Agusta Brutale 800 Maintenance Manual
Agusta Brutale 800 Maintenance Manual
English Version
                                                 CONTENTS
                                                              -2-
                                         MAINTENANCE                                             1
1.1.   Symbols
                                                                                                          1
                                                                                                          GB
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:
       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.
                                                 -3-
                                                 MAINTENANCE              1
                                                          -4-
                                 MAINTENANCE                                           1
WARNING
                                                                                               1
                                                                                               GB
• Impropriety or lack of recommended maintenance operations can lead to an increase of
the 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 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.
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                                                   MAINTENANCE                                                           1
     DESCRIPTION            OPERATION
                            Check level                                           Every time vehicle is used
     Engine oil                                                      !        !         !         !           !   !      !
                            Renew
                                                                                     At least once a year
                            Replace                                  !        !         !         !           !   !      !
     Engine oil filter      (Use only MV Agusta
                            genuine spare oil filters)                       Every time engine oil is changed
                            Check                                                       !                     !
     Timing chain
                            Replace                                                                                      !
                                                            -6-
                                            MAINTENANCE                                                       1
                                                                                                                      GB
km (mi) covered                                  0       1000     6000     12000     18000 24000 30000 36000
                                                         (600)   (3800)    (7500)   (11200) (14900) (18600) (22400)
                                                Pre-
Service coupon                                            A        B          C        D            E   F     G
                                              delivery
DESCRIPTION              OPERATION
                         Check / Replace                                      !                     !
                         Check / Replace                           !                   !                !
Spark plugs
                         Replace                                              !                     !         !
                         Check level             !        !        !          !        !                !     !
Brakes fluid
                                                                                                    !
                         Renew
                                                                        At least every two years
                                                 -7-
                                                     MAINTENANCE                                                               1
     DESCRIPTION                  OPERATION
                                  Check operation                                      Every time vehicle is used
                                  Clean lever / master cyl.                      Every 500 ÷ 1000 km (300 ÷ 600 mi)
                                  piston contact area
     Brakes / Clutch              Check operation                !         !       !           !        !           !   !       !
                                                                 -8-
                                               MAINTENANCE                                                           1
                                                                                                                         GB
km (mi) covered                                     0       1000      6000    12000     18000 24000 30000 36000
                                                            (600)    (3800)   (7500)   (11200) (14900) (18600) (22400)
                                                   Pre-
Service coupon                                                A        B         C        D         E        F       G
                                                 delivery
DESCRIPTION OPERATION
Lubricate Every 1000 Km (600 mi) and after riding under the rain
Lubricate ! ! ! !
Replace ! ! !
Check ! ! ! !
Check ! ! ! !
Rear sprocket                                                                    !                  !                !
                              Replace
                                                                      Every time drive chain is replaced
                                                    -9-
                                                     MAINTENANCE                                                               1
     DESCRIPTION                  OPERATION
     Rear sprocket spring drive   Check / Replace                                         !                  !                 !
                                  Check                               !                   !                  !                 !
     Steering bearings
                                  Lubricate                                                                  !
                                  Check wear                      Every time vehicle is used; at least every 500 Km (300 mi)
     Tyres
                                  Check pressure          !           !        !          !         !        !       !         !
Check wear ! ! ! ! ! ! !
                                                                      !        !          !         !        !       !         !
     Wheel rims                   Inspect visually
                                                                                    Every time tyre is replaced
                                                                               !          !         !        !       !
     Front wheel bearings         Check
                                                                                   Every time tyre is replaced
Replace !
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                                                      MAINTENANCE                                                             1
                                                                                                                                      GB
km (mi) covered                                                 0        1000     6000     12000     18000 24000 30000 36000
                                                                         (600)   (3800)    (7500)   (11200) (14900) (18600) (22400)
                                                               Pre-
Service coupon                                                            A        B          C        D            E   F     G
                                                             delivery
DESCRIPTION                       OPERATION
                                  Check operation                                      Every time vehicle is used
Sidestand
                                  Check operation               !         !        !          !        !            !   !     !
                                                                - 11 -
                                                   MAINTENANCE                                                        1
     DESCRIPTION               OPERATION
     Battery connections       Check and clean                    !        !         !         !        !     !       !
Headlight Adjust Every time geometry is changed and every time you seat a passenger
Check operation ! ! ! ! ! ! ! !
