Page 2 © 2014 The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta Motor S.p.A. Part no. 8A00B7596 - Edition no. 2 Printed – January 2014...
Page 3 Motorcycle workshop manual MV AGUSTA BRUTALE 675 - BRUTALE 800 - DRAGSTER 800...
Page 4 Everything that we do has repercussions on the entire planet and its resources. MV Agusta, wanting to protect the interest of the people, would like to make the client and the technicians of the technical assistance centres aware and to adopt modalities of use of the motorcycle and the disposure of its parts in full respect of the norms in force in terms of environmental pollution, disposal and the recycling of waste.
Page 5 General Index GENERAL DESCRIPTION..................Rev. 0 MAINTENANCE ......................Rev. 1 BODYWORK ......................Rev. 2 AIR INTAKE INJECTION SYSTEM ................Rev. 1 ELECTRICAL SYSTEM .................... Rev. 2 SUSPENSION AND WHEELS .................. Rev. 1 FRAME ........................Rev. 1 BRAKES........................Rev. 1 COOLING SYSTEM ....................Rev.
Page 7 General description SECTION Revision 0 - 1 -...
Page 8: Table Of Contents
General description SUMMARY HOW TO CONSULT THIS MANUAL ........... . .PAGE 3 THE PURPOSE OF THIS MANUAL .
Page 9: How To Consult This Manual
All information, instructions and technical data included in this manual are based upon information on the prod- uct updated at the moment of going to print. MV Agusta Motor S.p.A. reserves the right to carry out changes at any moment without prior notice and without incurring any obligation.
Page 10: Glossary And Symbols
General description GLOSSARY AND SYMBOLS This signifies that the lack ATTENTION incomplete Use the recommended suspension fluid. obser vance of this advice can be gravely dangerous for your safety and for the safety of other persons. This signifies that the lack Use the recommended coolant.
Page 11: Right Hand And Left Hand Standard
General description RIGHT HAND AND LEFT HAND STANDARD To clarify the right hand and left hand standard that is used in this manual, herewith below is a diagram of the motorcycle and the engine against which are indicated the right and left sides. Cylinder 3 Cylinder 2 Cylinder 1...
Page 12: Safety
• Used oil contains dangerous substances and poisonous for the environment. To substitute oil, it is recommended to go to an authorised MV Agusta dealer who is equipped to deal with the collection of used oil in respect of the norms in force.
Page 13 • The battery contains dangerous substances that are poisonous for the environment. It is advisable to substitute it at an MV Agusta dealer that is equipped to dispose of this product in respect of the norms in force. • Do not dispose of used batteries in the environment.
Page 14: Index
• Slackening or tightening nuts or screws, always start with those of a greater dimension or from the centre. Always respect the torque values indicated. • Utilise only MV Agusta spare parts. INDEX GENERAL INDEX SUMMARY OF EACH CHAPTER...
Page 15: Operative Technical Specifications
General description OPERATIVE TECHNICAL SPECIFICATIONS MOTORCYCLE IDENTIFICATION The registration number of the motorcycle is stamped on the right side of the steering head. The engine registration number is stamped on the upper engine casing, near the swingarm. 2) Engine registration number 1) Frame registration number 3) Homologation date Below is an example of the designation of the frame registration number:...
Page 16 General description - 10 -...
Page 17 Maintenance SECTION Revision 1 - 1 -...
Page 18 Maintenance SUMMARY TECHNICAL INFORMATION ............PAGE 3 TECHNICAL DATA .
Page 19: Technical Information
Maintenance TECHNICAL INFORMATION TECHNICAL DATA Description BRUTALE 675 BRUTALE 800 DRAGSTER 800 CHARACTERISTICS Wheelbase (mm) (*) 1380 1380 1380 Total length (mm) (*) 2085 2085 2060 Maximum width (mm) Seat height (mm) (*) Ground clearance (mm) (*) Trail (mm) (*)
Page 20 Maintenance TECHNICAL DATA Description BRUTALE 675 BRUTALE 800 DRAGSTER 800 TIMING Type Double-overhead camshaft LUBRICATION Type Wet sump IGNITION - FUEL FEED SYSTEM Type Integrated ignition-injection system MVICS with three injectors. Engine control unit Eldor EM2.0; Mikuni full drive by wire throttle body; pencil-coils with “ion-sensing” technology, control of detonation and misfire.
Page 21 Maintenance TECHNICAL DATA Description BRUTALE 675 BRUTALE 800 DRAGSTER 800 TYRES Front 120/70 ZR 17 M/C (58 W) 120/70 ZR 17 M/C (58 W) 120/70 ZR 17 M/C (58 W) Rear 180/55 ZR 17 M/C (73 W) 180/55 ZR 17 M/C (73 W)
Page 22: Periodical Maintenance Schedule
Everything that we do has repercussions on the whole planet and on its resources. MV Agusta, to protect the interests of the everyone, ask clients and technical assistance operators to use the motorcycle and dispose of its used parts with respect to the norms in force in terms of environmental pollution, disposal and recycling of refuse.
Page 23 Maintenance Programmed maintenance schedule 1000 6000 12000 18000 24000 30000 36000 Km (mi) covered (600) (3800) (7500) (11200) (14900) (18600) (22400) Pre- Service delivery Description Operation Check / adjust Transmission and flexible controls Check / adjust Drive chain Lubricate Substitution Check Front sprocket / stop washer Substitution...
Page 24: Maintenance And Tuning Operations
D.I.D. CHAIN LUBE – * : To find the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers. The eni i-Ride moto2 5W/40 engine oil has been manufactured for the Brutale motorcycle engine. If the described oil is not available, MV Agusta suggests using completely synthetic oils with char- acteristics equal or better than the ones prescribed in the following standards: –...
Page 25 Maintenance Place a container underneath the engine to collect the used oil. Remove the oil discharge plug (2). Recover the oil in an appropriate container. Do not scatter the drainage oil into the envi- ronment. Allow the lubrication system to drain completely. Substitution of the oil filter Remove the 3 fixing screws (3) of the oil filter cover.
Page 26 Maintenance Replace the oil filter and put the cover back on. Torque pressure for cover oil filter screws: 10 N·m 10 N•m On the oil discharge plug there is a magnet to attract any metal residues that could form in the engine during rotation.
Page 27: Engine Coolant
Maintenance Switch on the engine for several minutes. After switching off the engine, wait at least ten minutes and then check the oil level. Ensure that the motorcycle is placed on level ground and is in a vertical position. The level must be within the “MIN” and “MAX” refer- ences marked on the cap rod.
Page 28 Maintenance If the level is under the minimum line, proceed with top- ping-up as follows: With the engine cold, unscrew and remove the coolant filler cap (2). Using a syringe, top up with the recom- mended coolant on page B-8. Tightening torque of expansion vessel side cap: 8 N·m 8 N•m...
Page 29 Maintenance Engine coolant substitution Substitution‹ every two years Before emptying the plant, first perform the following operations: remove the right radiator panel (see figures to the side); place a container under the engine to collect the used coolant; remove the liquid drain screw (1) letting the liq- uid flow out;...
Page 30 Maintenance Check the level of the coolant in the radiator once again, keeping the connection tube to the expansion vessel closed with the specific rubber hose pliers. Should the level be too low, open the connection tube to the expansion vessel and let liquid flow out until the preset level.
Page 31: Electric Cooling Fan
Maintenance ELECTRIC COOLING FAN Check ‹ on pre-delivery and at the first 1000 kilometres and then every 6000 kilome- tres. To carry out the check on the functioning of the electric cooling fan, switch on the engine and heat it up. The electric fan must start up when the water temper- ature reaches the 5th or 6th notch on the dashboard.
Page 32 Maintenance After having removed the indicated components, the motorcycle is shown in the condition described by the photograph on side. Before proceeding with the various maintenance oper- ations, it is advisable to thoroughly wash and clean the motorcycle. Place the motorcycle (now without the components list- ed above and clean) on a workstation as indicated in the figure.
Page 33 Maintenance Disconnect the coil connector in three phases: a) move the “Secondary Lock” back. b) press the retainer clip. c) disconnect the connection. - 17 -...
Page 34 Maintenance The support remains connected with the three connec- tors linked to the coils. Remove the tappet cover acting on the 6 screws. Operating as shown in the figure, slightly lift up the cylinder head cover. To carry out this operation, use only the work surfaces indicated.
Page 35 Maintenance Remove the engine head cover. Complete removal of the engine head cover by tilting it towards the right side of the vehicle. To adjust the play of the tappets see the procedure in Engine Workshop Manual (Part. Code 8000B6231). Remove the head cover gasket.
Page 36: Spark Plugs
Maintenance Timing chain, mobile timing chain guide and timing chain tensioner Timing chain and mobile timing chain guide: Check ‹ Every 12000 kilometres Substitute ‹ Every 36000 kilometres Timing chain tensioner: Check / substitute ‹ Every 12000 kilometres To disassemble these parts and not being a part of nor- mal maintenance, it is necessary to proceed as described in the overhaul section of the B3 workshop engine manual (Part.
Page 37 Maintenance Heat Grade Check the heat grade of the spark plugs. Spark plug (as an alternative): - NGK CR9 EKB - NGK CR9 EIB-9 DO NOT use non-resistive spark plugs. Spark plug gap If appropriate (see Technical Data table), measure the spark gap with a thickness metre. Adjust the gap if necessary on the basis of the following information: Spark plugs...
Page 38: Fuel Filters
Maintenance FUEL FILTERS Substitute ‹ Every 50.000 km For the substitution of the engine intake system filters (fuel filter, fuel pump filter), it is necessary to remove in sequence the following parts: • Saddle • Radiator side panels • Airbox side panels •...
