MV Agusta TURISMO VELOCE 800 LUSSO Maintenance Manual
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MV Agusta TURISMO VELOCE 800 LUSSO Maintenance Manual

800 cc three-cylinder engine
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  • Page 2 Maintenance manual English Version...

  • Page 3: Table Of Contents

    CONTENTS chap. Subjects covered page chap. Subjects covered page MAINTENANCE TROUBLESHOOTING FLOW CHART 1.1. Symbols 2.1. Engine problems 1.2. Tables of scheduled maintenance and checks 2.2. Electrical equipment problems TECHNICAL INFORMATION 1.3. Tools and accessories supplied 1.4. Table of lubricants and fluids 3.1.

  • Page 4: Maintenance

    MAINTENANCE 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.

  • Page 5: Tables Of Scheduled Maintenance And Checks

    MAINTENANCE 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.
  • Page 6 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.
  • Page 7 Check / Restore level Renew Renew Engine oil filter (Use only original oil filters Every time engine oil is changed MV Agusta) Check / Restore level Every time vehicle is used Coolant Check / Restore level Renew At least every two years...
  • Page 8 MAINTENANCE Tables of scheduled maintenance (*): The mileage coupons can be carried along with the mandatory annual coupon 1000 Every 15000 30000 45000 60000 75000 90000 105000 km (mi) covered* (600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000) Deli- Service coupon very ESCRIPTION PERATION Timing fixed shoe Replace...
  • Page 9 MAINTENANCE Tables of scheduled maintenance (*): The mileage coupons can be carried along with the mandatory annual coupon 1000 Every 15000 30000 45000 60000 75000 90000 105000 km (mi) covered* (600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000) Deli- Service coupon very ESCRIPTION PERATION Check operation Every time vehicle is used...
  • Page 10 MAINTENANCE Tables of scheduled maintenance (*): The mileage coupons can be carried along with the mandatory annual coupon 1000 Every 15000 30000 45000 60000 75000 90000 105000 km (mi) covered* (600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000) Deli- Service coupon very ESCRIPTION PERATION Check Every 1000 Km ( 600 mi )
  • Page 11 MAINTENANCE Tables of scheduled maintenance (*): The mileage coupons can be carried along with the mandatory annual coupon 1000 Every 15000 30000 45000 60000 75000 90000 105000 km (mi) covered* (600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000) Deli- Service coupon very ESCRIPTION PERATION Check / Adjust Steering bearings...
  • Page 12 MAINTENANCE Tables of scheduled maintenance (*): The mileage coupons can be carried along with the mandatory annual coupon 1000 Every 15000 30000 45000 60000 75000 90000 105000 km (mi) covered* (600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000) Deli- Service coupon very ESCRIPTION PERATION Swingarm bearings Check / Lubricate...
  • Page 13 MAINTENANCE Tables of scheduled maintenance (*): The mileage coupons can be carried along with the mandatory annual coupon 1000 Every 15000 30000 45000 60000 75000 90000 105000 km (mi) covered* (600) year (9000) (18000)(27000)(36000)(45000)(54000) (63000) Deli- Service coupon very ESCRIPTION PERATION Check operation Every time vehicle is used...

  • Page 14: Tools And Accessories Supplied

    MAINTENANCE 1.3. Tools and accessories supplied Under the seat you can find the following tools: 2 Allen wrenches (2,5 mm - 4 mm hexagon); 1 spanner for rear wheel eccentric with extension; 1 fuse puller. Inside the fuse box are also provided the following spare fuses (see §1.13.1): 1 fuse 10A;...

  • Page 15: Table Of Lubricants And Fluids

    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 Turismo Veloce. motorcycle engine.

  • Page 16: Checking The Engine Oil Level

    MAINTENANCE 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.

  • Page 17: Topping Up The Engine Oil Level

    MAINTENANCE 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-...
  • Page 18 MAINTENANCE WARNING 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 • In the event of an engine oil ingestion, ingestion and contact.

  • Page 19: Checking The Coolant Level

    MAINTENANCE 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.

  • Page 20: Topping Up The Coolant Level

    MAINTENANCE 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.
  • Page 21 MAINTENANCE CAUTION WARNING To top up the coolant level and/or renew Under certain conditions, ethylene gly- the coolant, use only the product speci- col contained in the coolant can become fied in the table in section 1.4. Do not flammable. When it is lighted, it pro- mix nor dilute the coolant with additives duces an invisible flame.

  • Page 22: Checking The Wear Of The Brake Pads

    MAINTENANCE Front brake caliper Rear brake caliper 1.7. Checking the wear of the brake pads Disc Periodically check the width of the friction material layer of the pads, making sure it never falls below the wear limit (1 mm). WARNING: If the brake pads are excessively Pads worn out, the effectiveness of the braking system decreases, increasing the risk of acci-...

