Maintenance B3 800 - Team Double 3 Racing | MV...

Maintenance manualEnglish Version

chap. Subject covered page1 MAINTENANCE 31.1. Symbols 31.2. Tables of scheduled maintenance and checks 41.3. Tools and accessories supplied 141.4. Table of lubricants and fluids 151.5. Checking the engine oil level 161.5.1. Topping up the engine oil level 171.6. Checking the coolant level 191.6.1. Topping up the coolant level 201.7. Checking the wear of the brake pads 221.8. Checking the brake fluid level 231.9. Checking and replacing the tyres 251.10. Checking and lubricating the drive chain 311.11. Checking the idle speed 351.12. Replacing parts - General information 361.12.1. Replacing the fuses 361.12.2. Replacement headlight bulb 401.12.3. Replacing turn indicator bulbs 431.12.4 Replacing the license plate light bulb 451.12.5. Replacing the tail light bulb 471.12.6 Replacing the brake light bulb 491.13. Battery 50

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chap. Subject covered page1.14. Cleaning the motorcycle 521.15. Prolonged inactivity 542 TROUBLESHOOTING FLOW CHART 552.1. Engine problems 552.2. Electrical equipment problems 603 TECHNICAL INFORMATION 623.1. Motorcycle overview 623.1.1. Front brake circuit 643.1.2. Rear brake circuit 653.1.3. Engine lubrication 663.1.4. Coolant circuit 673.1.5. Fuel system 683.2. Specifications 693.3. Bodywork parts reference colours 773.4. Frame parts reference colours 79

CONTENTS

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1.1. Symbols

Sections of text that are particularly important in terms of personal safety or possible damage to themotorcycle are marked with the following symbols:

Danger - Failure to observe these prescriptions, even in part, may pose a serious hazardto the driver’s and other people’s safety.

Caution - Failure to observe these prescriptions, even in part, may result in damage to themotorcycle.

The following symbols give an indication of who is supposed to perform the different adjustments and/ormaintenance operations:

Information on operations that can be carried out by the user.

Information on operations that must be carried out only by authorized personnel.

The following symbols are used to provide further information:

The “ ” symbol points out the requirement to use a tool or a special equipment inorder to correctly perform the described operation.

§ The “ § ” symbol refers the reader to the chapter identified by the number that follows.

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1.2. Tables of scheduled maintenance and checks

The main periodic checks and maintenance operations areshown in the following tables. These operations are necessaryto keep the motorcycle safe and in perfect running order.

The intervals indicated in the periodic maintenance and lubri-cation tables must be intended as a general guide under nor-mal riding conditions. It could be necessary to reduce theseintervals according to the climate, the ground conditions, thegeographic position and the conditions of use.

Some of the operations can be carried out by the user, provid-ing he or she possesses the requisite skills. If unskilled, havethe operations performed by an authorized service centre.

As a rule maintenance operations must be performed whilethe motorcycle is on the rear stand after switching off theengine and setting the start switch to OFF. On the contrary,while checking the fluid levels it is advisable to keep the motor-cycle in an upright position without using the rear stand.

After the first 36,000 km (22,400 mi) the operations must beperformed at the same intervals shown in the tables.

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1 GBWARNING

• Impropriety or lack of recommended maintenance operations can lead to an increase ofthe risk of accidents and damage to the motorcycle.• Always use genuine MV Agusta spare parts. Using non-genuine spare parts can acceler-ate the wear of your motorcycle and shorten its life.• Failure to perform the recommended operations, as well as using non-genuine spareparts, could cause the warranty not to be operating.• To replace or top up the lubricants and fluids of your motorcycle, use only the productsgiven at paragraph 1.4.

WARNINGIf you use the motorcycle on race track, we recommend to have the bike checked beforeand after using it by skilled personnel belonging to the MV Agusta Service Centers network.Using the motorcycle on road track is allowed only occasionally and, however, not for com-petitive purpose, even during amateur events.Using the motorcycle on road track could cause a considerable increase of the wear of itscomponents, which would bring to a reduction of their life duration with reference to a nor-mal use on road or highway route.

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Tables of scheduled maintenance0 1000 6000 12000 18000 24000 30000 36000

(600) (3800) (7500) (11200) (14900) (18600) (22400)Pre-

delivery

DESCRIPTION OPERATION

km (mi) covered

Service coupon A B C D E F G

Check level Every time vehicle is used

Engine oilRenew

! ! ! ! ! ! !

At least once a year

Engine oil filter! ! ! ! ! ! !

Every time engine oil is changed

Coolant

Check / Restore level Every time vehicle is used

Check / Restore level ! ! ! ! ! ! ! !

Renew At least every two years

Cooling system Check for leakage ! ! ! ! ! ! ! !

Electric fans Check operation ! ! ! ! ! ! ! !

Valves Check / Adjust ! ! !

Timing chainCheck ! !

Replace !

Replace(Use only MV Agustagenuine spare oil filters)

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1 GBTables of scheduled maintenance

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

Pre-delivery


km (mi) covered


Timing movable shoeCheck / Replace ! !

Replace!

Every time timing chain is replaced

Timing chain stretcher Check / Replace ! ! !

Spark plugsCheck / Replace ! ! !

Replace ! ! !

Fuel filter Check / Replace ! ! !

Throttle body Check and Adjust ! ! ! ! ! ! !

Air filter Check / Replace ! ! ! ! ! !

Check level Every time vehicle is used

Brakes fluidCheck level ! ! ! ! ! ! !

Renew!

At least every two years

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(600) (3800) (7500) (11200) (14900) (18600) (22400)Pre-

delivery


km (mi) covered


Check operation Every time vehicle is used

Every 500 ÷ 1000 km (300 ÷ 600 mi)

Brakes / Clutch Check operation ! ! ! ! ! ! ! !

Check lines for leakage ! ! ! ! ! ! ! !

! ! ! ! ! ! ! !

Brake pads Check wear Every 1000 km (600 mi)( front and rear ) Check / Replace ! ! ! ! ! ! !

Fuel lines and connectionsCheck for leakage ! ! ! ! ! ! !