Page 39 Maintenance Removing the fuel pump unit Lift the tank and proceed with the removal of the 6 screws (1) that hold down the retaining flange of the "Fuel pump" unit. Take the flange (2) out if its place. Using a screwdriver open the edge of the gasket and gently create leverage between the gasket and the flange until you feel the unit move.
Page 40 Maintenance Take the "Fuel pump" unit out by hand. Check and replace the gasket Check the state of the sealing gasket (1) on the petrol pump unit. Make sure that the gasket is perfectly intact and lubri- cate it by applying silicone grease. If it is damaged, change it for a new one.
Page 41 Maintenance Cut the 2 straps on the electric cabling (2) and (3). Disconnect the cabling (4) from the probe. Detach the unit by pulling from both sides. - 25 -...
Page 42 Maintenance Disconnect the cabling from the flange part by lifting the flaps and taking out the connector. Unweld the thermistor from the support bracket. Replace it with a new part and put it back in place by following the disassembly operations in reverse order. Replacement the fuel filter Remove the 2 self-tapping screws (1).
Page 43 Maintenance Cut the 2 straps on the electric cabling (2) and (3). Disconnect the cabling (4) from the probe. Detach the unit by pulling from both sides. - 27 -...
Page 44 Maintenance To remove the filter take off the strap (5) and slid the tube out (6). Take the O-ring (7) off of the front of the filter and slid the clamp off (8). Replace the filter with a new one. Insert the tube into the new filter and secure it with a new strap taken from the new supply kit, using the required tool.
Page 45: Fuel Pump Assembly
Maintenance FUEL PUMP ASSEMBLY Code Q.ty Note BRUTALE 675 BRUTALE 800 DRAGSTER 800 I FRAME I I ENGINE I 8000B4722 • • • 8000B5991 • • • 8000B4723 • • • 8000B7161 • • • 8000B7162 • • • - 29 -...
Page 46 Maintenance Installing the fuel pump unit Position the fuel pump unit inside the fuel tank. Be careful of the filter, positioning the electric connec- tor in a vertical position. Set the flange (1) up on the pump unit aligning it with the threaded holes on the tank.
Page 47: Check, Disassembly And Reassembly Fuel Pipe/Fittings
Maintenance CHECK, DISASSEMBLY AND REASSEMBLY FUEL PIPE/FITTINGS Check for leaks ‹ First 1000 kilometres and then every 6000 kilometres Carry out a visual check for eventual leakages from the fuel feed tubing and the unions (see figure). Substitute damaged parts if leaks or evaporation are found.
Page 48 Maintenance Replacing fuel pipe from throttle body Press the two stop buttons simultaneously and pull the pipe off. To reassemble the Airbox pipe, insert the fuel pipe in the fitting on the throttle body until you hear it lock. UTILISE ONLY NEW PARTS. To reassemble the tank pipe, press the outer flange and insert the pipe.
Page 49: Checking Engine During Idle
BRUTALE 675: Engine rpm 1400 ± 50 rpm Adaptive lambda check...
Page 50 Maintenance Air Filter Check/substitute ‹ Every 6000 kilometres The left Airbox panel (1) must be removed to access the air filter as shown in the figure. Remove the left air conveyor (2) by removing the three screws. Remove the air filter (3) by sliding it out from the left airbox intake hole.
Page 51: Brakes
Maintenance BRAKES Check the levels of fluid in the systems‹ At pre-delivery, at first 1000 kilometres and then every 6000 kilometres. Check for leakages‹ At pre-delivery, at first 1000 kilometres and then every 6000 kilometres. Substitute fluid‹ Every 24000 kilometres or at least every two years.
Page 52 Maintenance Add brake fluid until the correct level is reached in the chamber. Recommended brake fluid: AGIP Brake 4 Do not use brake fluid that comes from old containers, has already been used or does not come from a sealed container. Do not use brake fluid that is left over from previ- ous maintenance or stored for long peri- ods.
Page 53 Maintenance Checking the level of the rear brake fluid No parts of the vehicle need to be removed from the vehicle to check the level of the rear brake fluid. If the fluid is below the low level mark, follow these steps to top up with brake fluid complying with the specifications: - Remove the oil tank (1) from the frame plate followed...
Page 54 Maintenance - Place the tank with a strap and a protective cloth, securing it to the plate of the frame. The fluid in the braking circuit is highly cor- rosive. Avoid any contact with eyes, skin and mucous membranes. In case of accidental contact, wash thor- oughly with water and consult a doctor.
Page 55 Maintenance Before closing the tank make sure its parts are intact. Secure the rear brake fluid tank to the plate and then to the frame plate applying the fluid thread lock on the threads of the fixing screw and the tightening torque indicated: Torque pressure: 8 ÷...
Page 56: Brake / Clutch / Gearchange Commands Check
Maintenance BRAKE / CLUTCH / GEARCHANGE COMMANDS CHECK It is possible to adjust the position of the front brake lever, of the clutch and of the gear. Such adjustments have been created to optimise the grip and the move- ment of the commands with regards to the needs of the motorcyclist.
Page 57 Maintenance If the measurement differs by ±1 mm it is possible to act on the register located on the handlebar control. For greater differences set the register on the handle- bar at the indicated measurement of 22 mm. Adjust the main register sheltered by the clutch cover by acting on the two nuts, in order to restore the initial play of 3 mm measured on the lever.
Page 58 Maintenance Adjusting the gear lever To adjust the gear lever it is necessary to: 1) Remove guard (1) by removing the two screws (2). 2) Slacken the two counter nuts (3) (rh thread) and (4) (lh thread). 3) Screw/unscrew by hand the gearbox transmission rod (4) until the lever reaches the desired position.
Page 59: Brake Pads
Maintenance BRAKE PADS Wear check / substitute ‹ At the first 1000 kilo- metres and then every 6000 kilometres Check the condition and thickness of the brake pads on the calipers. Front brake caliper Rear brake caliper Measure the thickness of the pad linings. If the thick- ness of the linings is equal to or less than the wear limit shown below, replace the pads as described in chapter H “Brakes”.
Page 60: Locks
Maintenance LOCKS Check ‹ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilo- metres. Ignition/steering block switch This switch has three operating positions. Do not attach key rings or other objects to the ignition key that could obstruct the rota- tion of the steering.
Page 61 Maintenance “LOCK” position Turn the handlebar left or right. Press the key down and rotate it to the “LOCK” position. All electrical circuits are disactivated and the steering is blocked. The key can be pulled out. “LOCK” position Left side Right side Fuel cap lock Lift up the anti-dust cover.
Page 62 Maintenance After refuelling, press the cap down and rotating the key contemporaneously to facilitate the closure. Let the key go free, bring it into a longitudinal position and pull it out. If the fuel filler cap does not function (the cap does not close, the lock blocks, etc.) substitute it with a new one as described in chapter C “Bodywork”.
Page 63: Steering
(see chapter F “Suspension and wheels”). The axis of the chain lower portion must be at a “X” distance from the lower chain guard. - BRUTALE 675: X = 112 mm “X” - BRUTALE 800 - DRAGSTER 800:...
Page 64 Maintenance Regulation‹ At the first 1000 kilometres and then every 6000 kilometres. To adjust the chain tension, proceed as follows: Loosen the 2 rear wheel hub screws. Using the special spanner as indicated in the figure, move the eccentric adjuster nut backwards or forwards respectively slackening or tightening the chain, until the correct play is reached (as described previously).
Page 65 Maintenance Chain lubrication Lubricate‹ At the first 1000 kilometres and at 6000 kilometres and then at every 12000 kilometres. The chain is of the O-ring type. Clean the chain with a clean cloth and/or a jet of air. Apply the lubricant after cleaning. Utilise only the recommended lubricants or the equivalent (see page B-8).
Page 66: Tyres
Therefore maintain the correct tyre pressures to obtain better roadholding and the maximum wear from the tyres. The cold tyre pressures are indicated in the table. Tyre pressures BRUTALE 675 BRUTALE 800 DRAGSTER 800 Brand and PIRELLI - Diablo PIRELLI - Diablo...
Page 67: Wheels
Maintenance WHEELS Visual check ‹ At the first 1000 kilometres and then every 6000 kilometres (at least every tyre change). After having visually checked or following even light collision damage, it is necessary to check the planari- ty, the eccentricity and the ovalisation of the wheel. See the control procedures described in chapter F “Suspension and wheels”.
Page 68: Rear Shock Absorber
Carry out a check on the length of the rear shock absorber spring; check for leakages and trickles of oil and also check the adjustment function. Standard spring adjustment “A”: - BRUTALE 675 (MY13): A = 174 mm - BRUTALE 675 (MY14): A = 175 mm...
Page 69 Maintenance To remove the stand, follow these steps: - after having removed the kickstand switch, remove the screw (3); - remove screw (4). To refit the stand, follow the same steps in reverse order, taking care to tighten the screws to the pre- 40÷44 N•m scribed torque.
Page 70 Maintenance - using the specific tool, unhook the 2 springs (1); The substitution of the springs must be car- ried out utilising the appropriate tool. Before reattaching the springs, ensure that the stand can swing freely (with no friction or sticking). - remove the hinge plate (2);...
Page 71: Front Forks
Maintenance FRONT FORK Substitute oil ‹ every 24000 kilometres The front fork is vitally important for the handling and stability of the motorcycle. It is therefore necessary to substitute the fork oil at the prescribed intervals. To substitute the fork oil and to do a complete overhaul of the forks, carry out the described operations in chap- ter F “Suspension and wheels”.
