compensator

and manifold of cylinders 1 and 2.
- 34 -
For Brutale 910 S - 910 R - 989 R - 1078 RR (MY

2007/08) models only:
cabling and pull outwards, on the right side of the vehi-
cle.

motorcycle, then remove the flange fixing the exhaust
During this operation, take care near the

discharge hoses in order to avoid scalding.
Specific tool: code 8000B2051
- 35 -

Only if it is necessary replacing the oil radia-

tor, perform the following operation.
Remove the oil delivery and return pipings connected

with the oil radiator unscrewing the fixing nuts.
If the oil radiator should be only removed

from its position instead of being replaced,
don’t intervene either on pipings or on
unions.
Remove the engine/ radiator support fixing screw pla-

ced on the left side.
N.B. This figure and the next ones show an

engine assembly which the water radiator
has been removed from; but the described
operations can be performed also when
the radiator is assembled.
- 36 -
Disconnect the engine/radiator anchor rod (1) on the

left side.
Remove the oil radiator moving it from right to left in

order to release the support peg inserted in the rubber
bulb support (1) on the right side.
- 37 -
REASSEMBLING OIL RADIATOR
Insert the support peg in the support (1) on the right

side making the oil radiator move from left to right.
Connect the engine/radiator anchor rod (1) on the left

side.
1
L
Put the radiator/engine support on the left side again

and secure it tightening the screw.
- 38 -
If pipings and unions had been removed from

the radiator, reassemble carefully. Lubricate
the union threads using engine oil. Tighten
pipings and unions to the prescribed torque
wrench.
Reconnect the oil delivery and return pipings with the

oil radiator lubricating previously the relative threads by
using engine oil.
Lubrificate using engine oil
Tighten the pipe fixing nuts to the radiator to the pre-

scribed torque wrench.
Torque wrench setting: 18 ÷ 20 N•m 18 ÷ 20 N•m 18 ÷ 20 N•m
For Brutale 750 ORO - S / Brutale 910 S-R (MY

05/06) models only
N.B. Reassemble the exhaust manifolds of the

cylinders 1-2-3-4.
In order to facilitate the reassembly of the

manifolds, you should place the fixing
flange before placing manifolds on the
engine.
Insert the flange inside and then turn it, at
last put the manifold flange assembly on
the fixing stud.
Insert the exhaust manifolds first on their seat on the

compensator and then secure them by the flange (1) to
the cylinders tightening the nut.
1
Torque wrench setting for exhaust flange nut:
20 ÷ 22 N•m
20 ÷ 22 N•m
- 39 -
Refasten the junction springs (1) between compensa-

tor and manifolds of cylinders 1-2-3-4.
Tighten the fixing nut of the flange (1) to the prescribed

torque.
Torque wrench setting for exhaust flange nut: 1

20 ÷ 22 N•m
L
20 ÷ 22 N•m
For Brutale 910 S - 910 R - 989 R - 1078 RR (MY

2007/08) models only:
Reassemble the exhaust manifolds by fitting into the
right side of the vehicle as illustrated in the figure.
- 40 -
To set up the pins fixing the compensator to the frame,

apply the recommended thread locking adhesive to the
threads of the screws and tighten them at the schedu-
led torque.
Specific tool: code 8000B2051
Tightening torque: 20 ÷ 22 N•m
Reconnect the lambda probe connector.

Position and fix the exhaust manifolds to the engine
head.
Reassemble the oil radiator protection securing it by

the appropriate screws.
- 41 -
Before replacing the cap, make sure it is thoroughly

clean and replace the sealing ring with a new one.
On the oil drain plug there is a magnet for attracting
any ferrous residuals which could form in the engine
during the rotation.
Reassemble the engine oil drain plug and tighten it to
the specific torque wrench.
Torque wrench setting for oil drain plug:

35 N•m
Fill the circuit complying with the specifications descri-

bed in the Chapter B “Maintenance”.
Reset the correct oil level inside the engine, verifying

from the appropriate port on the right side of the engi-
ne.
Refill to the correct level. Close the oil filler cap.

BRUTALE 910 S - R -
989 R - 1078 RR 2 1
Only for the Brutale 910 S - 910 R - 989 R - 1078
RR models:
Before replacing the filler cap, grease the O-ring (1)
with the silicon grease (see figure).
Tighten the cap (2) to the tightening torque indicated. 1
35 N•m 2
- 42 -
Start the engine for some minutes.

After having shut off the engine, wait for at least 10
minutes and check the oil level. Ensure that the ground
is flat and keep the motorcycle standing as much as
possible.
The level must be near the “MAX” reference on the
timing case as much as possible. Do not exceed this
limit.
Check any oil leakages.
Avoid making the engine turn with the oil

level lower than the minimum level; this can
impair the operation of the different parts of
the engine.
If the oil level, after the reset, is upper than
the “MAX” reference, correct it by emptying
the system.
- 43 -
- 44 -
Special tools
SECTION
Revision 4
M
-1-
Special tools
Maintenance tools
The special tools shown in the following chapter are indispensable for a correct carrying
out of the described maintenance operations.
To order the special tools, refer to the spare parts catalogue.
-2-
Special tools

N. Code Q.ty Note Descrizione Description I FRAME I I ENGINE I
750 ORO 750 S 910 S 910 R 989 R 1078 RR
1 800092872 2 • • • • • • Chiave perno Front wheel

ruota anteriore spindle spanner
2 800091645 1 • • • • • • Chiave ghiera Steering bearing
cuscinetti di sterzo pin wrench
3 800092857 1 • • • • • • Chiave ghiera Steering cam
eccentrico sterzo ring nut wrench
4 800092860 1 • • • • • • Estrattore cuscinetti Fork bearings
forcellone puller
5 800092861 1 • • • • • • Boccola estrattore Fork bearing
cuscinetti forcellone puller bushing
6 800092862 1 • • • • • • Estrattore cuscinetti Front wheel
ruota anteriore bearings puller
7 800092863 1 • • • • • • Chiave per CPC CPC spanner
8 8000A1953 1 • • • • • • Perno per albero Pin for centering
di centraggio shaft
9 800092865 1 • • • • • • Attr. bilanciamento Rear wheel
ruota posteriore balancing tool
10 800095850 1 • • • • • • Pinza montaggio/ Pliers for clic R
smontaggio clamps assembly/
fascette clic R disassembly
11 800098321 1 • • • • • • Pinza inclinata monta Clic R clamp
fascette clic R fitting pliers
12 800092866 1 • • • • • • Attrezzo montaggio Fork pack
pacco forcellone assembly tool
13 8000A1039 1 • • • • • • Attrezzo para- Dust cover and oil
polvere e paraolio splash guard tool
-3-
Special tools
-4-
Special tools