Replace At least every 3 years


Throttle control Check operation ! ! ! ! ! ! ! !

Check / Adjust play ! ! ! ! ! ! ! !

Choke control Check operation ! ! ! ! ! ! ! !

Clean lever / master cyl.piston contact area

Clean lever / master cyl.piston contact area

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

Pre-delivery


km (mi) covered


Flexible controls and Check / Adjust ! ! ! ! ! ! ! !transmissions

Check Every 1000 Km (600 mi)

Lubricate Every 1000 Km (600 mi) and after riding under the rain

Drive chain Check / Adjust ! ! ! ! ! ! ! !

Lubricate ! ! ! !

Replace ! ! !

Check ! ! ! !

Front sprocket / Tab washerReplace

! ! !

Every time drive chain is replaced

Check ! ! ! !

Rear sprocketReplace

! ! !

Every time drive chain is replaced

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

Pre-delivery


km (mi) covered


Tables of scheduled maintenance

Rear sprocket spring drive Check / Replace ! ! !

Steering bearingsCheck ! ! ! !

Lubricate !

Check pressure Every time vehicle is used; at least every 10 days

TyresCheck wear Every time vehicle is used; at least every 500 Km (300 mi)

Check pressure ! ! ! ! ! ! ! !

Check wear ! ! ! ! ! ! !

Wheel rims Inspect visually! ! ! ! ! ! !

Every time tyre is replaced

Check! ! ! ! !

Front wheel bearingsEvery time tyre is replaced

Replace !

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

Pre-delivery


km (mi) covered


SidestandCheck operation Every time vehicle is used

Check operation ! ! ! ! ! ! ! !


Every 500 ÷ 1000 km (300 ÷ 600 mi)Side stand switch


! ! ! ! ! ! ! !

Rear wheel hubCheck / ! !

Replace / !

Swingarm bearings Check / Lubricate !

Drive chain pads on swingarm Check / Replace ! ! ! ! ! ! !

Drive chain pads on frame plate Check / Replace ! ! ! ! ! ! !

Rear shock absorber Check / Adjust ! ! ! !

Front fork oil Renew !

Lubricateneedle bearing

Lubricateneedle bearing

Clean contact areawith side stand

Clean contact areawith side stand

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(600) (3800) (7500) (11200) (14900) (18600) (22400)Pre-

delivery


km (mi) covered


Battery connections Check and clean ! ! ! ! ! ! !

Electrical equipment Check operation ! ! ! ! ! ! ! !

Instrument panelCheck operation Every time vehicle is used


Lights / Visual signalsEvery time vehicle is used

! ! ! ! ! ! ! !

HornCheck operation Every time vehicle is used



Headlight Adjust Every time geometry is changed and every time you seat a passenger


Ignition switchCheck operation Every time vehicle is used


Check operation /Replace bulbsCheck operation /Replace bulbs

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

Pre-delivery


km (mi) covered


LocksCheck operation Every time vehicle is used


Screws and nuts Check / Tighten ! ! ! ! ! ! ! !

Hose clamps Check / Tighten ! ! ! ! ! ! ! !

General lubrication ! ! ! ! ! ! ! !

General test ! ! ! ! ! ! ! !

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1.3. Tools and accessories supplied

Under the passenger seat you can find the following Tools:- 2 Allen wrenches (2,5 mm. - 4 mm hexagon);- 1 spanner for rear wheel eccentric with extension;- 1 fuse puller;

Inside the fuse box are also provided the followingspare fuses (see §1.12.1):- 2 fuses (10A);- 1 fuse (15A).

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1 GB1.4. Table of lubricants and fluids

* : MV Agusta suggests to refer directly to its authorized dealers in order to purchase the recommendedproduct. The eni i-Ride moto2 5W/40 engine oil has been expressly produced for the Brutale motor-cycle engine. If the above described lubricant is not available, MVAgusta suggests to use a fully synthetic engine oil having character-istics equal or better than the ones prescribed in the following stan-dards:– Consistent with: API SL– Consistent with: ACEA A3– Consistent with: JASO MA, MA2– SAE Rating: SAE 5W-40NOTEThe above standard denominations must be written, alone ortogether, on the engine oil container label.

Engine oilSAE 5W-40

API SLACEA A3

JASO MA, MA2

Description Recommended product SpecificationsEngine lubrication oil eni i-Ride moto2 5W-40 (*) SAE 5W/40 - API SL

Ethylene glycol dilutedCoolant AGIP ECO - PERMANENT with 50 percent

distilled waterBrake and clutch fluid Agip Brake 4 DOT4Drive chain lubrication oil D.I.D. CHAIN LUBE –

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1.5. Checking the engine oil level

Check the oil level while the engine is not running, andhas been allowed to cool down for at least ten minutesafter a ride.The check must be performed after placing the motor-cycle in an upright position on a horizontal surface.

CAUTION: This operation is best carried outwith two people.

Unscrew the oil filler cap and remove it from its seat.Wipe the check dipstick with a clean cloth and fullyscrew the oil filler cap in its seat, then unscrew it againin order to check the engine oil level.

The level must be between the MAX and MIN marks onthe check dipstick connected to the cap.If the oil level is below the MIN mark, top up asdescribed in § 1.5.1.

WARNING: Do not start the engine if the oillevel is below the MIN mark.

Oil level MaxMin

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1 GB1.5.1. Topping up the engine oil level

Remove the oil filler plug. Pour an appropriateamount of engine oil of the recommended type.Never exceed the MAX level mark. At the end ofthe operation, place back the oil filler plug.

CAUTIONTo avoid clutch sliding and damage tothe engine, never add chemical addi-tives to the engine oil, nor use an engineoil different from the one specified in thetable at § 1.4. Make sure that no foreignbody gets in the crankcase while top-ping up the engine oil.

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WARNINGNew or exhaust engine oil can be dan-gerous. Engine oil is highly toxic forpeople and domestic animals. Avoidingestion and contact. It has beenproved that prolonged contact withengine oil can cause skin cancer onguinea pigs. Even a brief contact withengine oil can cause skin irritation.• In the event of an engine oil ingestion,immediately call a doctor and do notcause vomiting, in order to avoid inhala-tion of engine oil in lungs.

