MV Agusta BRUTALE 800 User manual

Maintenance manual
English Version

chap. Subject covered page
1MAINTENANCE 3
1.1. Symbols 3
1.2. Tables of scheduled maintenance and checks 4
1.3. Tools and accessories supplied 14
1.4. Table of lubricants and fluids 15
1.5. Checking the engine oil level 16
1.5.1. Topping up the engine oil level 17
1.6. Checking the coolant level 19
1.6.1. Topping up the coolant level 20
1.7. Checking the wear of the brake pads 22
1.8. Checking the brake fluid level 23
1.9. Checking and replacing the tyres 25
1.10. Checking and lubricating the drive chain 31
1.11. Checking the idle speed 35
1.12. Replacing parts - General information 36
1.12.1. Replacing the fuses 36
1.12.2. Replacement headlight bulb 40
1.12.3. Replacing turn indicator bulbs 43
1.12.4 Replacing the license plate light bulb 45
1.12.5. Replacing the tail light bulb 47
1.12.6 Replacing the brake light bulb 49
1.13. Battery 50
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1.14. Cleaning the motorcycle 52
1.15. Prolonged inactivity 54
2TROUBLESHOOTINGFLOWCHART55
2.1. Engine problems 55
2.2. Electrical equipment problems 60
3TECHNICALINFORMATION 62
3.1. Motorcycle overview 62
3.1.1. Front brake circuit 64
3.1.2. Rear brake circuit 65
3.1.3. Engine lubrication 66
3.1.4. Coolant circuit 67
3.1.5. Fuel system 68
3.2. Specifications 69
3.3. Bodywork parts reference colours 77
3.4. 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 the
motorcycle are marked with the following symbols:
Danger - Failure to observe these prescriptions, even in part, may pose a serious hazard
to the driver’s and other people’s safety.
Caution - Failure to observe these prescriptions, even in part, may result in damage to the
motorcycle.
The following symbols give an indication of who is supposed to perform the different adjustments and/or
maintenance 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 in
order to correctly perform the described operation.
§The “ § ” symbol refers the reader to the chapter identified by the number that follows.
1
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1.2. Tables of scheduled maintenance and checks
The main periodic checks and maintenance operations are
shown in the following tables. These operations are necessary
to 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 these
intervals according to the climate, the ground conditions, the
geographic 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, have
the operations performed by an authorized service centre.
As a rule maintenance operations must be performed while
the motorcycle is on the rear stand after switching off the
engine 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 be
performed at the same intervals shown in the tables.

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WARNING
•Improprietyorlackofrecommendedmaintenanceoperationscanleadtoanincreaseof
the risk of accidents and damage to the motorcycle.
•AlwaysusegenuineMVAgustaspareparts.Usingnon-genuinesparepartscanacceler-
ate the wear of your motorcycle and shorten its life.
•Failuretoperformtherecommendedoperations,aswellasusingnon-genuinespare
parts, could cause the warranty not to be operating.
•Toreplaceortopupthelubricantsandfluidsofyourmotorcycle,useonlytheproducts
given at paragraph 1.4.
WARNING
If you use the motorcycle on race track, we recommend to have the bike checked before
and 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 its
components, 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 maintenance
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
DESCRIPTION OPERATION
km (mi) covered
Service coupon ABCDEFG
Check level Every time vehicle is used
Engine oil Renew !!!!!!!
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 chain Check !!
Replace !
Replace
(Use only MV Agusta
genuine spare oil filters)

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Tables of scheduled maintenance
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
DESCRIPTION OPERATION
km (mi) covered
Service coupon ABCDEFG
Timing movable shoe
Check / Replace !!
Replace
!
Every time timing chain is replaced
Timing chain stretcher Check / Replace !!!
Spark plugs Check / Replace !!!
Replace !!!
Fuel filter Check / Replace !!!
Throttle body Check and Adjust !!!!!!!
Air filter Check / Replace !!!!!!
Check level Every time vehicle is used
Brakes fluid Check level !!!!! !!
Renew
!
At least every two years

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Tables of scheduled maintenance
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
DESCRIPTION OPERATION
km (mi) covered
Service coupon ABCDEFG
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 connections Check for leakage !!!!!!!
Replace At least every 3 years
Check operation Every time vehicle is used
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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Tables of scheduled maintenance
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
DESCRIPTION OPERATION
km (mi) covered
Service coupon ABCDEFG
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 washer Replace
!!!
Every time drive chain is replaced
Check !! ! !
Rear sprocket Replace !!!
Every time drive chain is replaced

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0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
DESCRIPTION OPERATION
km (mi) covered
Service coupon ABCDEFG
Tables of scheduled maintenance
Rear sprocket spring drive Check / Replace !!!
Steering bearings Check !!!!
Lubricate !
Check pressure Every time vehicle is used; at least every 10 days
Tyres Check 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 bearings Every time tyre is replaced
Replace !