750 ORO 750 S 910 S 910 R 989 R 1078 RR
1 800092867 1 • • • • • • Attrezzo montaggio Equaliser

pacco bilanciere pack tool
2 800092868 1 • • • • • • Attrezzo cuscinetti Front wheel
ruota anteriore bearings tool
3 800095389 1 • • • • Attrezzo catena Chain tool
(passo 520:532) (pitch 520:532)
4 800095390 1 • • • • Perno taglio e Cutting and
ribaditura riveting pin
(passo 520:532) (pitch 520:532)
5 800093347 1 • • • • • • Asta settaggio Rear suspension
sospens. posteriore setting rod
6 800095807 1 • • • • • • Cavalletto anteriore Front stand
7 800095808 1 • • • • • • Perno cavalletto Front stand pin
anteriore
8 800097887 1 • • • • • • Attrezzo cuscinetto Steering pin
perno di sterzo bearing tool
9 800097888 1 • • • • • • Piastra di riscontro Steering base
base di sterzo plate
10 800097889 1 • • • • • • Estrattore cuscinetto Steering pin
perno di sterzo bearing extractor
11 800097890 1 • • • • • • Attrezzo montaggio Steering pin
cuscinetto bearing
perno di sterzo assembly tool
12 8000A1878 1 • • • • Chiave per silent- Airbox vibration-
block per airbox damper spanner
13 8000B1439 1 • • Attrezzo taglio Chain cutting tool
catena
14 8000B1456 1 • • Attrezzo chiusura Chain joining tool
catena
15 8000B1457 1 • • Attrezzo ribaditura Chain riveting tool
catena
16 800095396 1 • Vernice “GOLD MAGNE-
“ORO MAGNESIO” SIUM” paint
-5-
Special tools
-6-
Special tools

750 ORO 750 S 910 S 910 R 989 R 1078 RR
1 800094792 1 • Attrezzo montaggio Gear change

cambio mounting tool
1 800094792 1 • Attrezzo montaggio Gear change 06446 I
cambio mounting tool I 09191
10410 I
I 10967
1 8A0094792 1 • Attrezzo montaggio Gear change 09192 I
cambio mounting tool I 10409
10968 I
1 8A0094792 1 • • • • Attrezzo montaggio Gear change
cambio mounting tool
2 800086119 8 • • • • • • Bussola di Locating bush
riferimento
3 800081424 1 • Cuscinetto Bearing
3 800081424 1 • Cuscinetto Bearing 06446 I
I 09191
10410 I
I 10967
3 8000A1087 1 • Cuscinetto Bearing 09192 I
I 10409
10968 I
3 8000A1087 1 • • • • Cuscinetto Bearing
4 800086121 1 • Cuscinetto Bearing
I 09191
10410 I
I 10967
I 10409
10968 I
4 800098405 1 • • • • Cuscinetto Bearing
5 800087300 1 • • • • • • Cuscinetto Bearing
6 8A00A5394 1 • • • • • • Software Diagnostics
diagnostica software
7 8000A3406 1 • • • • • • Attrezzo misura Piston projection
sporgenza pistoni measuring tool
8 800094797 1 • • • • • • Lastra sagomata Head cover
copri testa shaped plate
9 800094795 1 • • • • • • Attrezzo bloccaggio Alternator shaft M
rinvio albero transmission
alternatore locking tool
10 800094794 1 • • • • • • Attrezzo bloccaggio Male flexible
supporto coupling support
parastrappi locking tool
11 800094798 1 • • • • • • Attrezzo smontaggio Valve rubber caps
gommini valvola removal tool
12 62N115538 1 • • • • • • Rosetta elastica Spring washer
13 8C0069056 3 • • • • • • Vite TEF M8x30 Screw M8x30
14 800094796 1 • • • • • • Attrezzo montaggio/ Valve assembly/
smontaggio valvole disassembly tool
15 800051521 2 • • • • • • Vite M4x6 Screw M4x6
16 800095429 1 • • • • • • Tampone controllo Gauge pad
17 800095581 1 • • • • • • Punzone montaggio Valve seals
tenute valvola mounting punch
18 8000A2385 1 • • • • • • Tampone Guide mounting
montaggio guida pad
-7-
Special tools
-8-
Special tools

750 ORO 750 S 910 S 910 R 989 R 1078 RR
19 800097867 1 • • • • • • Supporto motore Engine support

20 800095179 1 • • • • • • Attrezzo smontaggio Half-cones
semiconi disassembling tool
21 800095180 1 • • • • • • Attrezzo montaggio Half-cones
semiconi assembling tool
22 8000A2625 1 • • • • • • Broccia per Broach for
guida valvole valve guide
23 8000A7688 1 • • • • • • Chiave USB USB key
24 8000A5393 1 • • • • • • Cavo interfaccia Interface cable
25 8A0093878 1 • • • • • • CD-Rom per Diagnostic
software software
diagnostica CD-Rom
26 8000A7689 1 • • • • • • Adattatore Serial/USB
USB/Seriale adapter
27 8000A9639 1 1 • • • • Piastra di base Base plate
28 8000B2114 1 • • Software Power unit
programmazione programming
centralina software
29 8000B2116 1 • • Chiave USB USB key
30 8000B2117 1 • • Cavo seriale Serial cable
31 8000B2118 1 • • CD-Rom software Power unit
programmazione programming
centralina software CD-Rom
32 8000A1432 1 • • Attrezzo stringifasce Piston ring
per montaggio pistoni assembly tool
33 8000B2859 1 • Tubo Pipe
D34-d25,2-L74,5 D34-d25.2-L74.5
33 8000B2859 1 • Tubo Pipe 06446 I
D34-d25,2-L74,5 D34-d25.2-L74.5 I 09191
10410 I
I 10967
33 8A00B2859 1 • Tubo Pipe 09192 I
D39-d27,2-L74,5 D39-d27.2-L74.5 I 10409
10968 I
33 8A00B2859 1 • • • • Tubo Pipe
D39-d27,2-L74,5 D39-d27.2-L74.5
1 Da utilizzare con il part. N° 14 (Cod. 800094796) - To be used with part No. 14 (Code No. 800094796) - Employez avec le piéce No° 14 (Code N°
800094796) - Mit Teil nr. 14 (Kennziffer Nr. 800094796) verwendet werden - Utilizar con la pieza N° 14 (Cod. N° 800094796).
-9-
Special tools
- 10 -
Special tools