• Keep new or exhaust engine oil out ofreach of children and domestic animals.• While topping up the engine oil, weara long-sleeved shirt and a pair of water-proof gloves to protect your skin.• If the engine oil comes in touch withyour skin, wash it away with soap andwater.• Correctly recycle or dispose of theexhaust engine oil, in order to avoidenvironmental pollution.

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1 GB1.6. Checking the coolant level

Check the coolant level while the engine is off and cold.The check must be performed after placing the motor-cycle in an upright position on a horizontal surface.

Ensure that the coolant level should be slightly abovethe MIN mark, as shown in the figure.

If the coolant level is below the MIN mark, top up thecoolant as described at paragraph 1.6.1.

WARNINGDo not start the engine if the coolant level isbelow the MIN mark.

MIN

Coolantlevel

1.6.1. Topping up the coolant levelUnscrew and remove the coolant fillercap. Using a syringe, top up with therecommended coolant (see §1.4).

WARNING: Perform the top-ping up of the coolant whenthe engine is off and cold.Never attempt to remove thecoolant filler cap when theengine is hot, in order toavoid the risk of burns. Thecooling system is under pres-sure!

After topping up, carefully replace thepreviously removed parts.

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1 GBCAUTION

To top up the coolant level and/or renewthe coolant, use only the product speci-fied in the table at paragraph 1.4. Do notmix nor dilute the coolant with additivesor different fluids. If the coolant speci-fied at paragraph 1.4 is not available,use a coolant having technical charac-teristics consistent with the prescribedproduct.

CAUTIONCoolant can damage painted and plasticparts. When you top up the coolantlevel, be careful not to spill coolant onany part of the motorcycle. If you dospill coolant on your motorcycle, imme-diately wipe it away using a clean cloth.

WARNINGUnder certain conditions, ethylene gly-col contained in the coolant can becomeflammable. When it is lighted, it pro-duces an invisible flame.Avoid spilling coolant on hot parts ofthe motorcycle, because the subse-quent combustion of ethylene glycolcould cause serious burns.

WARNINGCoolant is a highly toxic fluid. Avoidingestion and contact with your skin oreyes. Keep coolant out of reach of chil-dren and domestic animals. In the eventof a coolant ingestion, immediately calla doctor and do not cause vomiting, inorder to avoid inhalation of coolant inlungs. If the coolant comes in touch withyour skin or eyes, immediately wash itaway with water.

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1GB Front brake caliper

Rear brake caliper

Pads

Wear limit 1 mm

Disc 1.7. Checking the wear of the brake pads

Periodically check the width of the friction material layer of the pads,making sure it never falls below the wear limit (1 mm).

WARNINGIf the brake pads are excessively worn out, the effective-ness of the braking system decreases, increasing the riskof accidents. If the pads have worn to near the wear limit,have both pads replaced by an authorized service centre.Ensure that the new pads are suitably broken in.

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1.8. Checking the brake fluid level

WARNINGLack of maintenance of the braking sys-tem can increase the risk of accidents.Before riding, always check the brakingsystem according to the instructionsbelow.

The level of the brake fluid decreases as thebrake pads wear down. Ensure that the fluid levelis always between the MAX and MIN marks. If thelevel falls below the MIN mark, contact an autho-rized service centre and have the brake systemoverhauled.

Rear brake fluid reservoir Front brake fluid reservoir

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WARNINGNever use your motorcycle if the fluidlevel is below the MIN mark. The brakesmay fail to properly operate, whichcould lead to an accident. If the brakefluid level is below the MIN mark, youmust have the braking system over-hauled by an authorized MV Agustadealer.

WARNINGHave the topping up of the brake fluidperformed only by skilled personnel.Brake fluid is highly toxic. Avoid contactand ingestion. Keep brake fluid out ofreach of children and domestic animals.In the event of a brake fluid ingestion,immediately call a doctor and do notcause vomiting, in order to avoid inhala-tion of brake fluid in lungs. If the brakefluid comes in touch with your skin oreyes, immediately wash with water.

WARNINGUse only the brake fluid specified atparagraph 1.4. of this manual. Mixing dif-ferent brake fluids can cause a danger-ous chemical reaction, as well as thedecrease of the braking efficiency, withsubsequent increase of the risk of acci-dents.

WARNINGAn insufficient amount of brake fluid mayallow the introduction of air in the brakingsystem. This could compromise the effec-tiveness of the braking system, with sub-sequent increase of the risk of accidents.Presence of air in the braking system canbe identified in the moment you feel acharacteristic “spongy effect” whilepushing the brake lever. In this case, havea braking system bleeding performed byan authorized MV Agusta dealer beforeriding your motorcycle again.

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1 GB1.9. Checking and replacing the tyres

WARNINGBefore using the motorcycle,always check the pressure andwear of the tyres.

Checking the inflating pressure of thetyres is an essential requirement toensure driving safety. Insufficiently inflat-ed tyres can reduce the handling of themotorcycle and wear themselves outvery quickly. On the other hand, anexcessively high inflating pressurereduces the wideness of the surface incontact with the ground, and it can com-promise the grip of the vehicle.Before riding your motorcycle, it is there-fore necessary to measure the tyre pres-sure at room temperature. The vehiclemust be parked since three hours atleast.

WARNINGAn incorrect inflating pressure can lead to dan-gerous situations during riding. An insufficientlyinflated tyre can cause the sliding of the tyre onthe wheel rim or its detachment; this may lead tothe deflation of the tyre with subsequent loss ofcontrol of the vehicle.

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In fact, by checking the pressure soon afterwardsusing the motorcycle, you would obtain a highervalue than the actual one. This could cause anincorrect adjustment of the tyre pressure.Refer to the pressures given in § 2.2. and/or onthe label applied on the sleeve of the right frontfork. In the event of long travels, you can increasethe face value of the tyre pressure of 0.2 bar.