                                                        - 12 -
                                         MAINTENANCE                                                       1
                                                                                                                   GB
km (mi) covered                               0        1000     6000    12000     18000 24000 30000 36000
                                                       (600)   (3800)   (7500)   (11200) (14900) (18600) (22400)
                                             Pre-
Service coupon                                          A        B        C         D        E     F       G
                                           delivery
DESCRIPTION            OPERATION
                       Check operation                               Every time vehicle is used
Locks
                       Check operation        !         !        !        !         !        !     !       !
General lubrication ! ! ! ! ! ! ! !
General test ! ! ! ! ! ! ! !
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                                             MAINTENANCE     1
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                                         MAINTENANCE                                                    1
                                                                                                            GB
                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                           –
* : 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 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                                      Engine oil
   –   Consistent with:       JASO MA, MA2                                 SAE 5W-40
   –   SAE Rating:            SAE 5W-40                                      API SL
                                                                            ACEA A3
   NOTE
                                                                          JASO MA, MA2
   The above standard denominations must be written, alone or
   together, on the engine oil container label.
                                                - 15 -
                                                 MAINTENANCE                         1
     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.
     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.
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                                         MAINTENANCE     1
                                                             GB
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.
                                                - 17 -
                                       MAINTENANCE                                         1
     WARNING
 1
GB
     New or exhaust engine oil can be dan-             • Keep new or exhaust engine oil out of
     gerous. Engine oil is highly toxic for            reach of children and domestic animals.
     people and domestic animals. Avoid                • While topping up the engine oil, wear
     ingestion and contact. It has been                a long-sleeved shirt and a pair of water-
     proved that prolonged contact with                proof gloves to protect your skin.
     engine oil can cause skin cancer on               • If the engine oil comes in touch with
     guinea pigs. Even a brief contact with            your skin, wash it away with soap and
     engine oil can cause skin irritation.             water.
     • In the event of an engine oil ingestion,        • Correctly recycle or dispose of the
     immediately call a doctor and do not              exhaust engine oil, in order to avoid
     cause vomiting, in order to avoid inhala-         environmental pollution.
     tion of engine oil in lungs.
                                              - 18 -
                                          MAINTENANCE                       1
                                                                                GB
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
       Do not start the engine if the coolant level is
       below the MIN mark.
                                                            Coolant
                                                             level
                                                                      MIN
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                                 MAINTENANCE                                          1
WARNING                                          CAUTION
                                                                                              1
                                                                                              GB
Under certain conditions, ethylene gly-          To top up the coolant level and/or renew
col contained in the coolant can become          the coolant, use only the product speci-
flammable. When it is lighted, it pro-           fied in the table at paragraph 1.4. Do not
duces an invisible flame.                        mix nor dilute the coolant with additives
Avoid spilling coolant on hot parts of           or different fluids. If the coolant speci-
the motorcycle, because the subse-               fied at paragraph 1.4 is not available,
quent combustion of ethylene glycol              use a coolant having technical charac-
could cause serious burns.                       teristics consistent with the prescribed
                                                 product.
WARNING
Coolant is a highly toxic fluid. Avoid           CAUTION
ingestion and contact with your skin or          Coolant can damage painted and plastic
eyes. Keep coolant out of reach of chil-         parts. When you top up the coolant
dren and domestic animals. In the event          level, be careful not to spill coolant on
of a coolant ingestion, immediately call         any part of the motorcycle. If you do
a doctor and do not cause vomiting, in           spill coolant on your motorcycle, imme-
order to avoid inhalation of coolant in          diately wipe it away using a clean cloth.
lungs. If the coolant comes in touch with
your skin or eyes, immediately wash it
away with water.
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                                   MAINTENANCE                                                1
 1
GB
                                   WARNING
                                   If the brake pads are excessively worn out, the effective-
                                   ness of the braking system decreases, increasing the risk
                                   of accidents. If the pads have worn to near the wear limit,
                                   have both pads replaced by an authorized service centre.
     Wear limit 1 mm               Ensure that the new pads are suitably broken in.