750 ORO 750 S 910 S 910 R 989 R 1078 RR
1 8000A1874 1 • • • • Attrezzatura per Fuel tank

sostegno serbatoio support
benzina assembly
2 8000A0965 1 • • • • Supporto per Fuel tank
serbatoio benzina support
3 8000A1876 1 • • • • Cavo elettrico Wire cable
4 80A0A1875 1 • • • • Tubo mandata Fuel delivery
benzina completo pipe assembly
5 8000A1875 1 • • • • Tubo ritorno Fuel return
benzina completo pipe assembly
6 8000A4317 1 • • • • • • Attrezzo per Oil filter
filtro olio removal tool
7 8000A4686 1 • • • • Attrezzatura per CO control
controllo CO tool assembly
8 800079015 1 • • • • • • Attrezzo bloccaggio Clutch blocking
frizione tool
9 8000A2280 1 • • • • • • Attrezzo chiusura Timing chain
catena distribuzione mounting tool
10 8000A2281 1 • • • • • • Attrezzo apertura Timing chain
catena distribuz. cutting tool
11 800095318 1 • • • • • • Tampone per sede Pad for exhaust
valvola scarico valve seat
12 800095319 1 • • • • • • Tampone per sede Pad for intake
valvola aspirazione valve seat
13 8000A5018 1 • • • • • • Kit guarnizioni Cylinder head
cilindro testa gasket kit
14 8000A5019 1 • • • • • • Kit guarnizioni Cylinder
cilindro engine block
basamento gasket kit
15 8000B2051 1 • • Attrezzo fissaggio Exhaust screw
vite scarico fixing tool
- 11 -
Special tools
- 12 -
Torque pressures
SECTION N N
Revision 4
-1-
Torque pressures
SUMMARY
TORQUE PRESSURES – CYCLE PARTS, EXCLUDING ENGINE - BRUTALE 750 S

FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 4-5
HANDLEBARS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 4-5
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 4-5
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 4-5
FAIRING AND MUDGUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 4-5
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 4-5
FUEL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 4-5
WHEELS AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 4-5
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 4-5
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 4-5
NUTS AND SCREWS NOT INDICATED IN THE TABLE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 4-5
TORQUE PRESSURES – CYCLE PARTS, EXCLUDING ENGINE - BRUTALE 910 S (MY 05/06)
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 6-7
FUEL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 6-7
NUTS AND SCREWS NOT INDICATED IN THE TABLE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 6-7
TORQUE PRESSURES – CYCLE PARTS, EXCLUDING ENGINE - BRUTALE 910 R (MY 2006)
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 8-9
FUEL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 8-9
N NUTS AND SCREWS NOT INDICATED IN THE TABLE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 8-9
TORQUE PRESSURES – CYCLE PARTS, EXCLUDING ENGINE - BRUTALE 910 S (MY 2007)
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 10-11
HANDLEBARS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 10-11
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 10-11
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 10-11
FAIRING AND MUDGUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 10-11
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 10-11
FUEL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 10-11
WHEELS AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 10-11
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 10-11
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 10-11
NUTS AND SCREWS NOT INDICATED IN THE TABLE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 10-11
-2-
Torque pressures
SUMMARY
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 12-13
HANDLEBARS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 12-13
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 12-13
FUEL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 12-13
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 12-13
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 14-15
FUEL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 14-15
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 14-15
NUTS AND SCREWS NOT INDICATED IN THE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 14-15
TORQUE PRESSURES – CYCLE PARTS, EXCLUDING ENGINE - BRUTALE 1078 RR (MY 2008)
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 16-17
FUEL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 16-17
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGES 16-17 N
-3-
Torque pressures
-4-
Torque pressures
-5-
Torque pressures
MV Agusta Brutale 910 S (MY 05/06) motorcycle frame torque pressures
-6-
Torque pressures
MV Agusta Brutale 910 S (MY 05/06) motorcycle frame torque pressures
-7-
Torque pressures
MV Agusta Brutale 910 R (MY 2006) motorcycle frame torque pressures
-8-
Torque pressures
MV Agusta Brutale 910 R (MY 2006) motorcycle frame torque pressures
-9-
Torque pressures
- 10 -
Torque pressures
- 11 -
Torque pressures
- 12 -
Torque pressures
- 13 -
Torque pressures
- 14 -
Torque pressures
- 15 -
Torque pressures
- 16 -
Torque pressures
- 17 -
Torque pressures
- 18 -
Diagnostics
SECTION
Revision 0
O
O
-1-
Diagnostics
DIAGNOSTICS
ELECTRICAL PARTS
CHARGING SYSTEM
Battery warning light on Defective alternator Substitute
Defective alternator connection Check
Defective battery Substitute
Recharging fuse (40A) burnt out Substitute
Defective recharging fuse connection Deoxidise/replace
Oxidised battery connections Deoxidise/replace
SERVICES ELECTRICAL SYSTEM 12V

No function is operative Defective ignition switch Substitute
Defective ignition switch connection Deoxidise/replace
Defective general relay Substitute
Defective general relay connection Deoxidise/replace
STARTER SYSTEM
Starter motor does not function E5 fuse burnt out Substitute
Defective E5 fuse connection Deoxidise/replace
Defective neutral gear sensor Substitute
Defective clutch pump switch Substitute
Defective starter motor Substitute
Defective starter button Substitute
Defective electrical connection – right handlebar control unit Deoxidise/replace
Defective ignition switch Substitute
Defective power cable connection Deoxidise/replace
COOLING SYSTEM
Electric fan does not function A1 fuse burnt out Substitute
Defective A1 fuse connection Deoxidise/replace
Defective fan relay Substitute
Defective thermo-switch Substitute
Defective thermo-switch connection Deoxidise/replace
Defective fan Deoxidise/replace
LIGHTING/INDICATOR SYSTEM
Front/rear sidelights do not function C3 fuse burnt out Substitute
Defective C3 fuse connection Deoxidise/replace
Defective ignition switch Substitute
Defective ignition switch connection Deoxidise/replace
Burnt out bulbs Substitute
Defective bulb connections Deoxidise/replace
Defective light switch Substitute
Defective light switch connection Deoxidise/replace
Main beam/dipped beam lights do not function B2 fuse burnt out Substitute
Defective B2 fuse connection Deoxidise/replace
Burnt out bulbs Substitute
Defective light switch Substitute
O Defective light switch connection Deoxidise/replace
Defective main beam light relay Substitute
Defective main beam light relay connection Deoxidise/replace
Rear stop light does not function D4 fuse burnt out Substitute
Defective D4 fuse connection Deoxidise/replace
Burnt out bulb Substitute
Defective front brake lever switch Substitute
Defective front brake lever switch connection Deoxidise/replace
Defective rear brake lever switch Substitute
Defective rear brake lever switch connection Deoxidise/replace
Rear stop light remains on Front brake lever switch blocked Substitute/repair
Rear brake lever switch blocked Substitute/repair
-2-
Diagnostics
Horn does not function D4 fuse burnt out Substitute