Page 72: Battery
Maintenance BATTERY Check and clean connections ‹ At the first 1000 kilometres then every 6000 kilometres. Consult chapter E “Electrical system” for the check on the battery condition. If it is necessary to disconnect the battery and remove it during overhauls carried out on the motorcycle, fol- lowing the steps below.
Page 73 Maintenance When it has been mounted, place the protective cap on the positive pole (see figure). Mount the negative terminal (-) on the relative pole of the battery as shown in figure. Turn the screw of the negative terminal and perform the prescribed tightening torque, using a torque wrench.
Page 74 Battery charge indicator (red) Lights up when the alternator does not supply enough current to charge the battery. - BRUTALE 675 / 800 MY14 - DRAGSTER 800: ABS* warning light (orange) Lights up when the ABS system has a fault or is deactivated or the speed is lower than 5 km/h.
Page 75 Maintenance Multifunction display 10 Gear display It displays the currently engaged gear. “N” stands for “neutral”. 11 Control unit mapping display Indicates the number of the control unit mapping currently selected. 12 Speedometer It displays the speed of the motorbike. It can be given in kilometres per hour (Km/h) or in miles per hour (Mph).
Page 76 Maintenance Selecting and setting the display functions Some of the main measurements of the instruments may be changed. The available options include: - Select an operating mode: “RUN” (Odometer) “SPEED LIMITER” “TC” (Traction control) “CHRONO” (Chronometer) “QUICK SHIFT” * “ABS” (Antilock braking system)* “CLOCK”...
Page 77 Maintenance q “RUN” mode In addition to the speedometer, the display shows the following functions: • Total odometer “TOTAL” • Trip counter 1 “TRIP 1” As an alternative: • Total odometer “TOTAL” • Trip counter 2 “TRIP 2” q “SPEED LIMITER” mode This mode adjusts the maximum value of the vehicle speed to your driving requirements.
Page 78 Maintenance q “CHRONO” Mode This mode turns on the Chronometer and saves the recorded information. The following is displayed: • Chronometer Current lap “CURRENT LAP” • Chronometer Fastest lap “BEST LAP” • Chronometer Last lap “LAST LAP” • Rev counter Total laps covered “N° LAP” q “QUICK SHIFT”...
Page 79 Maintenance Trip reset To reset “TRIP 1” and “TRIP 2”, proceed as follows. WARNING The display modes may be changed or set when the engine is off, the gear in neutral, the motorbike stationary with your feet on the ground. The display may not be changed while driving.
Page 80 Maintenance - By pressing the “OK” key for more than three sec- onds, the “TRIP 2” value will be reset to zero. “SPEED LIMITER” mode When starting the engine, the “SPEED LIMITER” func- tion is disabled. In order to activate it, it is necessary to perform the following operations: - Press “SET”...
Page 81 Maintenance - Press “OK” for over three seconds to confirm the selected maximum speed value. The displayed digit stops blinking and the display returns to “RUN” mode. - On the other hand, if you press “SET” for over three seconds, the “SPEED LIMITER” function is disabled. The display shows the “OFF”...
Page 82 Maintenance - Press “OK” for less than three seconds: the traction control level rises up to the next value. On the other hand, by pressing “SET” for less than three seconds, the traction control level decreases to the lower value. Such value may range between 0 and 8.
Page 83 Maintenance - Press the headlight button again to record the time taken to cover the 1st lap. At the same time, the instrument starts recording the time taken to cover the second lap. The time measurement for the first lap is stored in the memory and is visualised on the display for ten sec- onds, after which the time measurement for the follow- ing lap appears.
Page 84 Maintenance - Press “OK” for less than three seconds until “LAPS VIEW” appears. - By repeatedly pressing the key of the flashing high beam headlight, all the times previously acquired starting from the last lap memorised can be displayed in sequence. - Once all the data have been displayed, press the “SET”...
Page 85 Maintenance How to delete data To delete the saved data, proceed as follows: WARNING The display modes may be changed or set when the engine is off, the gear in neutral, the motorbike stationary with your feet on the ground. Do not change the display while driving.
Page 86 Maintenance - Subsequently, by pressing the flashing high beam headlight key followed by the “OK” key for more than three seconds, all the previously acquired times can be cancelled. - Once all the data have been cancelled, press the “SET” key to return to the “SINGLE LAP RESET” mode and then to the following mode.
Page 87 Maintenance - Now, press “OK” for over three seconds to delete the value. Otherwise, press “SET” for less than three sec- onds to stop the deletion procedure. - Once all the data have been cancelled, press the “SET” key to exit the “BEST LAP RESET” mode and then pass to the following mode.
Page 88 Maintenance - By pressing the “OK” key for more than three sec- onds, all the previously acquired times will be can- celled. By pressing the “SET” key for less than three seconds, the cancellation procedure will be interrupt- - Once all the data have been cancelled, press the “SET”...
Page 89 Maintenance Selecting the ABS function ** - Press “SET” in order to access to “ABS” mode; SET- TING ABS” appears on the display. WARNING The display modes may be changed or set when the engine is off, the gear in neutral, the motorbike stationary with your feet on the ground.
Page 90 Maintenance Clock settings - To carry out clock settings, press the "SET" button until viewing the "CLOCK SETTING" caption. WARNING The display modes may be changed or set when the engine is off, the gear in neutral, the motorbike stationary with your feet on the ground.
Page 91 Maintenance How to select the mapping of the control unit On the Brutale and Dragster models it is possible to select different control unit mappings which allow to obtain variable power and performance characteristics based on the type of vehicle use. The mapping selection may be performed NOTE even during the use of the vehicle.
Page 92 Maintenance - Press “SET” until “SETTING C MAP” appears. In order to adjust the “Custom” mapping parameters to your driving requirements, perform the following oper- ations. - Throttle control sensitivity: Press “OK” for less than three seconds until “GAS SENSITIVITY” appears. - Press “SET”...
Page 93 Maintenance - Press “OK” for more than three seconds; the new set- ting will be confirmed. The displayed caption stops flashing and after a few seconds the display returns to “GAS SENSITIVITY” mode. It is now possible to pro- ceed with the setting of the following parameter. - Maximum engine torque: Press “OK”...
Page 94 Maintenance - Press “OK” for less than three seconds; the displayed setting will start flashing. - By repeatedly pressing “OK” for less than three sec- onds, the following settings can be displayed in sequence: • “RAIN” • “SPORT” - Press “OK” for more than three seconds; the new set- ting will be confirmed.
Page 95 Maintenance - Press “SET” for less than three seconds. The display shows the current setting for engine brake. - Press “OK” for less than three seconds; the displayed setting will start flashing. - By repeatedly pressing “OK” for less than three sec- onds, the following settings can be displayed in sequence: •...
Page 96 Maintenance - Engine response: Press “OK” for less than three sec- onds until “ENGINE RESPONSE” appears. - Press “SET” for less than three seconds. The display shows the current setting for engine response. - Press “OK” for less than three seconds; the displayed setting will start flashing.
Page 97 Maintenance - Press “OK” for more than three seconds; the new set- ting will be confirmed. The displayed caption stops flashing and after a few seconds the display returns to “ENGINE RESPONSE” mode. - Engine RPM limiter: Press “OK” for less than three seconds until “RPM LIMITER”...
Page 98 Maintenance - Press “OK” for less than three seconds; the displayed setting will start flashing. - By repeatedly pressing “OK” for less than three sec- onds, the following settings can be displayed in sequence: • “NORMAL” • “SPORT” - Press “OK” for more than three seconds; the new set- ting will be confirmed.
Page 99 Maintenance Warning/malfunction alerts The dashboard may highlight the presence of a fault or a malfunction during different using conditions of the motorcycle. - Engine start: As you turn the ignition switch to the ON position, the instruments and the warning lights will go through the self-diagnostic cycle.
Page 100 Maintenance - After the vehicle is stopped, the display shows the warning message highlighting the vehicle part or device on which the fault has been detected. - High coolant temperature: If a high value of the coolant temperature is detected, the display shows the warning alert shown in the picture.
Page 101 Maintenance q “SERVICE” Mode This operating mode displays the mileage range with respect to expiration of the next scheduled mainte- nance. NOTE When the mileage range upon mainte- nance servicing is less than 1000 km, its relative value automatically appears after the start-up screen of the motorcycle.
Page 102 Maintenance - Press the "OK " button for less than three seconds until the message "SERVICE" is displayed. The mileage range with respect to expiration of the next scheduled maintenance is shown on this screen. - Mileage range resetting: After performing scheduled maintenance, the mileage range must be reset using the following procedure.
Page 103 Maintenance Changing the unit of measurement Allows for simultaneous editing of the following units of measure: • Speed • Distance covered WARNING The modification or adjustment of display functions must be carried out with the engine off and running on neutral, with the motorcycle stopped with the stands on the ground.
Page 104: Lights
Maintenance - Press the "OK " button for more than three seconds and the new unit of measurement configuration will be confirmed. The display returns to the "RUN" mode. LIGHTS Check ‹ At the pre-delivery, at the first 1000 kilometres and then every 6000 kilo- metres.
Page 105 Maintenance - Before removing the headlight from its support, pull out the relay from its holder and detach the connector on the rear side of the headlight. - Place the headlight on a table in order to be able to perform the following operations.
Page 106 Replacing turn indicator bulbs - Front/rear turn indicator bulbs (Brutale 675 / Brutale 800) - Front turn indicator bulbs (Dragster 800) - Remove the fixing screw. - 90 -...
Page 107 - To fit the new bulb, press it and rotate it clockwise. - Replace the lens and insert the fixing screw. Replacing the license plate light bulb (Brutale 675 / Brutale 800) - Remove the fixing screws of the lower cover of the plate holder.