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                                        MAINTENANCE                                               1
                                                                                                       GB
1.8.   Checking the brake fluid level
                                             - 23 -
                                       MAINTENANCE                                            1
     WARNING                                           WARNING
 1
GB
     Never use your motorcycle if the fluid            Use only the brake fluid specified at
     level is below the MIN mark. The brakes           paragraph 1.4. of this manual. Mixing dif-
     may fail to properly operate, which               ferent brake fluids can cause a danger-
     could lead to an accident. If the brake           ous chemical reaction, as well as the
     fluid level is below the MIN mark, you            decrease of the braking efficiency, with
     must have the braking system over-                subsequent increase of the risk of acci-
     hauled by an authorized MV Agusta                 dents.
     dealer.
                                                       WARNING
     WARNING                                           An insufficient amount of brake fluid may
     Have the topping up of the brake fluid            allow the introduction of air in the braking
     performed only by skilled personnel.              system. This could compromise the effec-
     Brake fluid is highly toxic. Avoid contact        tiveness of the braking system, with sub-
     and ingestion. Keep brake fluid out of            sequent increase of the risk of accidents.
     reach of children and domestic animals.           Presence of air in the braking system can
     In the event of a brake fluid ingestion,          be identified in the moment you feel a
     immediately call a doctor and do not              characteristic “spongy effect” while
     cause vomiting, in order to avoid inhala-         pushing the brake lever. In this case, have
     tion of brake fluid in lungs. If the brake        a braking system bleeding performed by
     fluid comes in touch with your skin or            an authorized MV Agusta dealer before
     eyes, immediately wash with water.                riding your motorcycle again.
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                                                MAINTENANCE                                      1
                                                                                                         GB
       WARNING
       Before using the motorcycle,
       always check the pressure and
       wear of the tyres.
                                                   - 25 -
                                                MAINTENANCE                                           1
     using the motorcycle, you would obtain a higher             The limits of the tyre tread depth may
     value than the actual one. This could cause an              vary from country to country. Always
     incorrect adjustment of the tyre pressure.                  refer to the values prescribed by the law
     Refer to the pressures given in § 2.2. and/or on            provisions of the nation in which you
     the label applied on the sleeve of the right front          use your motorcycle.
     fork. In the event of long travels, you can increase
     the face value of the tyre pressure of 0.2 bar.             WARNING
                                                                 • If the tyres of your motorcycle are
     Moreover, it is extremely important to check the            excessively worn out, have it replaced
     wear of the tyres before riding. In fact, a worn out        by your MV Agusta dealer. Besides
     tyre can be punctured more easily than a new                being illegal, riding a motorcycle with
     one, and it can adversely affect handling and sta-          excessively worn out tyres can reduce
     bility of the motorcycle.                                   its stability and lead to the loss of con-
     Check that the depth of the tyre tread is not below         trol of the vehicle.
     the values prescribed by the Highway Code.                  • If a tyre is punctured it must be
     Verify the absence of crevices at the bottom of the         replaced, not repaired. A repaired tyre
     tread design and fissures on the tyre sidewall.             provides a restricted performance and
     Moreover, verify the absence of nails and glass             lower safety levels than a new one.
     splinters in the tyre. If these conditions are not
     verified, have the tyre replaced by an authorized
     MV Agusta dealer.
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                                  MAINTENANCE                                         1
                                                                                              GB
If you make a provisional or emergency            • When it is necessary to replace the
repair to a tyre, you must ride at very           tyres, use only the type specified in
low speed until you reach the nearest             paragraph 2.2. Moreover, avoid using
MV Agusta dealer and have the tyre                tyres of a different brand or type on the
replaced. With a provisionally repaired           front and on the rear wheel at the same
tyre, never exceed 60 km/h. Tyre repair-          time. Using tyres different from those
ing must never be performed if the tyre           specified can adversely affect the han-
is punctured on its sidewall, or if the           dling and stability of the motorcycle,
diameter of the puncture on the tread is          increasing the risk of accidents.
greater than 6 mm.                                • The wheel rims of your motorcycle
• MV Agusta recommends not to use                 have been designed for use with tube-
sealing fluids to repair a punctured tyre.        less tyres only. Do not assemble an air
These products can adversely affect the           tube tyre on rims designed for tubeless
material of the tyre layers, as well as           tyres. Otherwise, the tyre bead could
hide the minor damages caused by                  not properly settle down on the wheel
objects penetrated in the tyre.                   rim, leading to the deflation of the tyre
                                                  and the loss of control of the vehicle.