Defective klaxon Substitute
Direction indicators do not function D4 fuse burnt out Substitute
Defective intermittency Substitute
Defective intermittency connection Deoxidise/replace
Bulbs burnt out Substitute
Defective bulb connection Deoxidise/replace
Defective direction indicator switch Substitute
Defective indicator switch connection Deoxidise/replace
Direction indicator remains on Bulb of the other indicator, same side, is burnt out Substitute
The connection of the other indicator is defective Deoxidise/replace
INSTRUMENT PANEL SYSTEM

Instrument panel does not function G7 fuse burnt out Substitute
Defective G7 fuse connection Deoxidise/replace
Instrument panel does not illuminate G7 fuse burnt out Substitute
Defective G7 fuse connection Deoxidise/replace
C3 fuse burnt out Substitute
Defective instrument panel Substitute
Internal bulb burnt out Substitute
Defective bulb connection Deoxidise/replace
Defective injection CPU IAW 1.6M Substitute
Defective instrument panel connection Deoxidise/replace
Defective CPU connection Deoxidise/replace
Speedometer does not work Defective speed sensor Substitute
Defective speed sensor connection Deoxidise/replace
Water temperature indicator does not function Defective temperature sensor Substitute
Defective temperature indicator connection Deoxidise/replace
The oil warning light does not function Defective oil pressure sensor Substitute
Defective oil pressure sensor connection Deoxidise/replace
Neutral gear warning light does not function Defective neutral gear sensor Substitute
Defective neutral gear sensor connection Deoxidise/replace
Battery warning light does not function Defective alternator connection Deoxidise/replace
Side stand warning light does not function Defective side stand switch Substitute
Defective side stand switch connection Deoxidise/replace
Reserve fuel warning light does not function Defective fuel level sensor Substitute
Defective fuel level sensor connection Deoxidise/replace
Defective instrument panel Substitute O
Direction indicator warning light does not function Defective intermittency Substitute
Defective intermittency connection Deoxidise/replace
Sidelight warning light does not function Defective instrument panel Substitute
Main beam warning light does not function Defective instrument panel Substitute
-3-
Diagnostics
INJECTION IGNITION IAW 1.6M

Pressure sensor/air temperature signal error Defective sensor Substitute
Defective sensor connection Deoxidise/replace
Butterfly valve potentiometer signal error Defective potentiometer Substitute
Defective potentiometer connection Deoxidise/replace
Engine temperature sensor signal error Defective engine temperature sensor Substitute
Defective engine temperature sensor connection Deoxidise/replace
FUEL INJECTION SYSTEM

Injector does not inject fuel C6 fuse burnt out Substitute
E5 fuse burnt out Substitute
H8 fuse burnt out Substitute
Defective H8 fuse connection Deoxidise/replace
Defective power relay Substitute
Defective power relay connection Deoxidise/replace
Defective latch relay Substitute
Defective latch relay connection Deoxidise/replace
Defective injector Substitute
Defective injector connection Deoxidise/replace
Defective side stand switch Substitute
Defective safety CPU Substitute
Defective engine pick-up Substitute
Pick-up light/timing wheel not correct Reset
Defective fuel pump Substitute
IGNITION SYSTEM
Spark plug does not function F6 fuse burnt out Substitute
Defective F6 fuse connection Deoxidise/replace
E5 fuse burnt out Substitute
G7 fuse burnt out Substitute
Defective power relay Substitute
Defective power relay connection Deoxidise/replace
Defective latch relay Substitute
Defective latch relay connection Deoxidise/replace
Defective coil Substitute
Defective spark plug leads Substitute
Defective safety switch Substitute
Defective spark plug Substitute
Defective engine earth connection Reset
Defective side stand switch Substitute
Defective safety CPU Substitute
Defective engine pick-up Substitute
Pick-up light/timing wheel not correct Reset
FRAME
STEERING
O Steering is stiff Damaged steering bearings Substitute
Steering bearings over-tightened Adjust
Bent steering pin Substitute
Steering shock absorbers brake too much Adjust
Damaged shock absorber joint Substitute
Low tyre pressure. Adjust
The motorcycle does not proceed in a straight line Bent forks Substitute
Bent frame Substitute
Bent rear fork Substitute
Damaged shock absorber steering joint Substitute
Damaged steering bearings Substitute
Bent wheel spindle Substitute
Damaged rear fork bearings Substitute
-4-
Diagnostics
FRONT WHEEL
Front wheel oscillates/vibrates Bent wheel rim Substitute
Wheel not balanced Balance the wheel
Defective tyre Substitute
Non-recommended tyre Substitute
Damaged wheel bearings Substitute
Wheel fixing screws not tightened Tighten
Wheel spindle fixing ring not tightened Tighten
Front wheel does not turn easily Damaged bearings Substitute
Bent wheel spindle Substitute
Brake pads excessively brush against the discs /see brakes) Check
Deformed brake discs Substitute
Wheel spindle ring excessively tightened Tighten to the correct torque pressure
FRONT SUSPENSION
Front suspension too spongy Deteriorated fork oil Substitute
Insufficient spring loading Adjust
Insufficient hydraulic braking under compression Adjust
Low fork oil level Top-up
Low tyre pressure Adjust
Damaged forks Repair
Front suspension too rigid Excessive spring pre-loading Adjust
Excessive hydraulic braking under compression Adjust
Fork oil level too high Adjust
High tyre pressure Adjust
REAR WHEEL
Rear wheel oscillates/vibrates Bent wheel rim Substitute
Wheel not balanced Balance the wheel
Defective tyre Substitute
Non-recommended tyre Substitute
Damaged wheel bearings Tighten
Fixing nut not tightened Tighten
Suspension screws not tightened Tighten
Damaged suspension bearings Substitute
Rear wheel does not turn easily Damaged bearings Substitute
Wheel hub circlip out of its seat Check
Brake pads excessively brush against the disc Check
Bent brake disc Substitute
Damaged transmission chain Substitute
REAR SUSPENSION
Rear suspension too spongy Insufficient spring pre-loading Adjust
Insufficient hydraulic braking under compression Adjust
Insufficient hydraulic braking in extension Adjust
Low tyre pressure Adjust
Damaged shock absorber Substitute
Rear suspension too rigid Excessive spring pre-loading Adjust
Excessive hydraulic braking under compression Adjust
Excessive hydraulic braking in extension Adjust
High tyre pressure Adjust
Damaged fork bearings Substitute
Damaged compensator suspension bearings Substitute
Damaged shock absorber joint
Damaged connecting rod suspension joints
Substitute
Repair
O
Bent fork pin Substitute
BRAKES
Brake lever and pedal movement too spongy Air bubbles in the braking system Bleed
Leakages in the braking system Repair
Damaged pincer seals Substitute
Damaged pump seals Substitute
Pincer pistons do not operate smoothly Check
Low brake fluid level Top-up
Brake lever and pedal movement too hard Bent brake lever or pedal Substitute
-5-
Diagnostics
Insufficient braking power Discs dirty Clean

