Service Bulletin
Circolare Tecnica - Technisches Rundschreiben - Circulaire Technique - Circular Tecnica

Date:

25 September 2017

Subject:

cylinder head replacement

Product:

F3 675 / 800 MY 2017

Dear Sirs,
following the quality control procedures, it was discovered the existence of a condition that could affect the
functionality of the vehicle on some F3 675 MY 17 \ F3 800 MY 17 model motorcycles.
Although there is no immediate risk to the reliability of the bikes involved, it has been decided to start an
inspection and update on the vehicles that are potentially affected.
In this regard, before carrying out the DELIVERY of motorcycles equipped with the chassis numbers listed
in the attached list, the cylinder head group replacement should be performed.
The same procedure should also be carried out on vehicles already registered and circulating and we
invite you to contact your motorcycle owners with the chassis numbers listed in the list above.
In order to protect your customers' satisfaction and to avoid further aggravated costs, you must ensure
that the cylinder head replacement will be carried out on all motorcycles involved as soon as possible.
For any information, doubt or clarification regarding this intervention procedure, please contact MV
Agusta's Technical Support Service by e-mail.
Please send a warranty claim in accordance with the instructions given below: the required Cylinder head
Kit will be automatically shipped following the approval of the warranty claim.

The Dealers directly involved will receive a communication from MV Agusta with the details of the chassis
numbers billed to them.

Warranty claims:
Send the Warranty claim to activate the spare part order and subsequent reimbursement of spare parts
and labor time, in addition to the full details of the motorcycle, include the following information:
 Warranty type = 2 available options:
o New motorcycles in stock = GX
o Sold motorcycles with activated warranty = GS
 Special warranty number = 2811 (for both GS and GX)
 N° 1 spare part = 2 available options:
o W000W1425 x F3 675
o W000W1426 x F3 800
 Operation code: B 002 (8 hours)
 Problem code: 077
 Date of problem: enter the date in the warranty claim
NOTE: We also remind you that according to the new warranty features and management procedures
you will need to complete the claim with the date of the repair of the motorcycle in order to proceed
with the correct reimbursement of claim (see technical bulletin No. 004).
Please pay attention to the identification of the two different kits:

CYLINDER HEAD KIT F3 675: W000W1425
CYLINDER HEAD KIT F3 800: W000W1426
Each cylinder head is identified with a sticker reporting the code of the kit and the bike model:

Cylinder head replacement procedure:
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Place the bike on the central stand
Remove the driver’s seat, the right and left fairings, the belly fairing , the rear fairings and the
complete front fairing.
Remove the fuel tank.
Disconnect and rremove the battery.
Remove the left and right intake manifold and the related covers.
Remove the airbox and the air filter.
Remove the throttle body by adequately protecting the right frame area.

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Drain the coolant and remove the water radiator.
Remove the silencer and exhaust manifold; keep both the valve cables and the actuator connected.
Disconnect the two brake hoses that connect the front brake calipers and the front brake pump called
"MC1" (front brake pump) and "F" (front brake calipers) from the abs module:

NOTE: Properly protect the brake hoses to prevent the oil from escaping and causing accidental
damage.



Disconnect all electrical connections from the engine and from the rear part of the motorcycle, the
clutch cable, thekey- lock cable, and the main switch assenbly.
NOTE: The electrical system must be removed with the front part and the chassis; make sure that all
the connections are disconnected before removing the parts and be sure that there are no wiring or
tubes that may be damaged during handling:

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

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Secure the rear part of the motorcycle with a strap so you can operate on the chassis front
assembly without moving accidentally the back of the bike (secure the rear part preferably acting
on the rear wheel axel or on the swingarm).
Apply a suitable support under the engine to ensure stability during the operation on thecylinder
head:

Remove the two fixing screws 8000B2750; Properly protect all areas that may be subject to accidental
contact with work tools:

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
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remove the 8000B2715 nut on the right side of the motorcycle and remove the cod. 8B00B5645.
remove the two frame \cylinder head fixing screws cod. 8000C3696.
Place appropriate protections on the chassis in the area that can be subjected to accidental contact
with the cylinder head and valve cover:

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Remove the front chassis assembly by lifting the front assembly slightly to disengage it and then
sliding it forward, paying attention to contact points between the engine and chassis during
handling that could cause accidental damage:

Remove the three plugtops.
Remove the three spark plugs.
Remove the blow by pipe.
Remove the cylinder head’s gas draining pipe.
Remove the valve cover and the alternator cover.