                                         - 27 -
                                        MAINTENANCE                                          1
 1
GB
     • Do not assemble an air tube on a                  • New tyres should be run in for a short
     tubeless tyre. The overheating of the               period before demanding their full per-
     tyre could cause the explosion of the air           formance. In fact, during this period the
     tube, leading to the deflation of the tyre          tyres could have a reduced grip on
     and the loss of control of the vehicle.             some kind of roads. We suggest to ride
     • Have the tyres replaced according to              at reduced speed and exercise extreme
     their direction of spin, which is highlight-        caution during the first 100 km after the
     ed by a small arrow on the tyre sidewall.           replacement of a tyre.
                                                - 28 -
                                      MAINTENANCE                             1
                                                                                  GB
     CAUTION
     If you have the rear wheel tyre
     replaced by a tyre-dealer, make
     sure that the following tools are
     used in the rear wheel disassem-
     bling and reassembling:
                                              Polygonal nut
     • 55 mm polygonal socket wrench
     • Torque wrench
                                            - 29 -
                                            MAINTENANCE                                          1
                                                            WARNING
     Before riding, always verify the absence of            When you have a wheel balancing per-
     cracks, bending or buckling on the wheel rims.         formed, make sure to assemble only
                                                            approved counterweights on the wheel
          WARNING                                           rim. MV Agusta recommends not to use
          If you find that the wheel rim is dam-            balancing or balancing/sealing fluids.
          aged, have it replaced by an authorized
          MV Agusta dealer. Never attempt to                WARNING
          repair the wheel rim, even in case of             Do not attempt to have a tubeless tyre
          slight damage.                                    removed without using the proper tools
          Every time you replace a tyre or a rim,           and protections for the wheel rim.
          you must have a wheel balancing per-              Otherwise, you could damage the seal-
          formed by an authorized MV Agusta                 ing surface of the rim, leading to the
          dealer. Wheel unbalance can adversely             deflation of the tyre and the loss of con-
          affect performance and handling of the            trol of the vehicle.
          motorcycle, as well as shorten the life of
          the tyres.
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                                           MAINTENANCE                1
                                                                          GB
To perform this operation, you must put the motorcycle
on the rear stand, upright on a horizontal surface and
with the gear in neutral.
" Checking the chain adjustment
      WARNING: Before checking the chain adjust-
      ment, contact a MV Agusta authorized centre
      to verify that the value of the static setup of
      the rear suspension is correct. Also make              116 mm
      sure that the chain is properly lubricated.
The axis of the chain lower portion must be 116 mm
from the lower chain guard. Manually turn the rear
wheel and carry out the check at several points along
the chain. The distance between the chain and the
lower chain guard must remain almost constant as the
wheel turns. If, on the other hand, the play on the chain
varies considerably, it means that some chain links are
flattened, seized or elongated. If the distance is greater
than 116 mm, have the chain adjusted by your local MV
Agusta dealer.
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                                      MAINTENANCE                                          1
     WARNING                                          WARNING
 1
GB
     Riding your motorcycle when the drive            Using a chain with a fake link can be
     chain is in poor condition or improperly         dangerous. An uncompletely riveted or
     adjusted can lead to accidents. Before           fake link can accidentally split open and
     riding, always check the chain adjust-           cause accidents, as well as damage to
     ment according to the procedures                 the engine. Never use a chain with a
     shown in this paragraph. If necessary,           fake link.
     have the chain adjusted by your MV
     Agusta dealer.                                   WARNING
                                                      Every time it is requested to operate the
     WARNING                                          rear wheel hub screws, contact an
     If any chain link is flattened, seized or        authorized MV Agusta dealer. In order to
     elongated, have the chain replaced by a          tighten the screws, apply a tightening
     MV Agusta authorized service centre.             torque equal to the value shown in the
                                                      label placed on the swingarm. Applying
     WARNING                                          a torque higher than the indicated value
     If you notice damage or excessive wear           can cause the fast decay of the rear
     of the chain and the related sprockets,          wheel hub, compromising the reliability
     have them replaced by an authorized              of the vehicle and the safety of the pilot
     MV Agusta dealer. Every time the chain           and the passenger.
     is replaced, you must always replace
     the front and rear sprockets too.
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                                          MAINTENANCE                                       1
" Lubrication
                                                                                                    1
                                                                                                    GB
To ensure proper operation, the drive chain needs
to be properly lubricated.