Moreover, it is extremely important to check thewear of the tyres before riding. In fact, a worn outtyre can be punctured more easily than a newone, and it can adversely affect handling and sta-bility of the motorcycle.Check that the depth of the tyre tread is not belowthe values prescribed by the Highway Code.Verify the absence of crevices at the bottom of thetread design and fissures on the tyre sidewall.Moreover, verify the absence of nails and glasssplinters in the tyre. If these conditions are notverified, have the tyre replaced by an authorizedMV Agusta dealer.

WARNINGThe limits of the tyre tread depth mayvary from country to country. Alwaysrefer to the values prescribed by the lawprovisions of the nation in which youuse your motorcycle.

WARNING• If the tyres of your motorcycle areexcessively worn out, have it replacedby your MV Agusta dealer. Besidesbeing illegal, riding a motorcycle withexcessively worn out tyres can reduceits stability and lead to the loss of con-trol of the vehicle.• If a tyre is punctured it must bereplaced, not repaired. A repaired tyreprovides a restricted performance andlower safety levels than a new one.

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1 GBIf you make a provisional or emergency

repair to a tyre, you must ride at verylow speed until you reach the nearestMV Agusta dealer and have the tyrereplaced. With a provisionally repairedtyre, never exceed 60 km/h. Tyre repair-ing must never be performed if the tyreis punctured on its sidewall, or if thediameter of the puncture on the tread isgreater than 6 mm.• MV Agusta recommends not to usesealing fluids to repair a punctured tyre.These products can adversely affect thematerial of the tyre layers, as well ashide the minor damages caused byobjects penetrated in the tyre.

• When it is necessary to replace thetyres, use only the type specified inparagraph 2.2. Moreover, avoid usingtyres of a different brand or type on thefront and on the rear wheel at the sametime. Using tyres different from thosespecified can adversely affect the han-dling and stability of the motorcycle,increasing the risk of accidents.• The wheel rims of your motorcyclehave been designed for use with tube-less tyres only. Do not assemble an airtube tyre on rims designed for tubelesstyres. Otherwise, the tyre bead couldnot properly settle down on the wheelrim, leading to the deflation of the tyreand the loss of control of the vehicle.

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1GB • Do not assemble an air tube on a

tubeless tyre. The overheating of thetyre could cause the explosion of the airtube, leading to the deflation of the tyreand the loss of control of the vehicle.• Have the tyres replaced according totheir direction of spin, which is highlight-ed by a small arrow on the tyre sidewall.

• New tyres should be run in for a shortperiod before demanding their full per-formance. In fact, during this period thetyres could have a reduced grip onsome kind of roads. We suggest to rideat reduced speed and exercise extremecaution during the first 100 km after thereplacement of a tyre.

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1 GB" Rear wheel disassembling

CAUTIONIf you have the rear wheel tyrereplaced by a tyre-dealer, makesure that the following tools areused in the rear wheel disassem-bling and reassembling:

• 55 mm polygonal socket wrench• Torque wrench

If the above mentioned operationsare performed with tools other thanthose indicated, the rear wheelparts can be seriously damaged.Therefore, we strongly recommendnot to have the tyres replaced by animproperly equipped workshop.Always have the tyres replaced byan authorized MV Agusta dealer.

Wheel pin withM50x1.5 mmleft-hand pitch thread

Polygonal nut

55 mm polygonal socket wrench

Torque wrench

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" Checking the wheel rims

Before riding, always verify the absence ofcracks, bending or buckling on the wheel rims.

WARNINGIf you find that the wheel rim is dam-aged, have it replaced by an authorizedMV Agusta dealer. Never attempt torepair the wheel rim, even in case ofslight damage.Every time you replace a tyre or a rim,you must have a wheel balancing per-formed by an authorized MV Agustadealer. Wheel unbalance can adverselyaffect performance and handling of themotorcycle, as well as shorten the life ofthe tyres.

WARNINGWhen you have a wheel balancing per-formed, make sure to assemble onlyapproved counterweights on the wheelrim. MV Agusta recommends not to usebalancing or balancing/sealing fluids.

WARNINGDo not attempt to have a tubeless tyreremoved without using the proper toolsand protections for the wheel rim.Otherwise, you could damage the seal-ing surface of the rim, leading to thedeflation of the tyre and the loss of con-trol of the vehicle.

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1 GB1.10. Checking and lubricating the drive chain

To perform this operation, you must put the motorcycleon the rear stand, upright on a horizontal surface andwith the gear in neutral." Checking the chain adjustment

WARNING: Before checking the chain adjust-ment, contact a MV Agusta authorized centreto verify that the value of the static setup ofthe rear suspension is correct. Also makesure that the chain is properly lubricated.

The axis of the chain lower portion must be 116 mmfrom the lower chain guard. Manually turn the rearwheel and carry out the check at several points alongthe chain. The distance between the chain and thelower chain guard must remain almost constant as thewheel turns. If, on the other hand, the play on the chainvaries considerably, it means that some chain links areflattened, seized or elongated. If the distance is greaterthan 116 mm, have the chain adjusted by your local MVAgusta dealer.

116 mm

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WARNINGRiding your motorcycle when the drivechain is in poor condition or improperlyadjusted can lead to accidents. Beforeriding, always check the chain adjust-ment according to the proceduresshown in this paragraph. If necessary,have the chain adjusted by your MVAgusta dealer.

WARNINGIf any chain link is flattened, seized orelongated, have the chain replaced by aMV Agusta authorized service centre.

WARNINGIf you notice damage or excessive wearof the chain and the related sprockets,have them replaced by an authorizedMV Agusta dealer. Every time the chainis replaced, you must always replacethe front and rear sprockets too.

WARNINGUsing a chain with a fake link can bedangerous. An uncompletely riveted orfake link can accidentally split open andcause accidents, as well as damage tothe engine. Never use a chain with afake link.

WARNINGEvery time it is requested to operate therear wheel hub screws, contact anauthorized MV Agusta dealer. In order totighten the screws, apply a tighteningtorque equal to the value shown in thelabel placed on the swingarm. Applyinga torque higher than the indicated valuecan cause the fast decay of the rearwheel hub, compromising the reliabilityof the vehicle and the safety of the pilotand the passenger.

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1 GB" Lubrication

To ensure proper operation, the drive chain needsto be properly lubricated.