Air bubbles in the braking system Bleed
Leakages in the braking system Repair
Damaged pincer seals Substitute
Damaged pump seals Substitute
Low brake fluid level Top-up
Brake pads brush against the discs Damaged pad springs Substitute
Brake fluid level too high Adjust
Brake pads worn past the limit Substitute
EXHAUST SYSTEM
Excessive noise from the silencers Damaged exhaust tube Substitute
Slack tube fixings Tighten
Low engine performance Damaged exhaust tube Substitute
Slack tube fixings Tighten
COOLING SYSTEM
Engine temperature too high Low engine coolant level Top-up
Defective cooling fan Substitute
Defective coolant expansion chamber cap Substitute
Defective fan thermal switch Substitute
Defective temperature sensor Substitute
Thermostat is blocked in the closed position Substitute
Radiator finning bent or blocked Repair/clean
Encrusted radiator Clean
Damaged water pump Substitute
Defective injection/ignition system Check
Non-recommended fuel Substitute
Defective engine cooling system Check
Non-recommended thermal grade of the spark plug Substitute
Accumulation of carbon residues on the cylinder head/pistons Clean
Engine temperature too low Thermostat blocked in the open position Substitute
-6-
Analytical index
SECTION
Revision 4
P
-1-
Analytical index
ANALYTICAL INDEX – BRUTALE WORKSHOP Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-76

MANUAL Magnesium components
(F4 BRUTALE 750 ORO) . . . . . . . . . . . . . . . .B-9
Chapter A - General Description Maintenance and tuning operations . . . . . . . .B-12
Glossary and symbols . . . . . . . . . . . . . . . . . . .A-4 Periodical maintenance schedule . . . . . . . . . .B-10
How to consult this manual . . . . . . . . . . . . . .A-3 Rear shock absorber . . . . . . . . . . . . . . . . . . . .B-83
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8 Rear wheel hub . . . . . . . . . . . . . . . . . . . . . . . .B-83
Operative technical specifications . . . . . . . . . .A-9 Screws and nuts . . . . . . . . . . . . . . . . . . . . . . .B-85
Purpose of the manual . . . . . . . . . . . . . . . . . .A-3 Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-84
Right hand and left hand standard . . . . . . . . .A-5 Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . .B-37
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-78
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8 Swingarm bearings . . . . . . . . . . . . . . . . . . . . .B-83
Technical data . . . . . . . . . . . . . . . . . . . . . . . .B-3
Chapter B - Maintenance Technical information . . . . . . . . . . . . . . . . . . .B-3
Accelerator control . . . . . . . . . . . . . . . . . . . . .B-74 Throttle body adjustment and tuning . . . . . . .B-56
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-66 Transmission chain . . . . . . . . . . . . . . . . . . . . .B-78
Assembly of fuel tubes Tube band fasteners . . . . . . . . . . . . . . . . . . . .B-85
(BRUTALE 750 S - 750 ORO) . . . . . . . . . . . .B-51 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-81
Assembly of fuel tubes Valve mechanism adjustment . . . . . . . . . . . . .B-25
(BRUTALE 910 S - 910 R - 989 R - 1078 RR) .B-54 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-82
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-86
Brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . .B-74 Chapter C - Bodywork
Brake/clutch/gearchange commands check . .B-72 Air filter compartment . . . . . . . . . . . . . . . . . . .C-15
Brakes and clutch . . . . . . . . . . . . . . . . . . . . . .B-69 Fairing assembly . . . . . . . . . . . . . . . . . . . . . .C-3
Components in carbon fibre Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-8
(F4 BRUTALE 750 ORO) . . . . . . . . . . . . . . . .B-8 Tail unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-21
Electric fan Under-tail assembly . . . . . . . . . . . . . . . . . . . .C-25
(BRUTALE 750 ORO - S/910S - R MY 05/06) B-24
Electric fan (BRUTALE 910 S - R / 989 R Chapter D - Injection system
1078 RR -MY 2007/08) . . . . . . . . . . . . . . . . . .B-24 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16
Electrical system . . . . . . . . . . . . . . . . . . . . . . .B-86 Components . . . . . . . . . . . . . . . . . . . . . . . . . .D-10
Engine coolant . . . . . . . . . . . . . . . . . . . . . . . .B-22 Diagnostics system . . . . . . . . . . . . . . . . . . . . .D-17
Engine oil and oil filter . . . . . . . . . . . . . . . . . . .B-12 Engine pick-up . . . . . . . . . . . . . . . . . . . . . . . .D-15
Front fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-85 Fuel pump control system . . . . . . . . . . . . . . . .D-8
Front headlamp . . . . . . . . . . . . . . . . . . . . . . . .B-101 Ignition system . . . . . . . . . . . . . . . . . . . . . . . .D-5
P Front wheel bearings . . . . . . . . . . . . . . . . . . . .B-81 Injection arrest control . . . . . . . . . . . . . . . . . . .D-4

Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-38 Injection system -electrical diagram . . . . . . . .D-18
Fuel pump assembly . . . . . . . . . . . . . . . . . . . .B-48 Injection system technical characteristics . . . .D-3
Fuel union tubes . . . . . . . . . . . . . . . . . . . . . . .B-51 Injection time (injection volume) . . . . . . . . . . .D-3
Instruments and warning lights . . . . . . . . . . . .B-89 Injection time compensation . . . . . . . . . . . . . .D-4
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-94 Injection-ignition system . . . . . . . . . . . . . . . . .D-3
-2-
Analytical index
Position of engine-control system parts – Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-34

(BRUTALE 750 ORO S - 910 S - R MY 05/06) . . . . . .D-6 – Gearchange position switch . . . . . . . . . . .E-38
Position of engine-control system parts – Ignition/side stand safety
(BRUTALE 910 S - R MY07 - 989 R - 1078 RR MY08) .D-7 system parts check . . . . . . . . . . . . . . . . . .E-37
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-12 – Run off safety switch . . . . . . . . . . . . . . . .E-40
– Atmospheric air temperature/pressure – Side stand switch . . . . . . . . . . . . . . . . . . .E-38

– Starter motor assembly . . . . . . . . . . . . . .E-35
sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-12
– Starter motor removal . . . . . . . . . . . . . . . .E-34
– Intake air pressure sensor . . . . . . . . . . .D-12
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-48
Timing wheel gap . . . . . . . . . . . . . . . . . . . . . .D-15
Chapter E - Electrical syste
Chapter F - Suspension and wheels
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9
Front fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15
– Initial battery charge . . . . . . . . . . . . . . . . .E-9
– Front fork overhaul . . . . . . . . . . . . . . . . .F-16
– Cpu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-24
– Battery efficiency check . . . . . . . . . . . . . .E-22 Front wheel . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
– Battery assembly . . . . . . . . . . . . . . . . . . .E-9 – Front wheel assemby
– Charging system . . . . . . . . . . . . . . . . . . . .E-14 (Brutale 750 ORO - 750 S - 910 S) . . . . . .F-12
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3 – Front wheel assembly (Brutale 910 R
989 R - 1078 RR) . . . . . . . . . . . . . . . . . . .F-12
Cooling fan system . . . . . . . . . . . . . . . . . . . . .E-46
– Front wheel removal
Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
(Brutale 750 ORO - 750 S - 910 S) . . . . . .F-5
Electrical diagram
– Front wheel removal
(BRUTALE 750 ORO - S/910S - R MY 05/06) E-5
(Brutale 910 R - 989 R - 1078 RR) . . . . .F-6
– Parts list . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
Motorcycle set-up adjustment . . . . . . . . . . . .F-75
Electrical diagram (BRUTALE 910 S - R
Rear suspension . . . . . . . . . . . . . . . . . . . . . .F-35
(MY 2007) 989 R - 1078 RR (MY 2008) . . . . . . . . .E-7
Rear wheel hub and swingarm . . . . . . . . . . .F-43
– Parts list . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
– Chain reassembly (MY 2007 and previous) F-57
Function diagram . . . . . . . . . . . . . . . . . . . . . .E-24
– Chain reassembly (MY 2008) . . . . . . . . . . .F-60
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
– Chain removal (MY 2007 and previous) . .F-56
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . .E-42
– Chain removal (MY 2008) . . . . . . . . . . . . .F-59
– Instrument panel water sensor . . . . . . . . .E-44
– Rear wheel removal . . . . . . . . . . . . . . . . .F-44
– Starter relay activation . . . . . . . . . . . . . . .E-44
– Swingarm removal and overhaul . . . . . . .F-51
– Key ignition switch . . . . . . . . . . . . . . . . . .E-44
Steering assembly . . . . . . . . . . . . . . . . . . . . .F-29
– Fuel level warning light check switch . . . .E-43
– Steering assembly overhaul . . . . . . . . . .F-30
– Right direction indicator . . . . . . . . . . . . . .E-45
Wheel balance check . . . . . . . . . . . . . . . . . . .F-78
– Left direction indicator . . . . . . . . . . . . . . .E-45
– Oil pressure sensor . . . . . . . . . . . . . . . . .E-43
Chapter G - Frame
– Rpm indicator . . . . . . . . . . . . . . . . . . . . . .E-45
Assembly frame to the motorcycle . . . . . . . . .G-20
– Speed sensor . . . . . . . . . . . . . . . . . . . . . .E-45 P
Klaxon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-47 Coil Dismantling
Semiconductor parts . . . . . . . . . . . . . . . . . . . .E-4 (BRUTALE 750 ORO - S/910S - R MY 05/06) . . . . .G-9
Starter system . . . . . . . . . . . . . . . . . . . . . . . . .E-25 Coil Dismantling