      CAUTION
      The chain is of the O-ring type. To pre-
                                                          WARNING
      vent it from damaging, never clean the
                                                          Kerosene is highly toxic and flammable.
      chain with a steam or high pressure
                                                          Avoid contact and inhalation. Keep
      water jet, nor using gasoline or other
                                                          kerosene away from sparks and flames.
      solvents. The chain must be cleaned
                                                          Keep kerosene out of reach of children
      using kerosene only.
                                                          and domestic animals. Correctly dis-
                                                          pose of exhaust kerosene, in order to
                                                          avoid environmental pollution.
                                                 - 33 -
                                                    MAINTENANCE      1
                                                            - 34 -
                                          MAINTENANCE      1
                                                               GB
Check the idle speed when the engine has reached the
operating temperature. Ensure that the choke control
has not been activated.
                                                 - 35 -
                                                   MAINTENANCE                                                1
     The replacement of the fuses and the light bulbs               The battery recharge fuse is located on the
     can be carried out by the owner according to the           solenoid starter, in the position indicated on the
     indications provided below.                                right side of the motorcycle.
                                                                To reach them remove the protective cover by
           Battery recharge fuse - Replacement                  removing the two fixing screws.
           (§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.)
                                                           - 36 -
                                       MAINTENANCE                  1
     CAUTION
                                                                          1
                                                                          GB
     Turn the ignition key on the “OFF” posi-
     tion before checking or replacing the
     fuses, in order to avoid a short circuit
                                                         Recharge fuse
     with subsequent damage to other elec-
                                                         (40A)
     tric parts of the motorcycle.
    To replace the fuse, you must swap the             Spare fuse (40A)
recharge fuse with the spare fuse.
     WARNING
     Never replace a fuse with a rating other
     than that prescribed, in order to avoid
     damage to the electrical equipment of
     the motorcycle which could lead to a fire.
                                              - 37 -
                                                MAINTENANCE     1
of the motorcycle.
           CAUTION
           Turn the ignition key on the “OFF” posi-
           tion before checking or replacing the
           fuses, in order to avoid a short circuit
           with subsequent damage to other elec-
           tric parts of the motorcycle.
                                                       - 38 -
                                          MAINTENANCE                                                          1
                                                                                                                   GB
fuses, refer to the information provided under the
lid of the box and on the attached wiring diagram;
the reference letters in the figure correspond to
those shown in the diagram.
10A
10A
15A
15A
15A
                                                                                                    10A
Remember that the fuse box contains three spare                15A
fuses.
                                                                 10A             10A              15A
                                                 - 39 -
                                               MAINTENANCE       1
                                                       - 40 -
                                          MAINTENANCE      1
                                                               GB
perform the following operations.
                                                 - 41 -
                                                MAINTENANCE       1
                                                        - 42 -
                                        MAINTENANCE   1
                                                          GB
  Remove the fixing screw.
                                           - 43 -
                                                 MAINTENANCE      1
                                                         - 44 -
                                        MAINTENANCE       1
                                                              GB
    Remove the fixing screws of the lower cover
of the plate holder.
                                                 - 45 -
                                                 MAINTENANCE         1
                                                            - 46 -
                                         MAINTENANCE     1
                                                             GB
   Remove the two upper fixing screws of the tail
side fairings.
   Remove the two fixing screws of the tail lamp.
                                                - 47 -
                                                 MAINTENANCE      1
                                                         - 48 -
                                          MAINTENANCE     1
                                                              GB
   Remove the tail lamp as described at §1.12.5.
    To extract the bulb holder, rotate it counter-
clockwise.
                                                 - 49 -
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     1.13. Battery
 1
GB
                                                         - 50 -
                                          MAINTENANCE                                           1
Prolonged inactivity
                                                                                                        1
                                                                                                        GB
If the motorcycle is to remain unused for a long      To do this connect the charger on the connector
time (a month or longer), it is advisable remove      placed under the driver’s seat.
the recharging fuse (see §1.12.1). In case of pro-
longed inactivity, recharge the battery once a
month, in order to ensure durability.
Charging connector
                   Charging
                   fuse
                                                 - 51 -
                                               MAINTENANCE                                      1
           CAUTION
           Before washing the vehicle,
           stop up the exhaust pipes
           and protect the electrical
           parts.
           WARNING
                                                 CAUTION: Never use washing systems involving
           Do not wash your motorcy-
                                                 steam or high pressure water jets. These systems
           cle soon afterwards riding.