Preliminary cleaning - Before lubrication, thedirt accumulated on the chain must be dissolvedusing kerosene. The dirt must then be removedwith a clean rag and/or an air jet.

CAUTIONThe chain is of the O-ring type. To pre-vent it from damaging, never clean thechain with a steam or high pressurewater jet, nor using gasoline or othersolvents. The chain must be cleanedusing kerosene only.

WARNINGKerosene is highly toxic and flammable.Avoid contact and inhalation. Keepkerosene away from sparks and flames.Keep kerosene out of reach of childrenand domestic animals. Correctly dis-pose of exhaust kerosene, in order toavoid environmental pollution.

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1GB Lubrication - Apply a slight and uniform film of

lubricant over the whole length of the drive chain,taking care not to smear the surrounding parts, andin particular the tyres. Direct the lubricant jet on theinternal links, in order to lubricate the surface of theO-Rings and penetrate inside the chain roller.

CAUTIONOnly use the lubricant specified in theparagraph 1.4. of this manual, in orderto protect the drive chain and avoid oilspurts when the vehicle is in motion.WARNINGChain lubrication must be performedaccording to the intervals specified inthe tables of scheduled maintenance(see § 1.2.). It is also necessary to per-form this operation after riding under therain and after cleaning the motorcycle.Riding your motorcycle when the drivechain is in poor condition or improperlyadjusted can lead to accidents.

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1 GB1.11. Checking the idle speed

Check the idle speed when the engine has reached theoperating temperature. Ensure that the choke controlhas not been activated.

The idle speed should range from 1,250 to 1,350 rpm.

If a tune-up is necessary, contact an authorized servicecentre.

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1.12. Replacing parts - General information

The replacement of the fuses and the light bulbscan be carried out by the owner according to theindications provided below.

1.12.1.Replacing the fusesThe battery recharge fuse is located on the

solenoid starter, in the position indicated on theright side of the motorcycle.To reach them remove the protective cover byremoving the two fixing screws.

Solenoidstarter

Battery recharge fuse - Replacement(§1.12.1.)Fuses - Replacement (§1.12.1.)Headlight - Bulb replacement(§1.12.2.)Front and rear turn indicator - Bulb replace-ment (§1.12.3.)License plate light - Bulb replacement (§1.12.4.)Tail light - Bulb replacement (§1.12.5.)Brake light - Bulb replacement (§1.12.6.)

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Turn the ignition key on the “OFF” posi-tion before checking or replacing thefuses, in order to avoid a short circuitwith subsequent damage to other elec-tric parts of the motorcycle.

To replace the fuse, you must swap therecharge fuse with the spare fuse.

WARNINGNever replace a fuse with a rating otherthan that prescribed, in order to avoiddamage to the electrical equipment ofthe motorcycle which could lead to a fire.

Spare fuse (40A)

Recharge fuse(40A)

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1GB The service fuses are located on the right side

of the motorcycle.

Unfasten and lift the lid of the fuse box.

CAUTIONTurn the ignition key on the “OFF” posi-tion before checking or replacing thefuses, in order to avoid a short circuitwith subsequent damage to other elec-tric parts of the motorcycle.

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15A

10A

15A

F1 F2 F3 F4 F5 F6 F7

10A

10A

15A

15A

10A 10A 15A

To identify the position and function of thefuses, refer to the information provided under thelid of the box and on the attached wiring diagram;the reference letters in the figure correspond tothose shown in the diagram.

Remember that the fuse box contains three sparefuses.

Replace the blown fuse and refit the cover.WARNINGNever replace a fuse with a rating otherthan that prescribed, in order to avoiddamage to the electrical equipment ofthe motorcycle which could lead to a fire.

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1.12.2.Replacing the headlight bulb

Remove the two headlight lateral fixing screws. Payattention in slipping off the adjuster from its seat whenthe headlight is being removed from its support.

Before removing the headlight from its support, pullout the relay from its holder and detach the connectoron the rear side of the headlight.

- 41 -

MAINTENANCE 1

1 GBPlace the headlight on a table in order to be able to

perform the following operations.

Remove the protective cap.

Unplug the bulb connector.Release the retaining spring.

- 42 -

MAINTENANCE 1

1GB Extract the bulb.

CAUTION: Do not touch the bulb glass withbare hands. If you do, clean the bulb with anoil-free solvent.

Insert the new bulb.Reattach the retaining spring.Replug the bulb connector.Reposition the protective headlight cover.Reattach the headlight connector.Refit the relay to the holder.Replace the headlight on its support and insert the

two lateral fixing screws, making sure to insert the head-lamp adjuster in its proper seat on the headlight.

- 43 -

MAINTENANCE 1

1 GB1.12.3 Replacing turn indicator bulbs

Remove the fixing screw.

Remove the lens.

- 44 -

MAINTENANCE 1

1GB To remove the burnt-out bulb rotate it counter-

clockwise, while pulling outward.To fit the new bulb, press it and rotate it clock-

wise.Replace the lens and insert the fixing screw.

- 45 -

MAINTENANCE 1

1 GB1.12.4.Replacing the license plate light bulb

Remove the fixing screws of the lower coverof the plate holder.

Remove the cover complete with plate holder.

Extract the bulb holder pulling it from its seat.

Extract the burnt-out bulb by pulling it from theholder.

Fit the new bulb.Refit the bulb holder.Push back the lower cover in touch with the

upper surface.Refit the fixing screws of the cover.

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MAINTENANCE 1

1GB

- 47 -

MAINTENANCE 1

1 GB1.12.5.Replacing the tail light bulb

Remove the two upper fixing screws of the tailside fairings.

Remove the two fixing screws of the tail lamp.

Detach the tail lamp connector.

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MAINTENANCE 1

1GB Remove the tail lamp by rotating it to free it

from his seat.

Extract the bulb holder pulling it from its seat.Extract the burnt-out bulb.Fit the new bulb.Replace the bulb holder.Reassemble the tail lamp and all the previous-

ly removed parts.

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MAINTENANCE 1

1 GB1.12.6.Replacing the brake light bulb

Remove the tail lamp as described at §1.12.5.To extract the bulb holder, rotate it counter-

clockwise.