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Turning the generator nut with a 15 mm tool, turn the crankshaft clockwise until piston n ° 3 is on the
upper dead point (PMS (In this position, the mark "M" the phonic wheel is aligned with the reference
mark shown on the crankcase).
The reference marks on the camshaft’s drive wheels are horizontally positioned and facing outwards:
This position provides the minimum pressure of the valve springs and facilitate the disassembling of
the camshaft’s support.
Remove the distribution chain’s tensioner starting by the spring’s nut.
Remove the camshaft’s support by first operating following the pattern shown below in order to
balance the pressure imposed by the valve springs:

Move the distribution chain and remove both camshafts starting from theIntake camshaft
Remove the front slider’s fixing screw.
Remove the two spacers using a 8mm screw:

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Remove the Harmonic Damper’s screw
Loosen the 10 fixing screws of the cylinder head starting from the outer ones and proceeding
towards the inner ones, following a crossed pattern
Remove the cylinder head and place it on a clean surface
Remove the old gasket 8000B2179 and check the correct position of the centering bushes cod.
800081535 on the crankcase.
Remove any gasket residue from the crankcase top
Place the new gasket 8000B2179 provided with the cylinder head’s kit.
Before tightening, lubricate the screw’s head with nut oil (on base), screw threads and underside
Replace the new cylinder head provided in the kit, making sure to avoid damages on the plan
surfaces during the assembling: the contact surfaces between the cylinder and the head must be

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perfectly clean and free of scratches; place the cylinder head by lifting the distribution chain to
avoid having to retrieve it later.
Once thecylinder head is positioned, manually place the screws without tightening
Fix the front slider’s screw with the tightening torque of 8 Nm.
Follow the tightening sequence for thecylinder head’s screws as shown in the picture below and
make a first tightening of the 8 screws at 10 Nm:

Detight again the 8 screws and repeat the tightening at 10Nm.
Make the final tightening with the angle of 85 ° ± 1 using a digital angular key that can provide the
torque corresponding to the angle applied and verifying that the corresponding torque value is
kept between 53.5 ÷ 61.5 Nm.
WARNING: If the tightening angle of 85 ± 1 ° does not correspond with a torque value between 53.5
÷ 61.5 Nm, you will need to replace the screw with a new one and repeat the entire tightening
sequence from the start.
Insert the two spacers with the previously greased sealing O-rings.
Check that the "M" mark on the phonic wheel is aligned with the reference mark on the crankcase
(piston n° 3 is at the upper dead point - "PMS").
While holding the chain in tension, insert the exhaust camshaft with the timing mark on the driven
wheel parallel to the cylinder head’s upper plane and positioned outwards.

Insert the intake camshaft with the “M” mark placed in corrispondence of the pin n°30 of the
distribution chain, starting to count from the pin allighed with the “M” mark on the exhaust
camshaft timing wheel:

WARNING: camshaft timing marks can be represented by a double bevel or a "M" letter.

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Ensure the correct positioning of the new 3 O-Ring 8A0023111 contained in the kit under the
camshaft’s support and fix it by gradually approaching the screws;
WARNING: Do not tighten the camshaft’s support screws before mounting the chain tensioner.
After lubricating each component and with the chain tensioner at the minimum extension
(tensioner’s feet all inside the tensioner’s body), fit the tensioner by approaching the two screws by
hand without tightening;
Tighten the 2 screws at 8 Nm;
tighten the camshaft’s support according to the tightening sequence shown in the illustration
(tightening torque 12Nm)



Insert the tensioner spring and tighten the screw cap until it extends the tensioner; tighten the
spring’s screws to 12 Nm.



After the assembling of the camshaft’s support and the chain tensioner, perform a few revolutions
of the crankshaft (clockwise) and finally put the reference mark on the crankcase in corrispondence
of the letter
"M" on the phonic
wheel to
check if the timing is
correct
,following the position
on the picture
below:



Check the valve clearance:



Insert the thermostat and fix the cover with the grease on the new O-ring provided in the kit and
tighten the screws to 8 Nm.
Insert the cylinder head’s gas draining pipe with grease on the O-Ring. Fix the support plate and
tighten the screw to the torque of 10 Nm.
Reassemble the screw the Harmonic Damper screw and tighten it to the torque of 10Nm and
applying Loctite 243.
Apply on the valve cover the three new spark plug’s gasket cod. 8000B4285 provided in the kit.
Apply a silicon-sealing layer on the half-lugs on the cylinder head in corrispondence of camshafts
lavoration holes.
Place the new valve cover gasket supplied with cod. 8000B4284 and fit the valve cover; place the
screws by hand, then tighten them to 8 Nm.
Refit the spark plugs, the plugtops and the support plate of the filter box; tighten the screws to 8
Nm.
Replace the alternator cover using the new gasket cod. 8000B2617 supplied with kit and applying
the silicone seal in corrispondence of the matching of the two sides of the crankshaft; tighten the
screws to 8 Nm.
Replace the front part \ chassis assembly, taking care not to damage the parts during the
operations.
Replace the fixing screws ,the pin and the nut and tighten them to 60Nm torque in the following
sequence:

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1-cod. 8B00B5645 screw for chassis\ engine assembling M12x1,25 55/60 5,5/6,0
2-cod. 8B00B2715 screw for chassis\ engine assembling M12x1,25 55/60 5,5/6,0
3-cod. 8000B2750 screw for chassis\ engine assembling M12x1,25 55/60 5,5/6,0
Refit the exhaust manifold using the new gasket cod. 8000B4242 supplied with kit and then
reassemble the exhaust silencer; Check that the exhaust valve has the correct operating play.



Refit the brake hoses previously removed from the ABS module by carefully placing them in the
correct positions, then bleed the brake system by using new brake fluid that comes from a sealed
container



WARNING: Do not use the motorcycle before bleeding the brake system to prevent air bubbles
from entering the ABS module, compromising the functionality.
Place the wire harness
Replace the water radiator and fill the cooling system by keeping the front wheel raised at least 7080cm, keeping the coolant level in the expansion tank at the minimum level.
reposition all superstructures in reverse order with respect to disassembly.
Once bike’s reassembling is completed, connect the Texa Diagnostic System: Check the "Calibration
Version" code in the "INFO ECU" menu (if an updated mapping is available, update it before
executing other operations making reference to the dedicated service bulletins);
Then select "petrol Injection" – ECU model - "settings" and perform thecommand "Reset selfAdaptive Parameters" following the program instructions.
Check also the correct operation of the exhaust valve using the control "exhaust valve control".
Check the oil level and coolant level ,idle the engine until the radiator fan starts up.
Perform a road test of the bike.

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NOTE: For informations not shown in this manual, please refer to the workshop manuals.

Thanks in advance for your cooperation, we are at your disposal for any technical / commercial support

Best regards,
MV AGUSTA MOTOR S.p.A.
Technical assistance service

List of VINs involved:
ZCGF310BAHV006981
ZCGF310BAHV006989
ZCGF310BAHV006991
ZCGF310BAHV006992
ZCGF310BAHV006993
ZCGF310BAHV006994
ZCGF310BAHV006997
ZCG3F11BAHV007004
ZCG3F11BAHV007006
ZCG3F11BAHV007007
ZCG3F11BAHV007008
ZCG3F11BAHV007009
ZCG3F11BAHV007010
ZCG3F11BAHV007011
ZCG3F11BAHV007012
ZCG3F11BAHV007013
ZCG3F11BAHV007014
ZCG3F11BAHV007015
ZCG3F11BAHV007016
ZCG3F11BAHV007017
ZCG3F11BAHV007018
ZCG3F11BAHV007019
ZCG3F11BAHV007020
ZCG3F11BAHV007021
ZCG3F11BAHV007022
ZCGF310BAHV007029
ZCGF310BAHV007030
ZCGF310BAHV007067
ZCG3F11BAHV007093
ZCG3F11BAHV007094
ZCG3F11BAHV007095
ZCG3F11BAHV007096
ZCG3F11BAHV007098
ZCG3F11BAHV007099
ZCG3F11BAHV007100
ZCG3F11BAHV007102
ZCG3F11BAHV007103
ZCGF310BAHV007109
ZCGF310BAHV007110
ZCGF320BAHV007151
ZCGF320BAHV007162
ZCGF320BAHV007163
ZCGF320BAHV007167
ZCGF320BAHV007168
ZCGGEGNU8HV007169
ZCGF320BAHV007172
ZCGF320BAHV007191
ZCGF320BAHV007192
ZCGF320BAHV007193
ZCGF320BAHV007194
ZCGF320BAHV007204
ZCGF320BAHV007206
ZCGF320BAHV007210
ZCGF320BAHV007233
ZCGF320BAHV007234
ZCGF320BAHV007235
ZCGF320BAHV007257
ZCGF320BAHV007258
ZCGF320BAHV007259
ZCGF320BAHV007265
ZCGF320BAHV007266
ZCGF320BAHV007274