                                                 could cause water infiltration and damage the inter-
           Attend a few minutes to
                                                 nal parts of your motorcycle.
           allow the engine and the
                                                 INFORMATION: Spilling detergent can cause environ-
           exhaust pipes to thoroughly
                                                 mental pollution. Therefore, you should clean your
           cool.
                                                 motorcycle in an area equipped for collection and
                                                 disposal of washing fluids.
                                                   - 52 -
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                                                                                                        GB
and a sponge. Wipe the vehicle with a soft cloth.          Avoid smearing brakes or tyres with oil
Use an air jet to dry difficult-to-reach areas.            or wax. If necessary, clean the brake
                                                           discs with a brake disc detergent or with
      CAUTION                                              acetone, and wash the tyres with warm
      • Avoid using clothes or sponges that                water and a neutral detergent.
      have been in contact with strong or
      abrasive detergents, solvents, alcohol               WARNING
      or gasoline.                                         The presence of water on the brakes can
      • To avoid irreparable damage to the                 lead to a decrease of the braking effec-
      bodywork parts, never use alkaline or                tiveness with subsequent risk of acci-
      strongly acid detergents, petrol, brake              dents. After completing the washing, run
      fluid or other solvents.                             the engine for a few minutes and start off
      • If you have doubts about the chemical              at reduced speed. Carefully apply the
      composition of the detergent, test its effect        brakes a few times so as to dry the brake
      by applying it on a little area of the body-         pads and discs.
      work before using it on the whole bike.
                                                           WARNING
Periodically treat the paintwork with high quality         The drive chain must be correctly lubri-
wax. After riding on roads treated with corrosive          cated after washing the motorcycle, fol-
substances (salt), wash the vehicle as soon as             lowing the instructions provided at §
possible with cold water. Do not use hot water as          1.10. of this manual.
it enhances the corrosive action.
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                                               MAINTENANCE                                                 1
                                                       - 54 -
                                               TROUBLESHOOTING FLOW CHART                             2
                                                                                                          GB
            OK?
YES NO
NO NO
NO NO
       YES                                                                 NO
continued on next page
                                                          - 55 -
                                                        TROUBLESHOOTING FLOW CHART                          2
 2
                                 YES                                                     YES
GB
NO NO
YES NO
           YES                                                                  NO
       Contact a MV Agusta
     authorized service centre
                                                                - 56 -
                                                  TROUBLESHOOTING FLOW CHART                               2
                            NO
                                                                                                               2
                                                                                        YES
                                                                                                               GB
     Fuel tank empty                     Refuel                     Engine is running         Problem solved
YES NO
YES NO
  Contact a MV Agusta
authorized service centre
                                                           - 57 -
                                                      TROUBLESHOOTING FLOW CHART                                  2
ENGINE OVERHEATS
 2                               NO
GB
                                        Contact a MV Agusta
          Coolant level is
                                      authorized service centre
          correct (§1.7.)
YES
YES NO
       Contact a MV Agusta
     authorized service centre
                                                                  - 58 -
                                                 TROUBLESHOOTING FLOW CHART                                2
OIL PRESSURE IS TOO LOW (Engine oil pressure warning light is on with the engine running)
                                                                                                               2
                            NO       Have the oil level
                                                                                        YES
                                                                                                               GB
    Oil level is correct                                              Oil pressure is
                                 restored by a MV Agusta                                      Problem solved
          (§1.5.)                                                         optimal
                                 authorized service centre
YES NO
  Contact a MV Agusta
authorized service centre
                                                             - 59 -
                                                    TROUBLESHOOTING FLOW CHART                           2
 2                               NO                                                   YES
GB
YES NO
YES NO
       Contact a MV Agusta
     authorized service centre
                                                               - 60 -
                                            TROUBLESHOOTING FLOW CHART                           2
                            NO                                                YES
                                                                                                     2
        Fuse F6                  Replace fuse F6
                                                                                                     GB
                                                              Horn works            Problem solved
         is OK                      (§1.12.1)
      YES                                                            NO
  Contact a MV Agusta
authorized service centre
        Fuse F5
                            NO   Replace fuse F5                              YES
                                                            Dashboard works         Problem solved
         is OK                      (§1.12.1)
     YES                                                            NO
  Contact a MV Agusta
authorized service centre
                                                   - 61 -
                                  TECHNICAL INFORMATION                            3
(N) Dashboard
(I) Battery
 3
GB
       (G) Front
       suspension
                                                                         (F) Frame
       (E) Cooling system
(A) Engine
                                      - 62 -
                                              TECHNICAL INFORMATION                                    3
                                                                                                            GB
                                                           I - Battery: sealed and maintenance-free.