Extract the burnt-out bulb.Fit the new bulb.Replace the bulb holder by rotating it clock-

wise.Reassemble the tail lamp and all the previous-

ly removed parts.

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MAINTENANCE 1

1GB

1.13. Battery

The battery is of the maintenance-free type and isinstalled under the fuel tank. This battery does notrequire checking of the fluid level or adding of dis-tilled water.If the battery seems to be run-down (causing elec-trical problems or a difficult starting), recharge itas soon as possible by connecting the charger tothe present connector under the driver’s seat.Remember that the battery runs down morequickly if your motorcycle is equipped with addi-tive electrical accessories.

WARNINGIf the battery casing is damaged, theremay be a leakage of sulphuric acid, aHIGHLY TOXIC AND CORROSIVE sub-stance. Avoid any contact with youreyes, skin and clothes. Always wearprotective glasses when you have towork near the battery.

In the event of a contact with sulphuricacid, give the FIRST AID as describedbelow:• CONTACT WITH EYES: Wash awaywith water for about 15 minutes, andimmediately call a doctor.• CONTACT WITH SKIN: Wash awaywith a great amount of water.• INGESTION: Drink great amounts ofwater or milk, and immediately call adoctor.Furthermore, leakage of sulphuric acidcan result in the formation of hydrogengas which, if ignited by a spark or aflame, would cause an explosion.Always have the battery replaced byyour local MV Agusta dealer.

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MAINTENANCE 1

1 GBProlonged inactivity

If the motorcycle is to remain unused for a longtime (a month or longer), it is advisable removethe recharging fuse (see §1.12.1). In case of pro-longed inactivity, recharge the battery once amonth, in order to ensure durability.

To do this connect the charger on the connectorplaced under the driver’s seat.

Charging fuse

Charging connector

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MAINTENANCE 1

1GB

1.14. Cleaning the motorcycle

Periodic careful cleaning is a key fac-tor in preserving the value of themotorcycle, protecting its surface fin-ish and checking for damages, wearand leakage of corrosive fluids.

CAUTIONBefore washing the vehicle,stop up the exhaust pipesand protect the electricalparts.

WARNINGDo not wash your motorcy-cle soon afterwards riding.Attend a few minutes toallow the engine and theexhaust pipes to thoroughlycool.

CAUTION: Never use washing systems involvingsteam or high pressure water jets. These systemscould cause water infiltration and damage the inter-nal parts of your motorcycle.INFORMATION: Spilling detergent can cause environ-mental pollution. Therefore, you should clean yourmotorcycle in an area equipped for collection anddisposal of washing fluids.

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MAINTENANCE 1

1 GBWash the motorcycle with water, a mild detergent

and a sponge. Wipe the vehicle with a soft cloth.Use an air jet to dry difficult-to-reach areas.

CAUTION• Avoid using clothes or sponges thathave been in contact with strong orabrasive detergents, solvents, alcoholor gasoline.• To avoid irreparable damage to thebodywork parts, never use alkaline orstrongly acid detergents, petrol, brakefluid or other solvents.• If you have doubts about the chemicalcomposition of the detergent, test its effectby applying it on a little area of the body-work before using it on the whole bike.

Periodically treat the paintwork with high qualitywax. After riding on roads treated with corrosivesubstances (salt), wash the vehicle as soon aspossible with cold water. Do not use hot water asit enhances the corrosive action.

WARNINGAvoid smearing brakes or tyres with oilor wax. If necessary, clean the brakediscs with a brake disc detergent or withacetone, and wash the tyres with warmwater and a neutral detergent.

WARNINGThe presence of water on the brakes canlead to a decrease of the braking effec-tiveness with subsequent risk of acci-dents. After completing the washing, runthe engine for a few minutes and start offat reduced speed. Carefully apply thebrakes a few times so as to dry the brakepads and discs.

WARNINGThe drive chain must be correctly lubri-cated after washing the motorcycle, fol-lowing the instructions provided at §1.10. of this manual.

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MAINTENANCE 1

1GB

1.15. Prolonged inactivityIf the motorcycle is to remain unused for a long time, it isadvisable to carry out the following operations:

When the motorcycle is first put back into service, rememberto carry out a comprehensive check and, if necessary, to havethe vehicle serviced (§1.2.).

Empty the fuel tank.Remove the recharge fuse (§1.12.1). Recharge the battery every month. (§1.13).Remove the spark plug caps and the spark plugs. Pour a teaspoonful of engine oil in every sparkplug hole, then place back the spark plugs and the corresponding caps. Make the engine run idlefor a few times.Lubricate all control cables and the joints of all pedals and levers.Clean the motorcycle and treat the paintwork with high quality wax (§1.14.).In order to ensure integrity and performance of the tyres, park your motorcycle in a fresh, dry anddark place, with a temperature relatively constant and lower than 25° C. Avoid direct contact of thetyres with heating pipes or radiators, and prolonged contact with oil or gasoline. Avoid parking withthe tyres near to electrical motors or devices capable to produce sparks or electric discharge.During the period of inactivity, place your motorcycle on the rear stand.Cover the vehicle with an adequate canvas cover.

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TROUBLESHOOTING FLOW CHART 2

2 GB

2.1. Engine problems: ENGINE DOES NOT START

continued on next page

Problem solved

Problem solved

Problem solved

Engine stop switchdepressed

Gears engaged andside stand down

Starting procedurecorrectly performed

Disengage gears orlift stand and pull

clutch lever

Return the engine stopswitch in rest position

Correctly performstarting procedure

Engine starts

Engine starts

Engine starts

NO

NO

NO

NO

NO

NO

Problem solvedThe battery

charging fuse isOK?