Page 108 Maintenance - Remove the cover complete with plate holder. - Extract the bulb holder pulling it from its seat. - Extract the burnt-out bulb by pulling it from the holder. - Fit the new bulb. - Refit the bulb holder. - Push back the lower cover in touch with the upper surface.
Page 109 Maintenance Replacing the tail light bulb (Brutale 675 / Brutale 800) - Remove the two upper fixing screws of the tail side fairings. - Remove the two fixing screws of the tail lamp. - Detach the tail lamp connector. - Remove the tail lamp by rotating it to free it from his seat.
Page 110 - Reassemble the tail lamp and all the previously removed parts. Replacing the brake light bulb (Brutale 675 / Brutale 800) - Remove the tail lamp as described previously. - To extract the bulb holder, rotate it counterclockwise. - Extract the burnt-out bulb.
Page 111: Fuses
Maintenance FUSES - The battery recharge fuse is located on the solenoid starter, in the position indicated on the right side of the motorcycle. To reach them remove the protective cover by remov- ing the two fixing screws. Solenoid starter CAUTION Turn the ignition key on the “OFF”...
Page 112 Maintenance - The service fuses are located on the right side of the motorcycle. - Unfasten and lift the lid of the fuse box. CAUTION Turn the ignition key on the “OFF” position before checking or replacing the fuses, in order to avoid a short circuit with subse- quent damage to other electric parts of the motorcycle.
Page 113 Maintenance FRONT HEADLAMP Check adjustment ‹ At every variation of the motorcycle set-up. The headlight should be adjusted every time the geometry of the vehicle is altered and before carrying a pillion passenger. The motorcycle is not equipped with external adjusters and the front projector unit is fixed to the frame. Headlight adjustment Place the vehicle at a distance of 10 m from a vertical wall.
Page 114 Maintenance - 98 -...
Page 115 Superstructures SECTION Revision 2 - 1 -...
Page 116 REMOVINg fRONT MUDgUARD (BRUTAlE 675 / 800) ....... . .PAgE...
Page 117: Fairings
Superstructures fAIRINgS - 3 -...
Page 118: Removing Front Mudguard (Brutale 675 / 800)
Superstructures REMOVINg fRONT MUDgUARD (BRUTAlE 675 / 800) Remove the four screws of the mudguard as shown in figure (the screws are mounted with a spacer). Remove the front brake hoses from the clamps mount- ed on the mudguard. Pull off the mudguard towards the front.
Page 119: Removing Headlight
Superstructures Remove the front brake hose from the central clamp mounted on the mudguard. Pull off the mudguard towards the front. When reassembling the parts, take care of the correct disposition of the spacers on the lower fixing points of the mudguard (see picture).
Page 120 Superstructures Disengage the headlight from the support which adjusts the height of the light beam. Disconnect the flashing lights (1). Disconnect the electrical connection (2) and remove the light. - 6 -...
Page 121: Removing Dashboard
Superstructures REMOVINg DASHBOARD Unscrew the fixing screw and remove the dashboard from the low beam support, pulling it upwards and free- ing it from the two pins. Loosen the rubber cap and unhook the connector (1). Unscrew the three fixing screws and remove the dash- board cover.
Page 122: Removing Handlebar
Superstructures REMOVINg HANDlEBAR - Preliminary operations (for all models) Before performing this operation, first disassemble the front low beam, the dashboard and the low beam sup- port (optional) as described in the previous pages. Detach the four main connectors: - 2 located on the right side of the vehicle; - 2 located on the left side.
Page 123 Superstructures Dismantle the clutch protection by removing the screw (1) (only for Brutale 675 / 800). Remove the clutch cable from the throttle as shown in the figure. Remove the front brake pump by acting on the screw (2). Leave the pump unit on the handlebar.
Page 124 Superstructures - Handlebar removal (Brutale 675 / 800) Unscrew the four fixing screws (3) of the two handlebar clamps (two screws for each clamp). Remove the handlebar (4). when reassembling the handlebar, pay attention to the correct positioning of the clamps with reference to the handlebar.
Page 125 Superstructures - Half-handlebars removal/adjustment (Dragster 800) 9 ÷ 10 N•m Unscrew the four fixing screws (1) of the cover plates. when reassembling, tighten the screws at the prescribed torque. Cover plates screws torque: 9 ÷ 10 N•m Remove the two cover plates. Unscrew and remove the two fixing screws (2) of the central plate.
Page 126 Superstructures Once the half-handlebars have been adjusted, insert the screws in the corresponding fixing bores as shown Position “+1” Position “-1” in the picture. Tighten the screws at the prescribed torque. Half-handlebars central plate screws torque: 9 ÷ 10 N·m Apply loctite 243 9 ÷...
Page 127: Removing Rearview Mirrors (Dragster 800)
Superstructures REMOVINg REARVIEw MIRRORS (DRAgSTER 800) Disassemble the brake lever guard by removing the two fixing screws from the RH rearview mirror support. Repeat the operation on the other side of the motorcy- cle for the removal of the clutch lever guard. when reassembling, tighten the screws at the prescribed torque.
Page 128: Removing Low Beam Support And Ignition Switch
Superstructures REMOVINg lOw BEAM SUPPORT AND IgNITION SwITCH Unscrew the three fixing screws and remove the sup- port and the ignition switch. For reassembly, perform the following operations: - apply “Loctite 243” threadlocker fluid on the threaded part of the 3 fixing screws. - position the low beam support underneath the steer- ing base and insert the 3 screws without tightening them.
Page 129: Fuel Tank / Tail Fairings
Superstructures fUEl TANK / TAIl fAIRINgS BRUTAlE 675 / 800 DRAgSTER 800 - 15 -...
Page 130: Removing Underseat Panels And Rear Panels (Brutale 675 / 800)
Before removing the fuel tank, the driver's seat must be removed beforehand. REMOVINg UNDERSEAT PANElS AND REAR PANElS (BRUTAlE 675 / 800) Remove the top two screws (1) of the underseat panel (2) and fairing panel (3) (one screw per panel).
Page 131 Superstructures Pull the fairing panel off (3) disengaging it from the seat B of the 2 pins as shown in the figure. Pull the underseat panel off (2) disengaging it from the seat A of the 2 pins as shown in the figure. Repeat the operation on the other side of the motorcy- cle.
Page 132: Removing Underseat Panels And Rear Panels (Dragster 800)
Superstructures REMOVINg UNDERSEAT PANElS AND REAR PANElS (DRAgSTER 800) Remove the three fixing screws (1) of the underseat panel. Pull out the underseat panel as shown in the picture. Repeat the operation on the other side of the motorcy- cle. Remove the two upper fixing screws (2) of the RH rear panel as shown in the picture.
Page 133 Superstructures Remove the lower fixing screw (3) of the RH tail light. Detach the connector of the RH tail light. Pull out the RH rear panel complete with tail light in the direction shown in the picture. - 19 -...
Page 134: Removing Tail Piece (Dragster 800)
Superstructures Remove the 3 screws (4) which fix the tail light to the rear panel. Pull out the tail light from the rear panel in the direction shown in the picture. Repeat the operation on the other side of the motorcy- cle.
Page 135: Removing Fuel Tank
Superstructures Remove the tail piece (2). REMOVINg fUEl TANK Unscrew and remove the two rear screws (1) fastening the fuel tank to the rear seat rail. Unscrew and remove the two front screws (2) fasten- ing the fuel tank to the frame. - 21 -...
Page 136 Superstructures Working on the side part, unscrew and remove the two screws (3), one on each side. Remove the airbox panel (4) unscrewing the screw (5). Pull the airbox panel off (4) disengaging it from the two pins, pulling it the same direction as the pins. Repeat the operation on the other side of the vehicle.
Page 137 Superstructures Two persons are required for the following operation. When removing the fuel tank, pay attention not to dam- age the frame. Lift the fuel tank and tilt it forward. Disconnect the fuel pipe on the left side. - 23 -...
Page 138 Superstructures Disconnect the electric connection on the pump. Disconnect the overflow pipe on the bottom rear part. To make disengaging fittings from the fuel NOTE pump flange easier, two operators are rec- ommended, one to support the tank and the other to disconnect the quick cou- plings.
Page 139 Superstructures Unscrew and remove the three screws (1) at 120° (the other three screws are fake). 4 ÷ 5 N•m Remove the safety screw (2). When putting the fuel tank cap back on, perform the same operations in the opposite order as when disas- sembling it, being careful to tighten it at the prescribed tightening torque and to apply the indicated thread- locker.
Page 140: Radiator Side Panels
Superstructures RADIATOR SIDE PANElS - 26 -...
Page 141 Superstructures Remove the external screw (1). Remove the two internal screws (2). Disconnect the connector of the front turn signal (3) and remove the panel. - 27 -...
Page 142 Superstructures Remove the screw and pull the air outlet panel out- wards disengaging the two pins from their seats. Repeat the operation on the opposite side. - 28 -...
Page 143: Intake Air System - Airbox
Superstructures INTAKE AIR SYSTEM - AIRBOx - 29 -...
Page 144: Airbox Removal Preliminary Operations
Superstructures AIRBOx REMOVAl PRElIMINARY OPERATIONS Before removing the airbox, you must first remove the fuel tank as described in this chapter. Disconnect the air temperature sensor connector. Disconnect the air pressure sensor and engine phase connector. - 30 -...
Page 145: Airbox Removal
Superstructures Remove the right and left air inlet duct, unscrewing three screws on the side. Remove the air filter. AIRBOx REMOVAl Remove the nine fixing screws on the airbox cover. - 31 -...