C - Gearbox: removable, six-speed, with con-
    stant-mesh gears.                                      L - Front brake: dual semi-floating disc with
                                                               four-piston calipers.
D - Final drive: consisting of drive sprocket, rear
                                                           M - Rear brake: single disc with two-piston
    sprocket and chain.
                                                               caliper.
E - Cooling system: with separate liquid and oil
    radiators.                                             N - Instrument panel: with warning lights and
                                                               digital instruments.
F - Frame: tubular steel trellis with aluminium
    side plates.                                           O - Exhaust system: equipped with catalytic
                                                               converter for exhaust emission reduction.
                                                      - 63 -
                                     TECHNICAL INFORMATION                           3
                                           4
                                           5
                                         - 64 -
                                TECHNICAL INFORMATION                           3
                                                        1   Brake   lever
                            4                           2   Brake   master cylinder
                                                        3   Brake   line
                                                        4   Brake   fluid reservoir
                                                        5
                                                                                      3
                                                            Brake   caliper
                                                                                      GB
                                                        6   Brake   disc
            6
                                                               3
1 2
                                    - 65 -
                                 TECHNICAL INFORMATION             3
                                                         1 Oil sump
                                                         2 Oil filter
 3
GB
1 2
                                     - 66 -
                             TECHNICAL INFORMATION                        3
                         1                           1   Expansion tank
                                                     2   Upper radiator
                                                     3   Lower radiator
                                                     4   Coolant pump
                                                                              GB
                   2
3 4
                                 - 67 -
                          TECHNICAL INFORMATION                  3
                                                  1 Throttle bodies
                                                  2 Fuel pump
                                                  3 Fuel line
 3
GB
                                 - 68 -
                                                 TECHNICAL INFORMATION                                                  3
                                                                                                                            GB
3.2.   Specifications
Description                                                                 BRUTALE 800
SPECIFICATIONS
Wheelbase (mm) (*)                                                               1380
Overall length (mm) (*)                                                          2085
Max. width (mm)                                                                  725
Seat height (mm) (*)                                                             810
Min. ground clearance (mm) (*)                                                   160
Trail (mm) (*)                                                                   95.3
*: The indicated values must not be intended as binding informations. They can change according to the vehicle setup.
                                                          - 69 -
                                                      TECHNICAL INFORMATION                                               3
Specifications
     ENGINE
     Type                                                          Three-cylinder, four-stroke, 12 valves
     Bore (mm)                                                                      79.0
     Stroke (mm)                                                                    54.3
     Total displacement (cm3)                                                        798
     Compression ratio                                                             13.3 : 1
     Starting                                                                   Electric starter
     Cooling system                                              Cooling with separate liquid and oil radiators
     Crankcase and covers                                                          Die-cast
     Head and cylinders                                                           Chill-cast
     Valves                                                                         Steel
     VALVE TRAIN
     Type                                                                 Double-overhead camshaft
     * : 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 -
                                            TECHNICAL INFORMATION                                                3
Specifications
                                                                                                                         3
Type                                     Integrated ignition-injection system MVICS with three injectors. Engine
                                                                                                                         GB
                                       control unit Eldor EM2.0; throttle body full drive by wire Mikuni; pencil-coils
                                         with ion-sensing technology, control of detonation and misfire. Torque
                                         control with 4 mappings; Traction Control with 8 levels of intervention.