Replace the batterycharging fuse (§1.12.1) Engine startsNO YES

NO

YES

YES

YES

YES

YES

YES

YES

- 56 -


2GB

Problem solvedFuses F1, F2 andF5 are OK

Replace fuses F1, F2and F5 (§1.12.1)

Contact a MV Agustaauthorized service centre

Engine startsNO

Problem solvedThe battery ischarged

Recharge the battery(§1.13) Engine starts

NO

NO

NO

continued from previous page

Problem solvedFuel tank empty Refuel Engine startsYES

NO

YES

YES

YES

NO

YES

YES

- 57 -


2 GB

Problem solvedFuel tank empty Refuel


Engine is runningNO

Problem solvedFuses F1, F2 andF5 are OK

Replace fusesF1, F2 and F5 (§1.12.1) Engine is running

NO

NO

NO

ENGINE SHUTS OFF DURING RIDING

YES

YES

YES

YES

- 58 -


2GB

Problem solved

Coolant level iscorrect (§1.7.)

Fuse F7is OK

Replace fuse F7(§1.12.1.)



Engine coolsdown to operating

temperature

NO

NO

NO

ENGINE OVERHEATS

YES

YES

YES

- 59 -


2 GB

OIL PRESSURE IS TOO LOW (Engine oil pressure warning light is on with the engine running)

Oil level is correct(§1.5.)


Have the oil levelrestored by a MV Agustaauthorized service centre

Oil pressure isoptimal

NOProblem solved

NO

YES

YES

- 60 -


2GB

Problem solved

Problem solvedThe fuses F4 eF5 are OK

Bulbs are OK Replace bulb(s)(§1.12.)

Replace fuse(s) F4 andF5 (§1.12.1.)


Lights work

Lights work

NO

NO

NO

NO

2.2. Electrical equipment problems: LIGHTS DO NOT WORK

YES

YES

YES

YES

- 61 -


2 GB

HORN DOES NOT WORK

Fuse F6is OK


Replace fuse F6(§1.12.1) Horn works

NOProblem solved

NO

Fuse F5is OK


Replace fuse F5(§1.12.1) Dashboard works

NOProblem solved

NO

DASHBOARD DOES NOT WORK

YES

YES

YES

YES

TECHNICAL INFORMATION 3

3GB

- 62 -

3.1. Motorcycle overview

(N) Dashboard

(B) Ignition - Power supply

(F) Frame

(D) Final drive

(E) Cooling system

(G) Frontsuspension

(L) Front brake

(A) Engine

(C) Gearbox

(H) Rear suspension

(O) Exhaust system (M) Rear brake

(I) Battery

- 63 -


3 GB

A - Engine: four-stroke, inline three-cylinder.Double-overhead camshaft valve train. Wetsump lubrication.

B - Ignition - Power supply: integrated ignition-injection system. Inductive-discharge elec-tronic ignition. “Multipoint” electronic injection.

C - Gearbox: removable, six-speed, with con-stant-mesh gears.

D - Final drive: consisting of drive sprocket, rearsprocket and chain.

E - Cooling system: with separate liquid and oilradiators.

F - Frame: tubular steel trellis with aluminiumside plates.

G - Front suspension: upside-down hydraulicfork with external adjusting system.

H - Rear suspension: progressive, with single-sided swingarm and single shock absorberwith external adjusting system.

I - Battery: sealed and maintenance-free.

L - Front brake: dual semi-floating disc withfour-piston calipers.

M - Rear brake: single disc with two-pistoncaliper.

N - Instrument panel: with warning lights anddigital instruments.

O - Exhaust system: equipped with catalyticconverter for exhaust emission reduction.

- 64 -


3GB

3.1.1 Front brake circuit

12

3

5

1 Brake master cylinder2 Brake lever3 Brake line4 Brake caliper5 Brake discs

54

- 65 -


3 GB

3.1.2. Rear brake circuit

1 Brake lever2 Brake master cylinder3 Brake line4 Brake fluid reservoir5 Brake caliper6 Brake disc

4

6

1 2

35

- 66 -


3GB

3.1.3. Engine lubrication

1 Oil sump2 Oil filter

1 2

- 67 -


3 GB

3.1.4. Coolant circuit

1 Expansion tank2 Upper radiator3 Lower radiator4 Coolant pump

2

3 4

1

- 68 -


3GB

3.1.5. Fuel system

1 Throttle bodies2 Fuel pump3 Fuel line

2

3

1


3 GB

- 69 -

Description BRUTALE 800SPECIFICATIONSWheelbase (mm) (*) 1380Overall length (mm) (*) 2085Max. width (mm) 725Seat height (mm) (*) 810Min. ground clearance (mm) (*) 160Trail (mm) (*) 95.3

3.2. Specifications

*: The indicated values must not be intended as binding informations. They can change according to the vehicle setup.


3GB

Description BRUTALE 800Dry weight (kg) 167Fuel tank capacity (l) (*) 16.6Reserve fuel (l) (*) 5Oil in crankcase (kg) 2.5ENGINEType Three-cylinder, four-stroke, 12 valvesBore (mm) 79.0Stroke (mm) 54.3Total displacement (cm3) 798Compression ratio 13.3 : 1Starting Electric starterCooling system Cooling with separate liquid and oil radiatorsCrankcase and covers Die-castHead and cylinders Chill-castValves SteelVALVE TRAINType Double-overhead camshaft

Specifications

* : The indicated data must not be intended as binding informations. They can change according to the environmental temper-ature, the engine temperature and the evaporation point of the gasoline.

- 70 -

- 71 -


3 GB

Specifications

Description BRUTALE 800LUBRICATIONType Wet sumpIGNITION - POWER SUPPLYType Integrated ignition-injection system MVICS with three injectors. Engine

control unit Eldor EM2.0; throttle body full drive by wire Mikuni; pencil-coilswith ion-sensing technology, control of detonation and misfire. Torquecontrol with 4 mappings; Traction Control with 8 levels of intervention.