– Spark plugs . . . . . . . . . . . . . . . . . . . . . . . .E-39 (BRUTALE 910 S-R - 989 R - 1078 RR MY 07-08) . .G-9
– Starter motor check . . . . . . . . . . . . . . . . .E-35 Engine removal . . . . . . . . . . . . . . . . . . . . . . . .G-27
-3-
Analytical index
Frame control reference measurements . . . . .G-18 Complete cooling system assembly and
Frame disassembly . . . . . . . . . . . . . . . . . . . . .G-14 lubrication system . . . . . . . . . . . . . . . . . . . . . .L-3
Frame removal preliminary operations . . . . . .G-3 Cooling fan dismantling
Rear sub-frame removal . . . . . . . . . . . . . . . . .G-24 (BRUTALE 750 ORO - S/910S - R MY 05/06) . . . . . .L-12
Secondary air system dismantling Cooling fan dismantling
(Brutale 910 S-R - 989 R - 1078 RR MY 2007) . . . .G-11 (BRUTALE 910 S-R / 989 R / 1078 RR R MY 07/08) .L-13
Throttle body removal . . . . . . . . . . . . . . . . . . .G-7 Cooling fan reassembly
(BRUTALE 750 ORO - S/910S - R MY 05/06) . . . . . .L-15
Chapter H - Brakes Cooling fan reassembly
Front brake system . . . . . . . . . . . . . . . . . . . . .H-3 (BRUTALE 910 S-R / 989 R / 1078 RR R MY 07/08) .L-15
– Clutch lever removal . . . . . . . . . . . . . . . . .H-22 Cooling system leakage check . . . . . . . . . . . .L-4
– Front brake discs . . . . . . . . . . . . . . . . . . .H-23 Coolant temperature sensor
– Front brake disc removal . . . . . . . . . . . . .H-24 (BRUTALE 750 ORO - S / 910 S - R MY 05/06) . . . .L-19
– Front brake lever removal . . . . . . . . . . . . .H-21 Disassembling water radiator . . . . . . . . . . . . .L-8
– Front brake calipers substitution Engine coolant extraction . . . . . . . . . . . . . . . .L-5
(Brutale 750 ORO - 750 S - 910 S) . . . . . . . . . .H-18
Expansion tank cap check . . . . . . . . . . . . . . .L-4
– Front brake calipers substitution Expansion tank removal . . . . . . . . . . . . . . . . .L-5
(Brutale 910 R - 989 R - 1078 RR MY 2007-08) .H-19
Reassembling expansion tank . . . . . . . . . . . .L-25
– Front brake pads substitution Reassembling oil radiator . . . . . . . . . . . . . . . .L-38
(Brutale 750 ORO - 750 S - 910 S) . . . . . . . . . .H-4
Reassembling thermostat valve . . . . . . . . . . .L-22
– Front brake pads substitution
Removing oil radiator . . . . . . . . . . . . . . . . . . .L-33
(Brutale 910 R) . . . . . . . . . . . . . . . . . . . . . . .H-6
Removing thermostat valve . . . . . . . . . . . . . . .L-20
(Brutale 989 R) . . . . . . . . . . . . . . . . . . . . . . .H-8
Chapter M - Special tools
Maintenance tools . . . . . . . . . . . . . . . . . . . . . .M-2
(Brutale 1078 RR) . . . . . . . . . . . . . . . . . . . . .H-10
– Front brake pump removal . . . . . . . . . . . .H-19
Chapter N - Torque pressures
– Front mudguard removal . . . . . . . . . . . . .H-4
– Substitution and bleeding of the front Torque pressures - cycle parts, excluding engine -
brake fluid . . . . . . . . . . . . . . . . . . . . . . . . .H-14 BRUTALE 750 S . . . . . . . . . . . . . . . . . . . . . . .N-4-5
Rear brake system . . . . . . . . . . . . . . . . . . . . .H-26 Electrical system . . . . . . . . . . . . . . . . . . . . . .N-4-5
– Rear brake disc . . . . . . . . . . . . . . . . . . . .H-34 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . .N-4-5
– Rear brake disc removal . . . . . . . . . . . . . .H-35 Fairing and mudguards . . . . . . . . . . . . . . . . .N-4-5
– Rear brake pads substitution . . . . . . . . . .H-27 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N-4-5
– Rear brake caliper substitution . . . . . . . . .H-32 Front suspension . . . . . . . . . . . . . . . . . . . . . .N-4-5
– Substitution and bleeding of the rear Fuel feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N-4-5

P brake fluid . . . . . . . . . . . . . . . . . . . . . . . . .H-30 Handlebars and controls . . . . . . . . . . . . . . . .N-4-5
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . .N-4-5
Chapter L - Cooling system Nuts and screws not indicated in the table . . .N-4-5
Assembling water radiator . . . . . . . . . . . . . . . .L-27 Rear suspension . . . . . . . . . . . . . . . . . . . . . .N-4-5
Checking cooling fan starter . . . . . . . . . . . . . .L-15 Wheels and brakes . . . . . . . . . . . . . . . . . . . .N-4-5
-4-
Analytical index
BRUTALE 910 S (MY 05/06) . . . . . . . . . . . . .N-6-7 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N-12-13

Electrical system . . . . . . . . . . . . . . . . . . . . . .N-6-7 Front suspension . . . . . . . . . . . . . . . . . . . . .N-12-13
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . .N-6-7 Fuel feed . . . . . . . . . . . . . . . . . . . . . . . . . . .N-12-13
Fairing and mudguards . . . . . . . . . . . . . . . . .N-6-7 Handlebars and controls . . . . . . . . . . . . . . .N-12-13
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N-6-7 Instrumentation . . . . . . . . . . . . . . . . . . . . . . .N-12-13
Front suspension . . . . . . . . . . . . . . . . . . . . . .N-6-7 Nuts and screws not indicated in the table .N-12-13
Fuel feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N-6-7 Rear suspension . . . . . . . . . . . . . . . . . . . . .N-12-13
Handlebars and controls . . . . . . . . . . . . . . . .N-6-7 Wheels and brakes . . . . . . . . . . . . . . . . . . .N-12-13
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . .N-6-7 BRUTALE 910 R (MY 2008) . . . . . . . . . . . .N-14-15
Nuts and screws not indicated in the table . . .N-6-7 Electrical system . . . . . . . . . . . . . . . . . . . . .N-14-15
Rear suspension . . . . . . . . . . . . . . . . . . . . . .N-6-7 Exhaust system . . . . . . . . . . . . . . . . . . . . . .N-14-15
Wheels and brakes . . . . . . . . . . . . . . . . . . . .N-6-7 Fairing and mudguards . . . . . . . . . . . . . . . .N-14-15
BRUTALE 910 R (MY 2006) . . . . . . . . . . . . . .N-8-9 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N-14-15
Electrical system . . . . . . . . . . . . . . . . . . . . . .N-8-9 Front suspension . . . . . . . . . . . . . . . . . . . . .N-14-15
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . .N-8-9 Fuel feed . . . . . . . . . . . . . . . . . . . . . . . . . . .N-14-15
Fairing and mudguards . . . . . . . . . . . . . . . . .N-8-9 Handlebars and controls . . . . . . . . . . . . . . .N-14-15
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N-8-9 Instrumentation . . . . . . . . . . . . . . . . . . . . . . .N-14-15
Front suspension . . . . . . . . . . . . . . . . . . . . . .N-8-9 Nuts and screws not indicated in the table .N-14-15
Fuel feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N-8-9 Rear suspension . . . . . . . . . . . . . . . . . . . . .N-14-15
Handlebars and controls . . . . . . . . . . . . . . . .N-8-9 Wheels and brakes . . . . . . . . . . . . . . . . . . .N-14-15
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . .N-8-9 BRUTALE 1078 RR (MY 2008) . . . . . . . . . .N-16-17
Nuts and screws not indicated in the table . . .N-8-9 Electrical system . . . . . . . . . . . . . . . . . . . . .N-16-17
Rear suspension . . . . . . . . . . . . . . . . . . . . . .N-8-9 Exhaust system . . . . . . . . . . . . . . . . . . . . . .N-16-17
Wheels and brakes . . . . . . . . . . . . . . . . . . . .N-8-9 Fairing and mudguards . . . . . . . . . . . . . . . .N-16-17
BRUTALE 910 S (MY 2007) . . . . . . . . . . . .N-10-11 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N-16-17
Electrical system . . . . . . . . . . . . . . . . . . . . .N-10-11 Front suspension . . . . . . . . . . . . . . . . . . . . .N-16-17
Exhaust system . . . . . . . . . . . . . . . . . . . . . .N-10-11 Fuel feed . . . . . . . . . . . . . . . . . . . . . . . . . . .N-16-17
Fairing and mudguards . . . . . . . . . . . . . . . .N-10-11 Handlebars and controls . . . . . . . . . . . . . . .N-16-17
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N-10-11 Instrumentation . . . . . . . . . . . . . . . . . . . . . . .N-16-17
Front suspension . . . . . . . . . . . . . . . . . . . . .N-10-11 Nuts and screws not indicated in the table .N-16-17
Fuel feed . . . . . . . . . . . . . . . . . . . . . . . . . . .N-10-11 Rear suspension . . . . . . . . . . . . . . . . . . . . .N-16-17
Handlebars and controls . . . . . . . . . . . . . . .N-10-11 Wheels and brakes . . . . . . . . . . . . . . . . . . .N-16-17
Instrumentation . . . . . . . . . . . . . . . . . . . . . . .N-10-11
Nuts and screws not indicated in the table .N-10-11 Chapter O - Diagnostics
Rear suspension . . . . . . . . . . . . . . . . . . . . .N-10-11 Electrical parts . . . . . . . . . . . . . . . . . . . . . . .O-2
Wheels and brakes . . . . . . . . . . . . . . . . . . .N-10-11 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . .O-4 P
BRUTALE 910 R (MY 2007) . . . . . . . . . . . .N-12-13
Electrical system . . . . . . . . . . . . . . . . . . . . .N-12-13 Chapter P - Analytical index
Exhaust system . . . . . . . . . . . . . . . . . . . . . .N-12-13 Analytical index
Fairing and mudguards . . . . . . . . . . . . . . . .N-12-13 BRUTALE workshop manual . . . . . . . . . . . .P-2
-5-
Analytical index