Spark plugs                                                          NGK CR9 EIB-9
Spark gap (mm)                                                           0.8 ÷ 0.9
CLUTCH
Type                                                              Multiple-disc in oil bath
PRIMARY DRIVE
Number of teeth on countershaft gear                                      Z = 19
Number of teeth on clutch gear                                            Z = 36
Transmission ratio                                                         1.895
SECONDARY DRIVE
Number of teeth on front sprocket                                         Z = 16
Number of teeth on rear sprocket                                          Z = 41
Transmission ratio                                                         2.563
                                                     - 71 -
                                      TECHNICAL INFORMATION                                          3
Specifications
                                              - 72 -
                                  TECHNICAL INFORMATION                               3
Specifications
                                                                                          GB
Calipers, piston diameters (mm)                Radial-type, 4-piston ( Ø 32 )
REAR BRAKE
Type                                                 Single steel disc
Disc diameter (mm)                                          220
Caliper, piston diameter (mm)                        2-piston ( Ø 34 )
FRONT RIM
Material                                             Aluminium alloy
Dimensions                                              3.50” x 17”
REAR RIM
Material                                             Aluminium alloy
Dimensions                                              5.50” x 17”
TYRES
Front                                           120/70 ZR 17 M/C (58 W)
Rear                                            180/55 ZR 17 M/C (73 W)
Brand and type                                   PIRELLI - Diablo Rosso II
                                      - 73 -
                                                       TECHNICAL INFORMATION                                                 3
Specifications
     Equipment voltage                                                                 12 V
     Headlight bulb                                                              H4 12V 60/55W
     Front indicator                                                              HY6W 12V 6W
     Rear indicator                                                               HY6W 12V 6W
     Tail light bulb                                                              W5W 12V 5W
     Brake, rear light                                                           W16W 12V 16W
     Battery                                                                       12 V - 8,6Ah
     Alternator                                                                350 W at 5000 rpm.
     BODYWORK
     Fuel tank                                                                Thermoplastic   material
     Air box side panels                                                      Thermoplastic   material
     Under-seat side panels                                                   Thermoplastic   material
     Rear side panels                                                         Thermoplastic   material
     * : 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.
                                                                - 74 -
                       TECHNICAL INFORMATION                 3
Specifications
                                                                 GB
Rearview mirrors                    Thermoplastic material
Exhaust pipe guard                       Aluminium
Radiator side covers                     Aluminium
                           - 75 -
             TECHNICAL INFORMATION           3
         2
                                         6
 3
GB
                  - 76 -
                                         TECHNICAL INFORMATION                                       3
                                                                                                            GB
     Colour code B:                                           (Code Palinal 928.T671)
     CRC Pearly White (Code Palinal 927.PE20)                 Colour code B:
     Colour code C:                                           “Shoreline Mist” Matt Metal Grey
     Mamba Red (Code Palinal 929.T689)                        (Code Palinal F503 Y754)
     Colour code D: MV ICE Pastel White                       Colour code C:
     (Code Palinal 929.F364)                                  Gloss Pastel White
                                                              (Code Palinal CromaCard V098)
3. - Right hand central fairing;                              Colour code D:
4. - Left hand central fairing:                               MV ICE Pastel White
     Colour code A: Pearly Red                                (Code Palinal 929.F364) +
     (Code Palinal 928.T671)                                  “Italy” Pearly Blue (Code Palinal 928.T643)
     Colour code B: “Shoreline Mist”
     Matt Metal Grey (Code Palinal F503 Y754)             6. - Dashboard cover:
     Colour code C: Gloss Pastel White
     (Code Palinal CromaCard V098)                            Colour code D:
     Colour code D: MV ICE Pastel White                       MV ICE Pastel White
     (Code Palinal 929.F364)                                  (Code Palinal 929.F364)
                                                 - 77 -
                 TECHNICAL INFORMATION           3
                                         2
             5
                              1
 3
GB
3 4
                                                 7
     6
                     - 78 -
                                        TECHNICAL INFORMATION                                    3
                                                                                                        GB
    Colour codes A-C-D:
    Mica Black                                              Quasar Black
    (Code Pulverit 71B CL D 999)                            (Code Inver 61196 - Poliest/HD TGIC Free)
    Colour code B:
    Frame Red
                                                        6. - Rear wheel rim;
    (Code Akzo Nobel QG000K RED)                        7. - Front wheel rim:
                                               - 79 -
                                                            NOTE
                  Information
                  MV 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 Agusta
                  motorcycles are exported in several countries, in which different rules and regulations (concerning both the
                  Highway Code and the homologation procedures) are in force. Relying on your understanding, MV Agusta
                  Motor S.p.A. deems it necessary to reserve the right to change its products and the related documentation
                  at any time and without notice.
 3                We suggest to often visit the Internet site www.mvagusta.it in order to obtain informations and updates
GB
     © 2012
     This document may not, in whole or in part, be reproduced without prior consent, in writing, from MV Agusta Motor S.p.A.
     Part. n° 8000B7950
     Edition n° 1 - October 2012
- 80 -