MV Agusta TURISMO VELOCE 800 LUSSO User manual

Maintenance manual
English Version

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chap. Subjects covered page
1 MAINTENANCE 3
1.1. Symbols 3
1.2.
Tables of scheduled maintenance and checks 4
1.3. Tools and accessories supplied 13
1.4. Table of lubricants and fluids 14
1.5. Checking the engine oil level 15
1.5.1. Topping up the engine oil level 16
1.6. Checking the coolant level 18
1.6.1.
Topping up the coolant level 19
1.7. Checking the wear of the brake pads 21
1.8. Checking the brake fluid level 22
1.9. Clutch control fluid - Level check 24
1.10. Checking and replacing the tyres 25
1.11. Checking and lubricating the drive chain 31
1.12. Checking the idle speed 35
1.13. Replacing parts - General information 36
1.13.1. Replacing the fuses 36
1.14. Battery 40
1.15. Cleaning the motorcycle 42
1.16. Prolonged inactivity 44
chap. Subjects covered page
2 TROUBLESHOOTING FLOW CHART 45
2.1. Engine problems 45
2.2. Electrical equipment problems 50
3 TECHNICAL INFORMATION 52
3.1. Motorcycle overview 52
3.1.1. Braking system (ABS) 54
3.1.2. Engine lubrication 55
3.1.3. Coolant circuit 56
3.1.4. Fuel system 57
3.2. Specifications 58
3.3. Bodywork parts reference colours 67
3.4. Frame parts reference colours 69
CONTENTS

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1
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.
MAINTENANCE
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11.2. 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 105,000 Km (63,000 mi) the operations must be
performed at the same intervals shown in the tables.
MAINTENANCE
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WARNING
• Impropriety or lack of recommended maintenance operations can lead to an increase of
the risk of accidents and damage to the motorcycle.
• AlwaysusegenuineMVAgustaspareparts.Usingnon-genuinesparepartscanaccelerate
the wear of your motorcycle and shorten its life.
• Failure to perform the recommended operations, as well as using non-genuine spare
parts, could cause the warranty not to be operating.
• To replace or top up the lubricants and fluids of your motorcycle, use only the products
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.
MAINTENANCE
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Renew
(Use only original oil filters
MV Agusta)
MAINTENANCE
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0 1000 Every 15000 30000 45000 60000 75000 90000 105000
(600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000)
Deli-
very
DESCRIPTION OPERATION
Engine control unit Check mapping !!!!!!!!!
Check / Restore level Every time vehicle is used
Engine oil Check / Restore level !!
Renew !!!!!!!!
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 fan Check operation !!!!!!!!!!
Valves Check / Adjust !!!
Timing chain Replace !
Tables of scheduled maintenance
km (mi) covered*
Service coupon A B C D E F G H
(*): The mileage coupons can be carried along with the mandatory
annual coupon

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MAINTENANCE
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0 1000 Every 15000 30000 45000 60000 75000 90000 105000
(600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000)
Deli-
very
DESCRIPTION OPERATION
km (mi) covered*
Service coupon A B C D E F G H
Tables of scheduled maintenance (*): The mileage coupons can be carried along with the mandatory
annual coupon
Timing fixed shoe Replace !
Timing movable shoe Replace !
Timing chain stretcher Replace !
Spark plugs Replace !!!
Fuel filter Replace !!!
Throttle body !!!
!!!
Check / Replace !!!!
Replace !!!
Cylinders Check compression !!!
Check level Every time vehicle is used
Brakes / Clutch fluid Check level !!!!!!!!!!
Renew At least every two years
Check pressure sensor
Check / clean ducts
Air filter
(Reduce mileage intervals
when riding in highly polluted
areas)

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MAINTENANCE
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0 1000 Every 15000 30000 45000 60000 75000 90000 105000
(600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000)
Deli-
very
DESCRIPTION OPERATION
km (mi) covered*
Service coupon A B C D E F G H
Tables of scheduled maintenance (*): The mileage coupons can be carried along with the mandatory
annual coupon
Check operation Every time vehicle is used
Brakes / Clutch !!!!!!!!!!
!!!!!!!!!
Clutch spring drive Check / Replace !
Brake pads Check wear Every 1000 Km ( 600 mi )
( front and rear ) Check / Replace !!!!!!!!!
Fuel lines and connections
Check for defects/leakage !!!!!!!!!
Replace At least every 3 years
Check operation Every time vehicle is used
Throttle control !!!!!!!!!!
Check !
Rear sprocket spring drive Check / tighten nut !!
Replace !!!!!!!
Check operation
and lines
Check operation (with
TEXA diagnostic sw.)
Clean lever/master cyl.
piston contact area