  • Page 23: Checking The Brake Fluid Level

    MAINTENANCE Rear brake fluid reservoir 1.8. Checking the brake fluid level WARNING The level of the brake fluid decreases as the Lack of maintenance of the braking sys- brake pads wear down. Ensure that the fluid level tem can increase the risk of accidents. is always between the MAX and MIN marks.
  • Page 24 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...

  • Page 25: Clutch Control Fluid - Level Check

    MAINTENANCE 1.9. Clutch control fluid - Level check The level must be between the MAX and MIN marks. If the level falls below the MIN mark, contact an autho- rised service centre for a general check of the clutch control system. WARNING Do not use the motorcycle if the level is below the MIN mark;...

  • Page 26: Checking And Replacing The Tyres

    MAINTENANCE 1.10. Checking and replacing the tyres WARNING Before using the motorcycle, always check the pressure and wear of the tyres. Checking the inflating pressure of the tyres is an essential requirement to ensure driving safety. Insufficiently inflated tyres can reduce the han- dling of the motorcycle and wear themselves out very quickly.
  • Page 27 • If the tyres of your motorcycle are excessively worn out, have it replaced Moreover, it is extremely important to check the by your MV Agusta dealer. Besides wear of the tyres before riding. In fact, a worn out being illegal, riding a motorcycle with...
  • Page 28 3.2. Moreover, avoid using low speed until you reach the nearest tyres of a different brand or type on the MV Agusta dealer and have the tyre front and on the rear wheel at the same replaced. With a provisionally repaired time.
  • Page 29 MAINTENANCE • 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.
  • Page 30 MAINTENANCE Rear wheel disassembling Wheel pin with M50x1.5mm left-hand pitch tread CAUTION If you have the rear wheel tyre replaced Polygonal nut by a tyre-dealer, make sure that the fol- lowing tools are used in the rear wheel disassembling and reassembling: •...
  • Page 31 MV Agusta recommends not to use WARNING If you find that the wheel rim is dam- balancing or balancing/sealing fluids.

  • Page 32: Checking And Lubricating The Drive Chain

    If the distance is greater than 108 mm, have the chain adjusted by your local MV Agusta dealer. - 31 -...
  • Page 33 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.
  • Page 34 MAINTENANCE Lubrication To ensure proper operation, the drive chain needs to be properly lubricated. Preliminary cleaning - Before lubrication, the dirt accumulated on the chain must be dissolved using kerosene. The dirt must then be removed with a clean rag and/or an air jet. CAUTION The chain is of the O-ring type.
  • Page 35 MAINTENANCE Lubrication - Apply a slight and uniform film of lubricant over the whole of the drive chain, taking care not to smear the surrounding parts, and in particular the tyres. Direct the lubricant jet on the internal links, in order to lubricate the surface of the O-Rings and penetrate inside the chain roller.

  • Page 36: Checking The Idle Speed

    MAINTENANCE 1.12. Checking the idle speed Check the idle speed when the engine has reached the operating temperature. The idle speed should range from 1200 to 1400 rpm. If a tune-up is necessary, contact an authorized service centre. - 35 -...

  • Page 37: Replacing Parts - General Information

    MAINTENANCE 1.13. Replacing parts - General information 1.13.1. Replacing the fuses The battery recharge fuse is located on the The fuses can be replaced by the rider following solenoid starter of the motorcycle. To access it, the instructions properly. The lighting devices remove the passenger seat and the rider seat.
  • Page 38 MAINTENANCE CAUTION Spare fuse (30 A) Turn the ignition key on the “OFF” posi- tion before checking or replacing the Recharge fuse (30 A) fuses, in order to avoid a short circuit with subsequent damage to other elec- tric parts of the motorcycle. To make things easier remove the solenoid starter connector.
  • Page 39 MAINTENANCE The service fuses are located under the rider seat, near the ignition contactor. Release the two clamps and lift the fuse box cover. 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.
  • Page 40 MAINTENANCE To identify the position and function of the fuses, refer to the information shown in the enclosed electrical diagram. The reference letters F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 in the figure correspond to those shown in the dia- gram.

  • Page 41: Battery

    Always have the battery replaced by HIGHLY TOXIC AND CORROSIVE sub- your local MV Agusta dealer. stance. Avoid any contact with your eyes, skin and clothes. Always wear protective glasses when you have to work near the battery.
  • Page 42 MAINTENANCE Prolonged inactivity WARNING: The inversion of the battery wires can damage the battery and the If the motorcycle is to remain unused for a long recharging system. The red wire must time (a month or longer), it is advisable to discon- be connected to the positive terminal nect the battery cables or have the battery (+), while the black wires must be con-...