Spark plugs NGK CR9 EIB-9Spark gap (mm) 0.8 ÷ 0.9CLUTCHType Multiple-disc in oil bathPRIMARY DRIVENumber of teeth on countershaft gear Z = 19Number of teeth on clutch gear Z = 36Transmission ratio 1.895SECONDARY DRIVENumber of teeth on front sprocket Z = 16Number of teeth on rear sprocket Z = 41Transmission ratio 2.563

- 72 -


3GB

Specifications

Description BRUTALE 800TRANSMISSIONType Removable, six-speed gearbox with constant-mesh gearsGear ratio (overall ratios)First gear 2.846 (13.819)Second gear 2.125 (10.317)Third gear 1.778 (8.632)Fourth gear 1.579 (7.666)Fifth gear 1.429 (6.936)Sixth gear 1.318 (6.400)FRAME Type ALS steel tubular trellis (MAG welded)Swingarm pivot plates Aluminium alloyFRONT SUSPENSIONType “Upside down” telescopic hydraulic fork with external and separated

adjustment of rebound and compression damping and of spring preloadRod diameter (mm) 43Travel on leg axis (mm) 125REAR SUSPENSIONType Progressive, single shock absorber with extension,

compression and spring preload adjustmentSwingarm Aluminium alloyWheel travel (mm) 125

- 73 -


3 GB

SpecificationsDescription BRUTALE 800FRONT BRAKEType Dual floating disc with steel braking bandDisc diameter (mm) 320Disc flange SteelCalipers, piston diameters (mm) Radial-type, 4-piston ( Ø 32 )REAR BRAKEType Single steel discDisc diameter (mm) 220Caliper, piston diameter (mm) 2-piston ( Ø 34 )FRONT RIMMaterial Aluminium alloyDimensions 3.50” x 17”REAR RIMMaterial Aluminium alloyDimensions 5.50” x 17”TYRESFront 120/70 ZR 17 M/C (58 W)Rear 180/55 ZR 17 M/C (73 W)Brand and type PIRELLI - Diablo Rosso II

- 74 -


3GB

Specifications

* : If you use tyres of a brand different from the ones recommended, refer to the inflating pressure values marked by the man-ufacturer on the tyre sidewall.

Description BRUTALE 800Inflating pressure (*):Front 2.3 bar (33 psi)Rear 2.3 bar (33 psi)ELECTRICAL EQUIPMENT Equipment voltage 12 VHeadlight bulb H4 12V 60/55WFront indicator HY6W 12V 6WRear indicator HY6W 12V 6WTail light bulb W5W 12V 5WBrake, rear light W16W 12V 16WBattery 12 V - 8,6AhAlternator 350 W at 5000 rpm.BODYWORKFuel tank Thermoplastic materialAir box side panels Thermoplastic materialUnder-seat side panels Thermoplastic materialRear side panels Thermoplastic material

- 75 -


3 GB

Specifications

Description BRUTALE 800Dashboard cover Thermoplastic materialFront mudguard Thermoplastic materialChain guards Thermoplastic materialLicense-plate holder Thermoplastic materialRearview mirrors Thermoplastic materialExhaust pipe guard AluminiumRadiator side covers Aluminium

- 76 -


3GB

4

2

3

5

1

6

- 77 -


3 GB

3.3. Bodywork parts reference coloursBodywork parts are painted with the following reference colours, according to the corresponding motor-cycle colour combination:

5. - Fuel tank:Colour code A:Pearly Red(Code Palinal 928.T671)Colour code B:“Shoreline Mist” Matt Metal Grey(Code Palinal F503 Y754)Colour code C:Gloss Pastel White(Code Palinal CromaCard V098)Colour code D:MV ICE Pastel White(Code Palinal 929.F364) +“Italy” Pearly Blue (Code Palinal 928.T643)

1. - Rear side fairing, right-hand;2. - Rear side fairing, left-hand:

Colour code A:Coarse-grained Silver (Code Palinal F153)Colour code B:CRC Pearly White (Code Palinal 927.PE20)Colour code C:Mamba Red (Code Palinal 929.T689)Colour code D: MV ICE Pastel White(Code Palinal 929.F364)

3. - Right hand central fairing;4. - Left hand central fairing:

Colour code A: Pearly Red(Code Palinal 928.T671)Colour code B: “Shoreline Mist”Matt Metal Grey (Code Palinal F503 Y754)Colour code C: Gloss Pastel White(Code Palinal CromaCard V098)Colour code D: MV ICE Pastel White(Code Palinal 929.F364)

6. - Dashboard cover:Colour code D:MV ICE Pastel White(Code Palinal 929.F364)

- 78 -


3GB

1

7

4

25

3

6


3 GB

3.4. Frame parts reference coloursFrame parts are painted with the following reference colours, according to the corresponding motorcy-cle colour combination:

1. - Frame:

Colour codes A-C-D:Mica Black (Code Pulverit 71B CL D 999)Colour code B:Frame Red(Code Akzo Nobel QG000K RED)

2. - Engine:

Matt Aluminium Grey(Code Palinal 7530)

3. - Right-hand frame plate;4. - Left-hand frame plate;5. - Rear swingarm:

Quasar Black(Code Inver 61196 - Poliest/HD TGIC Free)

6. - Rear wheel rim;7. - Front wheel rim:

Colour codes A-B-C:Matt Black (Code ZNA 136)Colour code D:Pastel White(Code Caldart Acrilgrip K.713 +Arsonsisi Sebacryl TRS AV 38899098)

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- 80 -

NOTE

3GB

© 2012This document may not, in whole or in part, be reproduced without prior consent, in writing, from MV Agusta Motor S.p.A.

Part. n° 8000B7950Edition n° 1 - October 2012

InformationMV Agusta Motor S.p.A. is committed to a policy of constant improvement; therefore, you may find slight dif-ferences between the information provided in this document and the vehicle you purchased. MV Agustamotorcycles are exported in several countries, in which different rules and regulations (concerning both theHighway Code and the homologation procedures) are in force. Relying on your understanding, MV AgustaMotor S.p.A. deems it necessary to reserve the right to change its products and the related documentationat any time and without notice.

We suggest to often visit the Internet site www.mvagusta.it in order to obtain informations and updatesabout the MV Agusta products and the related documentation.

Respect and defend natural environmentEverything we do affects the whole planet as well as its resources.MV Agusta, in order to protect the interests of the community, awakens the Customers and the TechnicalAssistance operators to use the vehicle and dispose of its replaced parts respecting the laws in force con-cerning environmental pollution and waste disposal and recycling.

Maintenance B3 800 - Team Double 3 Racing | MV...

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