Page 146 Superstructures Remove the two front fixing screws. Remove the rear fixing screw. Disconnect the blow-by pipe. - 32 -...
Page 147 Superstructures Lift the airbox. When reassembling it, perform the same operations carried out during disassembly. No. 2 front fixing screws tightening torque: 10 N·m Apply loctite 2400 10 N•m Rear fixing screw tightening torque: 8 N·m 8 N•m - 33 -...
Page 148: Lower Bulkhead And Tail Light
Superstructures lOwER BUlKHEAD AND TAIl lIgHT - 34 -...
Page 149: Removing Lower Bulkhead (Brutale 675 / 800)
(for all models), the tail piece and the tail light (for Dragster 800), refer to the paragraph "Fuel tank / Tail piece" in this chapter. REMOVINg lOwER BUlKHEAD (BRUTAlE 675 / 800) Remove the two screws. Widen the two annexes. Pull out the bulkhead sideways.
Page 150: Removing Lower Bulkhead (Dragster 800)
Superstructures REMOVINg lOwER BUlKHEAD (DRAgSTER 800) Remove the two front lateral screws of the lower bulkhead (no. 1 RH / no. 1 LH). Remove the rear central screw. Remove the 4 lower lateral screws (no. 2 RH / no. 2 LH).
Page 151: Removing Tail Light (Brutale 675 / 800)
Superstructures REMOVINg TAIl lIgHT (BRUTAlE 675 / 800) Remove the three screws (two side and one central). Disconnect the connector. Pull the light from the back. - 37 -...
Page 152: Removing Number Plate Support (Brutale 675 / 800)
Superstructures REMOVINg NUMBER PlATE SUPPORT (BRUTAlE 675 / 800) Disconnect the three connectors of the turn signals and number plate light. Remove the four screws (to any side) holding the sup- port. Pull off the number plate support. - 38 -...
Page 153: Exhaust Protections
Superstructures ExHAUST PROTECTIONS BRUTAlE 675 / 800 DRAgSTER 800 - 39 -...
Page 154: Removing Exhaust Protection (Brutale 675 / 800)
Superstructures REMOVINg ExHAUST PROTECTION (BRUTAlE 675 / 800) Remove the two fixing screws of the exhaust protec- tion on the LH side of the vehicle. Remove the exhaust protection. When reassembling, apply the recommended product on the threads of the screws and tighten the screws at the prescribed torque.
Page 155: Removing Exhaust Protections (Dragster 800)
Superstructures REMOVINg ExHAUST PROTECTIONS (DRAgSTER 800) 8 N•m Remove the front fixing screw of the RH exhaust pro- tection. Remove the two rear fixing screws of the exhaust pro- 8 N•m (lH) tection. 10 N•m (RH) Remove the RH exhaust protection while supporting the rear brake pump.
Page 156 Superstructures - 42 -...
Page 157 Air intake injection system SECTION Revision 1 - 1 -...
Page 158 Air intake injection system SUMMARY INJECTION SYSTEM TECHNICAL CHARACTERISTICS ........PAGE 3 INJECTION TIME COMPENSATION (VOLUME) .
Page 159: Injection System Technical Characteristics
Air intake injection system INJECTION SYSTEM TECHNICAL CHARACTERISTICS INJECTION TIME (INJECTION VOLUME) The factors for the determination of the injection time are the basic injection time that is calculated on the basis of the torque request, the r.p.m., the pressure of the intake duct and various compensations that are determined according to signals coming from various sensors that reveal the condition of the engine and the riding conditions.
Page 160: Injection Time Compensation (Volume)
Air intake injection system INJECTION TIME COMPENSATION (VOLUME) The various sensors allow the injection time (volume) compensations to be carried out on the basis of the fol- lowing signals. SIGNAL DESCRIPTION When the atmospheric pressure is low, the sensor sends a signal to the ECU to reduce the injection ATMOSPHERIC PRESSURE SENSOR SIGNAL time (volume).
Page 161: Fuel Feed System
Air intake injection system FUEL FEED SYSTEM The fuel feed system consists of the tank, pump, filter, feed tube, feed tubes (including the fuel injectors) and the regulator of the pressure. The fuel in the tank is pumped into the feed tubing at a controlled pressure by the rel- ative regulator and maintained at a certain constant value higher than the suction generated by the motor.
Page 162 Air intake injection system FUEL PRESSURE REGULATOR The fuel pressure regulator is a diaphragm pressure release valve that consists of a diaphragm, spring and valve. It always maintains the pressure of the fuel sent to the injector at 3,5 kg/cm (350 kPa).
Page 163: Fuel Pump Control System
Air intake injection system FUEL PUMP CONTROL SYSTEM When the ignition switch is turned to the ON position, the fuel pump motor is started by the current supplied by the battery. As the CPU possesses a timer function, the pump motor stops turning three seconds after the ignition switch has been brought to the “ON”...
Page 164: Ecu (Electronic Control Unit)
Air intake injection system The ECU is situated under the tank behind the battery. The ECU consists of a CPU (Central Processing Unit), a memory unit and I/O sections (input/output). The signal of each individual sensor is sent to the input section and then to the CPU.
Page 165 Air intake injection system 2 INTAKE AIR TEMPERATURE SENSOR The temperature of the intake air is found by con- verting the resistance of the Thermistor into voltage and then sending it to the ECU. The volume of the injection increases when the air temperature is low. The resistance of the Thermistor increases when the air temperature is low and diminishes when the tem- perature is high.
Page 166: Throttle Body Position Sensor
Air intake injection system THROTTLE BODY POSITION SENSORS The throttle position sensors are inside the motor of the throttle body (1). These sensors are potentiometers with a variable resistance based on the opening angle of the acceler- ator and operate in a crossed fashion. The sensors are powered by the ECU at the estab- lished voltage of 5V and provide, in output, a voltage proportional to the throttle angle.
Page 167 Air intake injection system INJECTOR CHECK To check the injectors proceed as follows: - Disconnect the connector on each injector. - Proceed with checking the reel of each injector - The contact must not be open between the two pins of the injector, also, the resistance value must be 11 Ohm ±10% at 20°C.
Page 168 Air intake injection system - If the fuel pump unit does not continue to function correctly after the above-described tests, proceed with relative relay control (1) on the right side of the motorcycle, identified by a ring marked with "I" locat- ed on the cable bundle.
Page 169 Air intake injection system Ignition coils The ignition coils are of the top plug type (they are assembled directly on the spark plugs. This avoids the use of the HT leads and enhance the overall system reliability.. - 13 -...
Page 170: Diagnostics System
Air intake injection system DIAGNOSTICS SYSTEM Ignition and injection system diagnostics For the diagnosis of the ignition and injection system a TEXA diagnostic software is available which is capable of identifying and recording the faults present or that were present previously on the motorcycle. This soft- ware is equipped with a guide book for the use of the software itself to carry out checks on each individual component of the system.
Page 171: Air Intake System Technical Characteristics
Air intake injection system AIR INTAKE SYSTEM TECHNICAL CHARACTERISTICS This motorcycle utilises direct induction in the air intake system. The frontal pressure of the air during normal rid- ing conditions is conducted to the air filter compartment in such a way that the incoming air is pressurised there- by improving the air intake efficiency to obtain greater power from the engine.
Page 172: Positions Of Engine-Control System Parts
Air intake injection system POSITIONS OF ENGINE-CONTROL SYSTEM PARTS - 16 -...
Page 173: Injection System Electrical Diagram
Air intake injection system INJECTION SYSTEM ELECTRICAL DIAGRAM SOLENOID STARTER BATTERY FUEL PUMP, INJECTOR FUSE COIL FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY CLUTCH SWITCH - 17 -...
Page 174 Air intake injection system Engine control unit pinout, MV Agusta Brutale 675 - Brutale 800 - Dragster 800 Connector Vehicle Engine Pin name Description of associated function Type Pin n° Pin n° IN_REL+ INPUT CRANKSHAFT POSITION SENSOR + VRS interface...
Page 175 Air intake injection system Engine control unit pinout, MV Agusta Brutale 675 - Brutale 800 - Dragster 800 Connector Vehicle Engine Pin name Description of associated function Type Pin n° Pin n° OUT_LOW_BEAM OUTPUT LOW BEAM LIGHT RELAY MANAGEMENT CONTROL...
Page 176 Air intake injection system - 20 -...
Page 177 Electrical system SECTION Revision 2 - 1 -...
Page 178 ...............................PAGE 41 ECU DISASSEMBLY ..........................PAGE 41 SWITChES...............................PAGE 42 POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS (BRUTALE 675-800).......PAGE 43 POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS (BRUTALE 675-800 ABS) ......PAGE 56 POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS (DRAGSTER 800)........PAGE 61 - 2 -...
Page 179: Connectors
Electrical system CONNECTORS • When a connector is connected, check that it clicks into position. • Check the connector for corrosion, dirt or a broken cover. CLICK COUPLINGS CLICK • Block couplings – ensure that the block is released before disconnecting it to push it completely home when connecting it.
Page 180: Semiconductor Parts
Electrical system SEMICONDUCTOR PARTS • Do not drop semiconductor parts such as those INCORRECT incorporated in the ECU. • When checking these parts, carry out the instruc- tions to the letter. The lack of using the correct pro- cedure can cause grave damage. - 4 -...