ZCGF320BAHV007276
ZCGF320BAHV007277
ZCGF320BAHV007278
ZCGF320BAHV007279
ZCGF320BAHV007280
ZCGF320BAHV007281
ZCGF320BAHV007282
ZCGF320BAHV007330
ZCGF320BAHV007331
ZCGF320BAHV007333
ZCGF320BAHV007334
ZCGF320BAHV007335
ZCGF320BAHV007336
ZCGF320BAHV007337
ZCGF320BAHV007339
ZCGF320BAHV007340
ZCGF320BAHV007341
ZCGF320BAHV007342
ZCGF320BAHV007343
ZCGF320BAHV007344
ZCGF310BAHV007375
ZCGF310BAHV007440
ZCGF310BAHV007441
ZCGF310BAHV007489
ZCGF320BAHV007572
ZCGF320BAHV007589
ZCGF320BAHV007596
ZCGF320BAHV007597
ZCGF320BAHV007607
ZCGF320BAHV007612
ZCGF320BAHV007621
ZCGF320BAHV007625
ZCGF320BAHV007626
ZCG3F11BAHV007656
ZCG3F11BAHV007661
ZCG3F11BAHV007662
ZCG3F11BAHV007665
ZCG3F11BAHV007666
ZCG3F11BAHV007667
ZCG3F11BAHV007670
ZCGF310BAHV007671
ZCG3F11BAHV007674
ZCGGEGNU7HV007826
ZCGGEGNU9HV007827
ZCGGEGNU0HV007828
ZCGGEGNU2HV007829
ZCGGEGNU9HV007830
ZCGGEGNU0HV007831
ZCGGEGNU2HV007832
ZCGGEGNU6HV007834
ZCGGEGNU8HV007835
ZCGGEGNUXHV007836
ZCGGEGNU1HV007837
ZCGGEGNU5HV007839
ZCGF310BAHV007841
ZCGF310BAHV007842
ZCGF310BAHV007851
ZCGF320BAHV007868
ZCGF310BAHV007869
ZCGF310BAHV007870
ZCGF310BAHV007871
ZCGF310BAHV007872
ZCGF320BAHV007873

ZCGF320BAHV007874
ZCGF320BAHV007875
ZCGF320BAHV007876
ZCGF320BAHV007877
ZCGF320BAHV007878
ZCGF320BAHV007879
ZCGF310BAHV007881
ZCGF310BAHV007903
ZCGF310BAHV007906
ZCGF320BAHV007907
ZCGF320BAHV007910
ZCGF320BAHV007915
ZCGF320BAHV007916
ZCGF320BAHV007917
ZCGF320BAHV007918
ZCGF320BAHV007919
ZCGF320BAHV007920
ZCGF320BAHV007921
ZCGF320BAHV007925
ZCGF320BAHV007926
ZCGF310BAHV007931
ZCGF310BAHV007932
ZCGF310BAHV007933
ZCGF310BAHV007934
ZCGF310BAHV007935
ZCGF310BAHV007936
ZCGGEGLU3HV007938
ZCGGEGLU7HV007943
ZCGGEGLU9HV007944
ZCGGEGLU0HV007945
ZCGGEGLU2HV007946
ZCGF320BAHV007969
ZCGF320BAHV007970
ZCGF320BAHV007971
ZCGF320BAHV007972
ZCGF320BAHV007973
ZCGF320BAHV007974
ZCGF320BAHV007975
ZCGF320BAHV007976
ZCGGEGNU8HV007978
ZCGGEGNUXHV007979
ZCGGEGNU6HV007980
ZCGGEGNU8HV007981
ZCGGEGNU1HV007983
ZCGGEGNU3HV007984
ZCGGEGNU5HV007985
ZCGGEGNU7HV007986
ZCGGEGNU9HV007987
ZCGGEGNU0HV007988
ZCGGEGNU2HV007989
ZCGGEGNU9HV007990
ZCGGEGNU0HV007991
ZCGGEGNU2HV007992
ZCGGEGNU4HV007993
ZCGGEGNU6HV007994
ZCGGEGNU8HV007995
ZCGGEGNUXHV007996
ZCGGEGNU1HV007997
ZCGGEGNU3HV007998
ZCGGEGNU5HV007999
ZCGF310BAHV008021
ZCGF310BAHV008022
ZCGF310BAHV008023

ZCGF310BAHV008024
ZCGF310BAHV008025
ZCGF310BAHV008026
ZCGF310BAHV008027
ZCGF310BAHV008028
ZCGF310BAHV008029
ZCGF310BAHV008030
ZCGF320BAHV008040
ZCGGEGNU9HV008041
ZCGF320BAHV008066
ZCGF320BAHV008067
ZCGF320BAHV008068
ZCGF320BAHV008069
ZCGF320BAHV008070
ZCGF320BAHV008071
ZCGF320BAHV008072
ZCGF320BAHV008073
ZCGF320BAHV008074
ZCGF320BAHV008075
ZCGF320BAHV008076
ZCGF320BAHV008077
ZCGF320BAHV008078
ZCGF320BAHV008079
ZCGF320BAHV008080
ZCGF320BAHV008081
ZCGF320BAHV008082
ZCGF320BAHV008083
ZCGF320BAHV008084
ZCGF320BAHV008085