  • Page 43: Cleaning The Motorcycle

    MAINTENANCE 1.15. Cleaning the motorcycle Periodic careful cleaning is a key fac- tor in preserving the value of the motorcycle, protecting its surface fin- ish and checking for damages, wear and leakage of corrosive fluids. CAUTION: Before washing the vehicle, stop up the exhaust pipes and protect the electrical parts.
  • Page 44 MAINTENANCE Wash the motorcycle with water, a mild detergent possible with cold water. Do not use hot water as and a sponge. Wipe the vehicle with a soft cloth. it enhances the corrosive action. Use an air jet to dry difficult-to-reach areas. WARNING: Avoid smearing brakes or CAUTION tyres with oil or wax.

  • Page 45: Prolonged Inactivity

    MAINTENANCE 1.16. Prolonged inactivity If the motorcycle is to remain unused for a long time, it is advisable to carry out the following operations: Empty the fuel tank. Remove the battery and store it in a suitable place. Recharge the battery every month. Remove the spark plug caps and the spark plugs.

  • Page 46: Troubleshooting Flow Chart

    TROUBLESHOOTING FLOW CHART 2.1. Engine problems: ENGINE DOES NOT START The battery Replace the battery charging fuse is Problem solved Engine starts charging fuse (§1.13.1) Return the engine stop Engine stop switch Problem solved Engine starts switch in rest position depressed Disengage gears or Gears engaged and...
  • Page 47 Replace fuses F1, F2 Fuses F1, F2 and Problem solved Engine starts and F5 (§1.13.1) F5 are OK Recharge the battery The battery is Problem solved Engine starts (§1.14) charged Contact a MV Agusta authorized service centre - 46 -...
  • Page 48 ENGINE SHUTS OFF DURING RIDING Refuel Fuel tank empty Engine is running Problem solved Replace fuses Fuses F1, F2 and Engine is running Problem solved F1, F2 and F5 (§1.13.1) F5 are OK Contact a MV Agusta authorized service centre - 47 -...
  • Page 49 TROUBLESHOOTING FLOW CHART ENGINE OVERHEATS Contact a MV Agusta Coolant level is authorized service centre correct (§1.6.) Engine cools Replace fuse F7 Fuse F7 Problem solved down to operat- (§1.13.1.) is OK ing temperature Contact a MV Agusta authorized service centre...
  • Page 50 TROUBLESHOOTING FLOW CHART OIL PRESSURE IS TOO LOW (Engine oil pressure warning light is on with the engine running) Have the oil level Oil pressure is Oil level is correct restored by a MV Agusta Problem solved optimal (§1.5.) authorized service centre...

  • Page 51: Electrical Equipment Problems

    LIGHTS DO NOT WORK Replace fuse(s) F4 and The fuses F4 e Problem solved Lights work F5 (§1.13.1.) F5 are OK Replace bulb(s) Problem solved Bulbs are OK Lights work (§1.13.) Contact a MV Agusta authorized service centre - 50 -...
  • Page 52 TROUBLESHOOTING FLOW CHART HORN DOES NOT WORK Fuse F6 Replace fuse F6 Problem solved Horn works is OK (§1.13.1) Contact a MV Agusta authorized service centre DASHBOARD DOES NOT WORK Fuse F5 Replace fuse F5 Problem solved Dashboard works is OK (§1.13.1)

  • Page 53: Technical Information

    TECHNICAL INFORMATION 3.1. Motorcycle overview (N) Dashboard (B) Ignition - Power supply (F) Frame (I) Battery (G) Front suspension (E) Cooling system (P) Side cases (L) Front brake (D) Final drive (A) Engine (C) Gearbox (M) Rear brake (O) Exhaust system (H) Rear suspension - 52 -...
  • Page 54 TECHNICAL INFORMATION A - Engine: four-stroke, inline three-cylinder. H - Rear suspension: progressive, with single- Double-overhead camshaft valve train. Wet sided swingarm and single shock absorber sump lubrication. with external adjusting system (TV Lusso: electronic adjustment). B - Ignition - Power supply: integrated ignition- injection system.

  • Page 55: Braking System (Abs)

    TECHNICAL INFORMATION 3.1.1. Braking system (ABS) 1 Brake master cylinder 2 Brake lever 3 Brake line 4 Brake caliper 5 Brake disc 6 Brake fluid reservoir 7 ABS unit - 54 -...

  • Page 56: Engine Lubrication

    TECHNICAL INFORMATION 3.1.2. Engine lubrication 1 Oil sump 2 Oil filter - 55 -...

  • Page 57: Coolant Circuit

    TECHNICAL INFORMATION 3.1.3. Coolant circuit 1 Expansion tank 2 Upper radiator 3 Lower radiator 4 Coolant pump - 56 -...

  • Page 58: Fuel System

    TECHNICAL INFORMATION 3.1.4. Fuel system 1 Throttle bodies 2 Fuel pump 3 Fuel line - 57 -...