Page 181: Electrical Diagram Brutale 675 / Brutale
Electrical system ELECTRICAL DIAGRAM BRUTALE 675 - BRUTALE 800 47 48 R/G Gy/R LOCK PRESS. R-BK Br-Y V-Gr R-Gr Gr-Bk B-Bk Br-W Br-P Br-B Gr-O B-Bk Gr-Bk Gr-P Br-Y Gy-R Gr-Bk Br-W Y-Bk Sb-Bk Y-Bk Gr-Bk R-Bk Sb-Bk O-Bk Sb-Bk...
Page 182: Parts List
Electrical system Parts list Parts list Ref. Description Ref. Description Front right indicator Front headlight Number plate light Rear right indicator Instrument panel Rear left indicator Air temperature sensor Diagnostic connector Front left indicator Rear and stop light Horn Gear position sensor Air pressure sensor Battery Light switch...
Page 183: Electrical Diagram Brutale 675 / Brutale 800 (Abs)
Electrical system ELECTRICAL DIAGRAM BRUTALE 675 - BRUTALE 800 (ABS) F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 R/G Gy/R F1 F2 F3 LOCK R-Bk Br-Y V-Gr R-Gr Gr-Bk B-Bk Br-W Br-P Br-B Gr-O B-Bk Gr-Bk Gr-P Br-Y...
Page 184: Parts List
Electrical system Parts list Parts list Ref. Description Ref. Description Front right indicator Front headlight Number plate light Rear right indicator Instrument panel Rear left indicator Air temperature sensor CAN line Front left indicator Rear and stop light Horn Gear position sensor Air pressure sensor Battery Light switch...
Page 185: Electrical Diagram Dragster
Electrical system ELECTRICAL DIAGRAM DRAGSTER 800 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F1 F2 F3 - 9 -...
Page 186: Parts List
Electrical system Parts list Parts list Ref. Description Ref. Description Instrument panel Air temperature sensor Number plate light Rear right indicator Front left indicator Rear left indicator Horn CAN line Air pressure sensor Rear and stop light Light switch Gear position sensor “Drive By Wire”...
Page 187: Battery
Electrical system BATTERY The battery mounted on this motorcycle is a sealed battery therefore no maintenance is required. The following battery is used: BS BTZ10S This is a sealed battery with breather valve. No elec- trolyte level checking is required. Never remove the battery seal caps nor block the breather opening.
Page 188: Charging The Battery
Electrical system ChARGING ThE BATTERY The battery is charged by connecting the supplied bat- tery charger to the connector located under the pas- senger seat. If the battery is charged after a period of vehicle downtime, make sure that the charger fuse is placed inside its housing on the remote ignition switch.
Page 189: Removal Of The Battery
Electrical system REMOVAL OF ThE BATTERY To carry out this operation it is necessary to remove the seat, the sides and the tank as described in sec. C (Bodyworks). 1) Remove the negative pole (-) cable screw first. 2) Remove the positive pole (+) cable screw first. 3) Remove the battery by lifting it from its housing.
Page 190: Recharging System
Electrical system • Check the voltage charge after about thirty minutes at the battery terminals. Voltage > 12,5 Volt. ChARGING SYSTEM Warning function Conditions of abnormal operation of the battery charg- ing function (voltage 10V) is indicated by the warning lamp (only for MY13) and the voltage value displayed ≥...
Page 191 Electrical system A list of possible problems that could occur when the warning light is switched on (only for MY13) and the alter- nator is working. RESTORE OR CLEAN CON- WARNING LIGHT STILL ON PROBLEMS OCCUR NECTION WITH CONNECTION SI RISCONTRANO PROBLEMI RIPRISTINARE O PULIRE LA SPIA ANCORA ACCESA SULLA CONNESSIONE...
Page 192 Electrical system BATTERY EFFICIENCY ChECK Battery current loss check • Remove the seat as described in chapter C “Bodywork”. • Turn the ignition switch to the “OFF” position. • Disconnect the cable from the negative (-) pole of the battery. •...
Page 193: Starter System
Electrical system Measure the DC voltage between the positive (+) and the negative (-) terminals of the battery with a multi- tester. If the tester indicates less than 12.6V or more than 14.5V the cause will be found in the generator. When carrying out this check, ensure that NOTE the battery is fully charged.
Page 194 Electrical system SOLENOID STARTER BATTERY FUEL PUMP, INJECTOR FUSE COIL FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY CLUTCH SWITCH - 18 -...
Page 195 Electrical system SOLENOID STARTER BATTERY FUEL PUMP, INJECTOR FUSE COIL FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY CLUTCH SWITCH - 19 -...
Page 196 Electrical system SOLENOID STARTER BATTERY FUEL PUMP, INJECTOR FUSE COIL FUSE FUEL PUMP - COILS - INJECTORS RELAY MAIN RELAY CLUTCH SWITCH - 20 -...
Page 197: Checking The Generator
Electrical system ChECKING ThE GENERATOR • Disconnect the generator connector. • Make sure that there is a resistance of 0.3 Ohm ±10% at 20°C between each of the contacts of the 3 pins (generator line). • Make sure that there is NO continuity between each of the 3 pins and the engine earth.
Page 198: Starter Motor Removal
Electrical system STARTER MOTOR REMOVAL • Remove the fuel tank (see chapter C “Bodywork”). • Remove the battery mounting by unscrewing the three clamping screws (1). • Remove the seat lock plate. • Remove the blow-by tube. • Disconnect the cable of the starter motor. •...
Page 199: Starter Motor Check
Electrical system STARTER MOTOR ChECK If a fault has been diagnosed in the starter motor, it is necessary to proceed as follows with the check: • Connect a tester between earth and the starter motor terminal. • Check that there is continuity between the positive pole and the engine earth.
Page 200: Tilt Sensor
Electrical system • Disconnect the cables (1) of the starter motor and the positive cable of the battery from the relay . Apply 12 volts to the terminals (1) and (2) of the relay and check the continuity between terminals B-M. Do not apply the battery voltage to the starter relay for more than five seconds to avoid overheating and therefore damaging the...
Page 201: Gear Position Switch
Electrical system GEARChANGE POSITION SWITCh The connector (1) of the gear position sensor is locat- ed on the left beneath the tank. Disconnect the connector of the gear position switch and check the resistance value, using a multitester, in the six gears as well as the idle position, as shown in the attached table.
Page 202: Fuses
The charger fuse is located on the remote switch high- er up than the spare fuse. Fuses table (Brutale 675-800 ABS / Dragster 800) Amp. Fuse Application...
Page 203: Spark Plugs
Electrical system SPARK PLUGS Remove the components of the motorcycle to remove the spark plugs as described in chapter B “Mainte- nance”. Remove the spark plugs utilising the appropriate 16mm hexagonal spark plug spanner. Check the resistance between the electrode and the screw cap of the spark plug as shown in the figure.
Page 204: Main Relay
Electrical system MAIN RELAY The main relay relay is on the right side of the battery compartment and it is identified by the “M” letter. To operate the relays conveniently it is necessary to remove the battery and its mounting. Take the general relay out (M) from the connector and check that there is a resistance of 82 Ohm ±10% at 20°C between pins 1 and 3.
Page 205: Engine Pick-Up
Electrical system ENGINE PICK-UP The engine pick-up is situated on the left side of the motorcycle. To check this component it is necessary to identify the relative connector positioned as shown in the figure, inside the frame on the left side of the motor- cycle.
Page 206: Timing Wheel Gap
Electrical system TIMING WhEEL GAP To guarantee the correct functioning of the pick-up it is necessary to measure the gap between the pick-up and the timing wheel by utilising a feeler gauge as shown in the figure. Gap width: 0.6 – 0.7 mm To carry out this check it is necessary to remove the cover of the timing wheel by consulting the Workshop Engine Manual.
Page 207: Instrumentation
Electrical system Remove the connector holding device. With the switch in the RUN position make sure there is continuity between the Y/R (yellow/red) and Y/W (yel- low/white) wires. Holding the START button down, make sure there is continuity between the Y (yellow) and W/R (white/red) wires.
Page 208: Oil Pressure Sensor
Electrical system Consult the diagram below to identify the contacts of 16 pin AMP 174975-2 the various components: Supply Turning led 10 Oil pressure + CAN 11 Ignition key - CAN 12 - SET SWITCH 13 - High beam 14 - Fuel warning led 15 - 16 OK SWITCH...
Page 209: Water Sensor
Electrical system Having ascertained the good condition of the fuses in question, proceed as follows: With the fuel tank removed from the motorcycle and empty of fuel, connect a small circuit composed of 12V battery and a light bulb of 12V – 1.7W to the connector of the fuel level indicator as shown in the diagram.
Page 210: Turn Indicators Check
Electrical system KEY SWITCh Whenever the dashboard, with the switch on the ON position, is not powered, first check the conditions of the fuse located on the starter relay and, if this should be in good condition, check the conditions of the fuse located in position 5 on the fuse box.
Page 211: Speed Sensor
Electrical system SPEED SENSOR Whenever the speed is not indicated on the dashboard and the message SPEED SENSOR appears, proceed as follows: • Check the conditions of the fuse in position 1 on the fuse box. If the fuse in question is in good condition, proceed with the check of the speed sensor as follows: Keeping the sensor connected to the system and with the key ON, use a Tester to make sure that when the...
Page 212: High Beam Headlight
Electrical system hIGh BEAM hEADLIGhT In the event that the driving beam does not work, check the conditions of fuse 4. If the fuse is ok, check the continuity of the left handle- bar control connector between positions between the Y\B (yellow\blue) and the Y (yellow) wires with the dri- ving beam function selected.
Page 213: Turn Indicators
Electrical system After having checked the bulbs of the headlight, the rel- ative fuses and the controls as described herewith, proceed with checks of the relay B on the left side of the motorcycle. TURN INDICATORS In the event that turn indicators do not work, check the conditions of fuse 6 on the fuse box.