MV AGUSTA Motor S.p.A. - Technical Assistance Service
Via Giovanni Macchi, 144 - 21100 Varese (VA) ITALY
Tel. (Italy) 800.36.44.06 - (foreign) ++39 0332 254.712
Fax ++39 0332 329.379 - website “www.mvagusta.it”
Part No. 8A0099360 Edition N. 5

MV Agusta BRUTALE 750 S, Brutale 750 Oro, Brutale 910 S, Brutale 1078 RR, Brutale 989 R, Brutale 910 R Workshop Manual

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MV Agusta BRUTALE 750 S, Brutale 750 Oro, Brutale 910 S, Brutale 1078 RR, Brutale 989 R, Brutale 910 R Workshop Manual

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

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Part No. 8A0099360 - Edition No. 5

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Downloaded from www.Manualslib.com manuals search engine

Respect and defend the environment

GENERAL DESCRIPTION ........................................................................................ A

AIR INTAKE INJECTION SYSTEM .......................................................................... D

ELECTRICAL SYSTEM ............................................................................................ E

HOW TO CONSULT THIS MANUAL .........................................................................................................PAGE 3

HOW TO CONSULT THIS MANUAL A

Display of the operations

Specific tool N. 800091645 30° 1

PURPOSE OF THE MANUAL

A GLOSSARY AND SYMBOLS

This signifies that the lack of Use the recommended coolant.

Utilise a specific tool or equipment for

Tighten to the specified torque. Use the recommended adhesive.

Tolerance or limit of use. Carry out accurate cleaning.

Utilise the tester. Use new components.

Use the recommended oil. Substitute the component.

Use the recommended grease. Do not leave litter about.

The information marked with this symbol

RIGHT HAND AND LEFT HAND STANDARD A

Nitrogen - rear shock absorber

• Thoroughly clean the motorcycle before disassembling it.

GENERAL INDEX SUMMARY OF EACH CHAPTER

OPERATIVE TECHNICAL SPECIFICATIONS A

★ Only for the F4 BRUTALE series ORO: the pre-

Below is an example of the designation of the frame registration number:

★ COMPONENTS IN CARBON FIBRE (F4 BRUTALE 750 ORO)

★ MAGNESIUM COMPONENTS (F4 BRUTALE 750 ORO)

PERIODICAL MAINTENANCE SCHEDULE

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

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

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

Valves Check / adjustment ■ ● ● ●

Timing chain tensioner ●

Timing chain tensioner Check / Substitution ● ● ●

Fuel filter Check / Substitution ● ● ●

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

Air filter Check / Substitution ● ● ● ● ● ●

Brakes / Clutch fluid ●

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

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

Programmed maintenance schedule

Front sprocket / stop washer ★ ★● ★ ★● ★ ★●

Rear sprocket spring drive Check ★ ★● ★ ★● ★ ★●

Check for pressure ● ● ● ● ● ● ● ●

Visual check for knocks ★ ★ ★ ★ ★ ★ ★

Side Check functioning ● ● ● ● ● ● ● ●

Rear fork bearings Check / lubricate ●

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

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

Rear shock absorber Check / Adjust ● ● ● ●

Front fork oil Substitution ●

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

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

Instrument Check functioning ● ● ● ● ● ● ● ●

Horn Check functioning ● ● ● ● ● ● ● ●

Adjust At every variation of the riding set-up of the motorcycle

Ignition switch Check functioning ● ● ● ● ● ● ● ●

Locks Check functioning ● ● ● ● ● ● ● ●

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

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

Programmed maintenance schedule

Table of lubricants and fluids

MAINTENANCE AND TUNING OPERATIONS

ENGINE OIL AND OIL FILTER

Substitute:→ at the first 1000 kilometres and then

Substitute:→ at the first 1000 kilometres and then

To accede to the oil filter and the discharge and filling

Recover the oil in an appropriate container.

Only for the Brutale 910 S - 910 R - 989 R - 1078 RR

Wait until the lubrication system is completely empty of

Substitution of the oil filter