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MAINTENANCE
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0 1000 Every 15000 30000 45000 60000 75000 90000 105000
(600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000)
Deli-
very
DESCRIPTION OPERATION
km (mi) covered*
Service coupon A B C D E F G H
Tables of scheduled maintenance (*): The mileage coupons can be carried along with the mandatory
annual coupon
Check Every 1000 Km ( 600 mi )
Lubricate Every 1000 Km ( 600 mi ) and after riding under the rain
Drive chain Check / Adjust !!!At least every 1000 Km ( 600 mi )
Lubricate At least every 1000 Km ( 600 mi )
Replace !!!!!!!
Front sprocket / Check !!
Tab washer Replace !!!!!!!
Check !!
Rear sprocket
Replace !!!!!!!
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 !!!!!!!!!

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MAINTENANCE
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0 1000 Every 15000 30000 45000 60000 75000 90000 105000
(600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000)
Deli-
very
DESCRIPTION OPERATION
km (mi) covered*
Service coupon A B C D E F G H
Tables of scheduled maintenance (*): The mileage coupons can be carried along with the mandatory
annual coupon
Steering bearings Check / Adjust !!!!!
Lubricate !!!
Wheel rims Inspect visually !!!!!!!!!!
Every time tyre is replaced
Front wheel
Check !!!!!!
bearings Every time tyre is replaced
Replace !
Sidestand / Check operation Every time vehicle is used
Central stand Check operation !!!!!!!!!!
Side stand switch
Check operation Every time vehicle is used
Check operation !!!!!!!!!!
Rear wheel hub Check / !!!!!
Replace
!!
Lubricate
needle bearing

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MAINTENANCE
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0 1000 Every 15000 30000 45000 60000 75000 90000 105000
(600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000)
Deli-
very
DESCRIPTION OPERATION
km (mi) covered*
Service coupon A B C D E F G H
Tables of scheduled maintenance (*): The mileage coupons can be carried along with the mandatory
annual coupon
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 forks Check / Adjust !!!!!!!!!
Renew fork oil !!!
Battery connections Check and clean !!!!!!!
Electrical equipment Check operation !!!!!!!!!!
Instrument panel Check operation Every time vehicle is used
Check operation !!!!!!!!!!
Check operation Every time vehicle is used
Lights / Visual signals
Check operation / !!!!!!!!!!
Replace

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MAINTENANCE
GB
0 1000 Every 15000 30000 45000 60000 75000 90000 105000
(600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000)
Deli-
very
DESCRIPTION OPERATION
km (mi) covered*
Service coupon A B C D E F G H
Tables of scheduled maintenance (*): The mileage coupons can be carried along with the mandatory
annual coupon
Horn Check operation Every time vehicle is used
Check operation !!!!!!!!!!
Check operation Every time vehicle is used
Headlight Adjust Every time geometry is changed
Ignition switch Check operation Every time vehicle is used
Check operation !!!!!!!!!!
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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MAINTENANCE
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1.3. Tools and accessories supplied
Under the 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 §1.13.1):
- 1fuse10A;
- 2fuses15A;
- 1fuse25A.

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MAINTENANCE
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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 (*) SAE 5W/40 - API SL
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 –
1.4. Table of lubricants and fluids
*:
MV Agusta suggests to refer directly to its authorized dealers in order to
purchase the recommended product. The eni i-Ride moto2 5W/40 engine
oil has been expressly produced for the Turismo Veloce. motorcycle
engine. If the above described lubricant is not available, MV Agusta sug-
gests to use a fully synthetic engine oil having characteristics equal or bet-
ter than the ones prescribed in the following standards:
– 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.

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MAINTENANCE
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Max
Min
Oil level
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.
Unscrew the oil filler cap and remove it from its seat.
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.

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MAINTENANCE
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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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MAINTENANCE
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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.
• If the engine oil comes in touch with
your skin, wash it away with soap and
water.
• Keepneworexhaustengineoiloutof
reach of children and domestic animals.
• In the event of an engine oil ingestion,
immediately call a doctor and do not
cause vomiting, in order to avoid inhala-
tion of engine oil in lungs.
• While topping up the engine oil, wear
a long-sleeved shirt and a pair of water-
proof gloves to protect your skin.
• Correctly recycle or dispose of the
exhaust engine oil, in order to avoid
environmental pollution.

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MAINTENANCE
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Min
Coolant level
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.
WARNING
This operation must be performed by two
people.
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.

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MAINTENANCE
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1.6.1. Topping up the coolant level
Unscrew the plug and refill using the coolant rec-
ommended in § 1.4.
WARNING
Perform the topping 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 pressure!
After topping up, carefully replace the previously
removed parts.