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Tables of scheduled maintenance
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
DESCRIPTION OPERATION
km (mi) covered
Service coupon ABCDEFG
Sidestand Check operation Every time vehicle is used
Check operation !!!!!!!!
Check operation Every time vehicle is used
Every 500 ÷ 1000 km (300 ÷ 600 mi)
Side stand switch Check operation !!!!!!!!
!!!!!!!!
Rear wheel hub Check / !!
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 !
Lubricate
needle bearing
Lubricate
needle bearing
Clean contact area
with side stand
Clean contact area
with side stand

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Tables of scheduled maintenance
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
DESCRIPTION OPERATION
km (mi) covered
Service coupon ABCDEFG
Battery connections Check and clean !!!!!!!
Electrical equipment Check operation !!!!!!!!
Instrument panel Check operation Every time vehicle is used
Check operation !!!!!!!!
Lights / Visual signals Every time vehicle is used
!!!!!!!!
Horn Check operation Every time vehicle is used
Check operation !!!!!!!!
Check operation Every time vehicle is used
Headlight Adjust Every time geometry is changed and every time you seat a passenger
Check operation !!!!!!!!
Ignition switch Check operation Every time vehicle is used
Check operation !!!!!!!!
Check operation /
Replace bulbs
Check operation /
Replace bulbs

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Tables of scheduled maintenance
0100060001200018000240003000036000
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Pre-
delivery
DESCRIPTION OPERATION
km (mi) covered
Service coupon ABCDEFG
Locks Check operation Every time vehicle is used
Check operation !!!!!!!!
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:
-2Allenwrenches(2,5mm.-4mmhexagon);
-1spannerforrearwheeleccentricwithextension;
-1fusepuller;
Inside the fuse box are also provided the following
spare fuses (see §1.12.1):
-2fuses(10A);
-1fuse(15A).

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1.4. Table of lubricants and fluids
*:MVAgustasuggeststoreferdirectlytoitsauthorizeddealersinordertopurchasetherecommended
product. 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, MV
Agusta 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-40
NOTE
The above standard denominations must be written, alone or
together, on the engine oil container label.
Engine oil
SAE 5W-40
API SL
ACEA A3
JASO MA, MA2
Description Recommended product Specifications
Engine lubrication oil eni i-Ride moto2 5W-40 (*)SAE5W/40-APISL
Ethylene glycol diluted
Coolant AGIP ECO - PERMANENT with 50 percent
distilled water
Brake and clutch fluid Agip Brake 4 DOT4
Drive 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, and
has been allowed to cool down for at least ten minutes
after 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 out
with two people.
Unscrew the oil filler cap and remove it from its seat.
Wipe the check dipstick with a clean cloth and fully
screw the oil filler cap in its seat, then unscrew it again
in order to check the engine oil level.
The level must be between the MAX and MIN marks on
the check dipstick connected to the cap.
If the oil level is below the MIN mark, top up as
described in § 1.5.1.
WARNING: Do not start the engine if the oil
level is below the MIN mark.
Oil level Max
Min

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1.5.1. Topping up the engine oil level
Remove the oil filler plug. Pour an appropriate
amount of engine oil of the recommended type.
Never exceed the MAX level mark. At the end of
the operation, place back the oil filler plug.
CAUTION
To avoid clutch sliding and damage to
the engine, never add chemical addi-
tives to the engine oil, nor use an engine
oil different from the one specified in the
table at § 1.4. Make sure that no foreign
body gets in the crankcase while top-
ping up the engine oil.

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WARNING
New or exhaust engine oil can be dan-
gerous. Engine oil is highly toxic for
people and domestic animals. Avoid
ingestion and contact. It has been
proved that prolonged contact with
engine oil can cause skin cancer on
guinea pigs. Even a brief contact with
engine oil can cause skin irritation.
•Intheeventofanengineoilingestion,
immediately call a doctor and do not
cause vomiting, in order to avoid inhala-
tion of engine oil in lungs.
•Keepneworexhaustengineoiloutof
reach of children and domestic animals.
•Whiletoppinguptheengineoil,wear
a long-sleeved shirt and a pair of water-
proof gloves to protect your skin.
•Iftheengineoilcomesintouchwith
your skin, wash it away with soap and
water.
•Correctlyrecycleordisposeofthe
exhaust engine oil, in order to avoid
environmental pollution.

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1.6. 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 above
the MIN mark, as shown in the figure.
If the coolant level is below the MIN mark, top up the
coolant as described at paragraph 1.6.1.
WARNING
Do not start the engine if the coolant level is
below the MIN mark.
MIN
Coolant
level

1.6.1. Topping up the coolant level
Unscrew and remove the coolant filler
cap. Using a syringe, top up with the
recommended coolant (see §1.4).
WARNING: Perform the top-
ping up of the coolant when
the engine is off and cold.
Never attempt to remove the
coolant filler cap when the
engine is hot, in order to
avoid the risk of burns. The
cooling system is under pres-
sure!
After topping up, carefully replace the
previously removed parts.
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