Page 214: Tail Light Diagnosis Module (Dragster 800)
Electrical system TAIL LIGhT DIAGNOSIS MODULE (DRAGSTER 800) In order to accede to the tail light diagnosis module, carry out the disassembling of the fixing screws of the RH radiator protection (no.1 upper screw / no.2 lower screws) as described in chap. C - “Superstructures”. Remove the RH radiator protection.
Page 215 Electrical system Pull out the diagnosis module from its support. If it is necessary to replace the diagnosis module, detach the defective part and connect the new module. - 39 -...
Page 216: Licence Plate Light
3 in the fuse box; if these are ok, replace the bulb as shown in Chapter B - Maintenance (only for Brutale 675-800 models). COOLING FAN SYSTEM If there is a fault in the functioning of the cooling fan, proceed with the following check:: •...
Page 217: Horn
Electrical system hORN A fault in the horn system should be checked at various points: • Check the condition of fuse 1 in the fuse box. • If the fuse is in good condition, disconnect the con- nector of the left control and check the continuity between contact 3-4 of the control with the horn but- ton pressed as in the following page under “Switches”.
Page 218: Switches
Electrical system SWITChES Check the continuity of each switch with a tester. If there is any anomaly, substitute the respective switch unit with a new one. R.H. switch L.H. switch - 42 -...
Page 219: Positioning Of Electrical System Wire Clamps (Brutale 675-800)
Electrical system POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS (BRUTALE 675 / 800) LIST OF FASTENING CLAMPS FOR ELECTRICAL SYSTEM CABLES (BRUTALE 675-800) Code Qty. Length Name 800092248 14 (*) L = 82 mm Rubber clamp L 82 800092247 L = 62 mm...
Page 220 Electrical system For the position of the clamps for electrical system fastening for Brutale 675-800 cables, refer to the layout shown below (see figs. 04-35). Battery Starter motor Keep the remote switch cables away from the throt- tle body plate...
Page 221 Electrical system Protection Ø13 L=100 + No. 2 clamps Code 800092661 N.B.: Place the connector in vertical position - 45 -...
Page 222 Electrical system Code Code Note: Be careful to correctly pass cable Code Code NOTE: Place the (Contains the Code clutch cable expansion tank under the breather hose) throttle control cable Code NOTE: Check that the connector does not interfere in the steering Code NOTE: Pay attention to the...
Page 223 Electrical system Code Protection Ø25 L=150 + No. 2 clamps Code 800056783 Note: Place the Protection Ø13 L=150 harness under the + No. 2 clamps Code battery support 800092661 Code Code Note: Be careful to correctly pass the plug-top connector cables - 47 -...
Page 224 Electrical system Protection No. 8F0047859 - L=75 (Apply Loctite 480 both on protection internal side and on crankcase edge) Note: Be careful to correctly pass cables and battery connections Code Code - 48 -...
Page 225 Electrical system Code NOTE: Keep the brake pipe and the harness behind Code the headlight adjustment support (See Fig. 08) NOTE: Keep the har- NOTE: Position the blinker ness separated from rubber support on the the steering limiter - headlight left side - 49 -...
Page 226 Electrical system Note: Recovery of exceeding cabling (only until Rev. C cabling) Code NOTE: Pay attention to the position of the left front turn signal cable Code Code Code Code Code - 50 -...
Page 227 Electrical system Code Code Note: Correct cable routing – L=82 (Contains (only until Rev. C cabling) EAS connector) Code Note: Correct – L=82 (Contains cable routing generator (only from Rev. connector) D cabling) Code – L=25 (only for Rev. A cabling) Note: For “Quick- shift”...
Page 228 Electrical system Code Code Code Code Code Code NOTE: Align the end of vent and drain pipes - 52 -...
Page 229 Electrical system Code Note: Insert the bottom Code edge of the ECU rub- ber support in the crankcase Code Code Note: Be careful to correctly pass cables Protection Ø13 L=150 + No. 2 clamps Code 800092661 - 53 -...
Page 230 Electrical system Note: Keep separated the Code lock transmission from the plate Code Code – L=62 (Contains diagnostic and bat- tery charge cable) Code Note: Keep the harness under the lock transmission near the plate Note: Be careful to correctly pass the saddle lock trans- mission cable Code...
Page 231 Electrical system After assembling the motorcycle make sure to insert the cables of left and right front turn indicators inside the outlet opening side of the radiator protections (see Figs. 36-37). - 55 -...
Page 232: Positioning Of Electrical System Wire Clamps (Brutale 675-800 Abs)
(no. 8000B8834), at a distance of 280 mm from the brake caliper union (see fig. 01). Adhesive protection Code For the position of the clamps for ABS system pipes fastening for Brutale 675-800, refer to the layout shown below (see figs. 02-12). Code...
Page 233 Electrical system Code Remove No.1 (clamps the speed sensor brake pipe cable to the front brake clamp Code hose behind the headlamp) 8000B5906 Code (only for bikes without ABS) Code Place the clutch cable over the ABS pipe - Be careful Code not to interlace each cable with the other...
Page 234 Electrical system Note: Be careful to correctly pass the cables and the ABS pipes Code (already used on bikes Code without ABS) (contains only the (contains only the elec- ABS pipes) tric harness cables) (*): NOTE: All the plastic clamps highlighted with this symbol must not be fixed until the ABS pipes are connected to the unit (see fig.
Page 235 Electrical system Be careful to correctly pass the pipes (left of the power unit and under the battery Code support) L=39 (contains rear brake pipes + electric cables) Code (already used on bikes without ABS) Code Code (already used on (already used on bikes without ABS) bikes without ABS)
Page 236 Electrical system No.1 Protection Ø19 Code L=100 + No. 2 clamps Code 800092661 Code No.1 Protection Ø19 L=100 + No. 2 clamps Code 800092661 - When the pipes positioning and fixing operations have been completed, fix the related unions to the ABS unit placed on its support on the rear frame as shown in fig. 13. Tighten the union nuts at a torque of 18 Nm.
Page 237: Positioning Of Electrical System Wire Clamps (Dragster 800)
Electrical system POSITIONING OF ELECTRICAL SYSTEM WIRE CLAMPS (DRAGSTER 800) LIST OF FASTENING CLAMPS FOR ELECTRICAL SYSTEM CABLES (DRAGSTER 800) Code Qty. Length Name 800092248 L = 82 mm Rubber clamp L 82 800092247 L = 62 mm Rubber clamp L 62 800053724 L = 39 mm Rubber clamp L 39...
Page 238 Electrical system For the position of the clamps for electrical system fastening for Dragster 800 cables, refer to the layout shown below (see figs. 04-44). Battery Starter motor Keep the remote switch cables away from the throt- tle body plate Position the remote switch cables above the cabling of the...
Page 239 Electrical system Protection Ø13 L=100 + No. 2 clamps Code 800092661 N.B.: Place the connector in vertical position - 63 -...
Page 240 Electrical system Code Code Code Code (Contains the expansion tank breather hose) Code Code (Contains the ignition connector - placed behind the frame tube) NOTE: Check that NOTE: Place the the connector does clutch cable under the not interfere in the throttle control cable steering Code...
Page 241 Electrical system Protection Ø25 L=150 + No. 2 clamps Code 800056783 Code Protection Ø13 L=150 + No. 2 clamps Code 800092661 Note: Place the relay connection cable under the battery support Code Note: Be careful to Code correctly pass the plug-top connector cables - 65 -...
Page 242 Electrical system Protection No. 8F0047859 - L=75 (Apply Loctite 480 both on protection internal side and on crankcase edge) Note: Be careful to correctly pass cables and battery connections Code Code - 66 -...
Page 243 Electrical system Code Code NOTE: Keep the electric harness behind the headlight adjustment support (See Fig. 08) NOTE: Keep the har- ness separated from the steering limiter - left side - 67 -...
Page 244 Electrical system Before assembling the brake fluid pipes on the bike, apply no. 1 adhesive protection code no. 8000B4536 on the hose connecting the RH brake caliper and the ABS unit (no. 8000B8814), at a distance of 280 mm from the brake caliper union (see fig. 15). Adhesive protection Code Code...
Page 245 Electrical system Code Code Code Code Code Place the clutch cable over the ABS pipe - Be careful not to interlace each cable with the other (*): NOTE: All the plastic clamps highlighted with this symbol must not be fixed until the ABS pipes are connected to the unit (see fig. 47). Only after having reached the correct disposition of the no.
Page 246 Electrical system Code Note: Pay atten- tion to the posi- tion of the LH front turn indica- tor cable Code Code Code Code Code - 70 -...
Page 247 Electrical system Code – L=25 (For EAS sensor cable) Code – L=82 (Contains Code EAS connector) – L=82 (Contains generator connector) Code Code Code Code Note: Be careful (Contains the fan connector) to correctly pass cables Code Code – L=82 (Contains (Contains the the lambda sensor lambda sensor...
Page 248 Electrical system Code Be careful not to crush the cables and the ABS pipes against the frame when assembling the airbox Note: Be careful to correctly pass the cables and the ABS pipes See Fig. 24 Code (contains only the (contains only the electric cables) ABS pipes)
Page 249 Electrical system Code Code – L=62 (Contains the connectors) Code Code Code NOTE: Align the end of vent and drain pipes - 73 -...
Page 250 Electrical system Note: Pay attention to the correct position of the con- Code nectors on the plate Code Contains: - rear speed sensor cable - rear brake pipe - plate holder lights cable Code Code Note: Pay attention to the cor- Note: Insert the bottom rect position of the gear sensor edge of the ECU rub-...