  • Page 59: Specifications

    TECHNICAL INFORMATION 3.2. Specifications Description TURISMO VELOCE 800 TURISMO VELOCE EDITION 1 TURISMO VELOCE LUSSO SPECIFICATIONS Wheelbase (mm) (*) 1475 1475 1475 Overall length (mm) (*) 2125 2125 2125 Max. width (mm) Seat height (mm) (*) Min. ground clearance (mm) (*) Trail (mm) (*) * : The indicated values must not be intended as binding informations. They can change according to the vehicle setup. - 58 -...
  • Page 60 TECHNICAL INFORMATION Specifications Description TURISMO VELOCE 800 TURISMO VELOCE EDITION 1 TURISMO VELOCE LUSSO Dry weight (kg) Fuel tank capacity (l) (*) Reserve fuel (l) (*) Oil in crankcase (l) ENGINE Type Three-cylinder, four-stroke, 12 valves Bore (mm) Stroke (mm) 54,3 54,3 54,3 Total displacement (cm Compression ratio 12,2 : 1 12,2 : 1...
  • Page 61 TECHNICAL INFORMATION Specifications Description TURISMO VELOCE 800 TURISMO VELOCE EDITION 1 TURISMO VELOCE LUSSO LUBRICATION Type Wet sump Wet sump Wet sump IGNITION - POWER SUPPLY Type Integrated ignition-injection system MVICS 2.0 (Motor & Vehicle Integrated Control System) with three injectors. Eldor EM2.0 ECU; full drive throttle body by wire Mikuni; pencil-coils with “ion-sensing”...
  • Page 62 Hydraulic Sachs semi-active upside down rods and external upside down rods and external fork with upside down and separated adjustment of and separated adjustment of rods MVCSC (MV Agusta rebound and compression rebound and compression Chassis Stability Control) damping and of spring preload damping and of spring preload...
  • Page 63 MVCSC (MV Agusta Chassis Stability Control) Swingarm Aluminium alloy Aluminium alloy Aluminium alloy...
  • Page 64 TECHNICAL INFORMATION Specifications Description TURISMO VELOCE 800 TURISMO VELOCE EDITION 1 TURISMO VELOCE LUSSO Inflating pressure (*) Rider only With rider and bags With passenger With passenger and bags Front 2.6 bar (38 psi) 2.6 bar (38 psi) 2.6 bar (38 psi) 2.6 bar (38 psi) Rear 2.6 bar (38 psi) 2.7 bar (39 psi)
  • Page 65 TECHNICAL INFORMATION Specifications Description TURISMO VELOCE 800 TURISMO VELOCE EDITION 1 TURISMO VELOCE LUSSO BODYWORK Side fairings Thermoplastic material Thermoplastic material Thermoplastic material Front fairing Thermoplastic material Thermoplastic material Thermoplastic material Rear fairings Thermoplastic material Thermoplastic material Thermoplastic material Fuel tank Thermoplastic material Thermoplastic material Thermoplastic material Air-box Thermoplastic material Thermoplastic material...
  • Page 66 TECHNICAL INFORMATION Specifications Description TURISMO VELOCE 800 TURISMO VELOCE EDITION 1 TURISMO VELOCE LUSSO EQUIPMENT Standard accessories Immobilizer Immobilizer Immobilizer Bluetooth connection Bluetooth connection Bluetooth connection Adjustable windscreen Heated grips Integrated GPS Central stand Central stand Side bags (30 l each) Adjustable windscreen Navigator kit Garmin Zumo 390 navigator Adjustable windscreen Optional Side bags (30 l each)
  • Page 67 TECHNICAL INFORMATION - 66 -...

  • Page 68: Bodywork Parts Reference Colours

    TECHNICAL INFORMATION 3.3. Bodywork parts reference colours Bodywork parts are painted with the following reference colours, according to the corresponding motor- cycle colour combination: 1. - Front fairing; 7. - Right side fairing; 2. - Windscreen support; 8. - Left side fairing: 3.
  • Page 69 TECHNICAL INFORMATION - 68 -...

  • Page 70: Frame Parts Reference Colours

    TECHNICAL INFORMATION 3.4. Frame parts reference colours Frame parts are painted with the following reference colours: 1. - Frame: 3. - Left frame side plate; 4. - Right frame side plate; - Turismo Veloce 800 / Edition 1 / Lusso 5.
  • Page 71 Assistance operators to use the vehicle and dispose of its replaced parts respecting the laws in force con- cerning environmental pollution and waste disposal and recycling. © 2015 This document may not, in whole or in part, be reproduced without prior consent, in writing, from MV Agusta S.p.A. Part. n° 8000C0119 Edition n° 1 - March 2015...

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