Page 251 Electrical system Protection Ø13 L=150 + No. 2 clamps Code 800092661 Code Code Code Code Code Note: Be careful to correctly pass the saddle lock trans- mission cable Note: Recharge connector position Code Note: Diagnostics connector position - 75 -...
Page 252 Electrical system Note: Fix the cable to the No.1 Protection Ø13 L=150 L=62 clamp (see Fig.39) + No. 2 clamps Code Note: If necessary, 800092661 slightly round off the sharp edge on the rear frame plate Note: Place the ABS unit cable under the Place the protection at rear frame plate and...
Page 253 Electrical system No.1 Protection Ø19 L=100 + No. 2 clamps Code 800092661 No.1 Protection Ø19 L=100 + No. 2 clamps Code 800092661 (*): NOTE: All the plastic clamps highlighted with this symbol must not be fixed until the ABS pipes are connected to the unit (see fig. 47). Only after having reached the correct disposition of the no.
Page 254 Electrical system After assembling the motorcycle make sure to insert the cables of left and right front turn indicators inside the outlet opening side of the radiator protections (see Figs. 48-49). - 78 -...
Page 255 Suspension and wheels SECTION Revision 1 - 1 -...
Page 256 Suspension and wheels SUMMARY FRONT WHEEL ..............PAGE 3 FRONT FORKS .
Page 257: Front Wheel
Suspension and wheels FRONT WHEEL N·m 16 ÷ 18 Torque Kg·m pressure ft·lb Operation Description Brutale 675 Brutale 800 Dragster 800 FRONT WHEEL Material Aluminium alloy Aluminium alloy Aluminium alloy Dimensions 3,50” x 17” 3,50” x 17” 3,50” x 17”...
Page 258 Suspension and wheels Before proceeding with the removal and overhaul of the components relative to the front suspension, it is advisable to remove beforehand the front mudguard as described in detail in chapter C “Bodywork”. Place the motorcycle on the rear stand. Special tool N.
Page 259 Suspension and wheels Remove the screw (1) on both front wheel/fork attach- ments. Unscrew the nut from the left side. Holding the wheel up with your left hand, use your right hand to push the pin towards the right part of the motorcycle Take the wheel pin out (2) from the right side, freeing up the wheel.
Page 260 Suspension and wheels Front wheel bearing check With the wheel spindle still mounted to the wheel, rotate the wheel to check that the bearings are not pit- ted and rotate with a smooth action. Check also for axial (A) and/or radial (B) movement. If either condition is verified, substitute the bearings.
Page 261 Suspension and wheels Mount the flange, spacer ring and nut utilising a 14 mm spanner and a 27 mm spanner and extract the bearing as shown in the figure. Operate in the same way on both bearings. NOTE Check that the ends of the aluminium spacer and the seats of the bearings on the wheels are not scored or marked.
Page 262 Suspension and wheels Insert it on the opposite part, keeping the rim in a verti- cal position. Insert the guide spacer and utilising a press, squeeze down the bearings. Proceed as illustrated in the figure. Attention: the wheel bearings should be mounted with little interference but should the action of the press be blocked in any way, release the press.
Page 263 Suspension and wheels Wheel spindle check Place the wheel spindle on two v-prisms on a flat sur- face. Utilising a dial gauge, check that the eccen- tricity in the central part does not exceed 0.05 mm. Wheel assembly If the front tyre is substituted, before assem- bling the wheel it is necessary to balance the wheel following the indications in page 82.
Page 264: Front Forks
N·m 16 ÷ 18 22 ÷ 24 Torque Kg·m pressure ft·lb Operation Brutale 675 Brutale 800 Dragster 800 Description FRONT SUSPENSION Type “Upside down” telescopic hydraulic fork with external and “Upside down” telescopic separated adjustment of rebound and compression damping...
Page 265 Suspension and wheels FRONT FORK OvERHAUL Remove the front wheel as described in the paragraph ”Front wheel removal” of this Chapter. Support the motorcycle by the rear stand with special tool. Special tool N. 800092642 Remove the fixing screw (1) of the holding clamp (2) of the brake line (Brutale ABS / Dragster excluded).
Page 266 Proceed with the same operation for both stems. Right fork tube overhaul (Brutale 675) Loosen the cap by approximately 1 turn. Place the fork leg in a vice, in a vertical position taking care to protect its surface against possible damage.
Page 267 Suspension and wheels Completely unscrew the plug and lower the sheath as shown in the figure. Perform this operation while hold- ing the leg in a vertical position. Unscrew the plug. Proceed by acting with the spanner on the fork cap while locking the nut on the damping piston rod.
Page 268 Suspension and wheels Remove the spring. Turn the stem upside down and completely pour out the oil into a suitable container. Recover the oil in an appropriate container. Do not dispose of the used oil in the environ- ment. During this phase also take the spring pre-load spacer out (1).
Page 269 Suspension and wheels Remove the central lower screw that fixes the damping piston. Keep the sealing washer underneath. 35 N•m When refitting, tighten at 35 N•m. Pull out the damping piston. Remove dust cap (1), taking care not to damage the seat on the sheath.
Page 270 Suspension and wheels Remove the retaining ring (2) with a screwdriver. Extract the oil seal. Fork assembly check (right stem) (Brutale 675) Check that the sleeve does not have marks on the external part that could have repercussions inside the assembly.
Page 271 Suspension and wheels Assembly oil seal and anti-dust seal (right stem) (Brutale 675) After having carefully checked all components, substi- tute those damaged and/or deteriorated. Grease the lips of the new anti-dust seal (1) and the new oil seal (2) with the appropriate grease.
Page 272 Suspension and wheels Install the stem with the pump in the sleeve, putting the oil seal in place using the required tool. Special tool N. 8000B6785 Insert the clamping ring (1) in place. Then, put the dust seal in (2) by hand. - 18 -...
Page 273 Suspension and wheels While holding the sheath in an upright position, insert the spring press spacer; pour in the following oil quan- tities: - Brutale 675 (right stem): 510 cc(*) (*): approximate quantity calculated in relation to the actual maintenance level Repeatedly move the damping piston rod up and down until the it slides smoothly.
Page 274 Suspension and wheels Put the spring in by holding the pump rod in an extend- ed position outside of the sleeve. Insert the 13 mm wrench under the pump nut (1) to stop the rod from falling out. Install the cap (2) complete with new o-ring, by hand, and screw it on until it hits the rod and not the nut.
Page 275 Insert and screw in the complete cap (1) on the fork slider at the required torque. Sleeve cap torque pressure: 20 N•m Left fork tube overhaul (Brutale 675) Loosen the cap by approximately 1 turn. Place the fork leg in a vice, in a vertical position taking care to protect its surface against possible damage..
Page 276 Suspension and wheels Completely unscrew the plug and lower the sheath as shown in the figure. Perform this operation while hold- ing the leg in a vertical position. Unscrew and remove the plug (1). Turn the stem upside down and completely pour out the oil into a suitable container.
Page 277 Suspension and wheels Separate sleeve and stem by pulling along the axis. Pull off the cartridge together with the rod from the case. Unscrew the ring nut of the left rod cartridge using a hook wrench as shown in the figure. Remove the ring nut and the rod.
Page 278 Suspension and wheels Pull the spring and spacer off. Remove dust cap (1), taking care not to damage the seat on the sheath. Remove the retaining ring (2) with a screwdriver. - 24 -...
Page 279 Suspension and wheels Extract the oil seal. Fork assembly check (left stem) (Brutale 675) Check that the sleeve does not have marks on the external part that could have repercussions inside the assembly. Ensure that the inside is completely smooth, without any scratches.
Page 280 Suspension and wheels Reinsert the spacer and spring in the left rod cartridge. Put the ring nut and rod back on and tighten the ring nut at the prescribed tightening torque. LH rod cartridge ring nut tightening torque: 40 N•m 40 N•m Reinsert the cartridge in the rod.
Page 281 Then, put the dust seal in (2) by hand. While holding the sheath in an upright position, pour in the following oil quantities: - Brutale 675 (left stem): 540 cc(*) (*): approximate quantity calculated in relation to the actual maintenance level Repeatedly move the rod up and down until it slides smoothly.
Page 282 Suspension and wheels Insert and screw in the complete cap (1) on the fork slider at the required torque. Sleeve cap torque pressure: 20 N•m Fork tube overhaul (Brutale 800 / Dragster) Loosen the spring preload adjuster until you feel it rea- ches the end.
Page 283 Suspension and wheels Place the fork leg in a vice, in a vertical position taking care to protect its surface against possible damage. Completely unscrew the plug and lower the sheath as shown in the figure. Perform this operation while hold- ing the leg in a vertical position.
Page 284 Suspension and wheels Remove the plug (1). Remove the spring. Turn the stem upside down and completely pour out the oil into a suitable container. Recover the oil in an appropriate container. Do not dispose of the used oil in the environ- ment.
Page 285 Suspension and wheels Separate sleeve and stem by pulling along the axis. Remove the central lower screw that fixes the damping piston. Keep the sealing washer underneath. 35 N•m When refitting, tighten at 35 N•m. Pull out the damping piston. Take care not to reverse the pumping elements on the fork while fitting them back in, according to the fol- lowing configuration:...
Page 286 Suspension and wheels Remove dust cap (1), taking care not to damage the seat on the sheath. Remove the retaining ring (2) with a screwdriver. Extract the oil seal. - 32 -...
Page 287 Suspension and wheels Fork assembly check (Brutale 800 / Dragster) Check that the sleeve does not have marks on the external part that could have repercussions inside the assembly. Ensure that the inside is completely smooth, without any scratches. If necessary, substitute with a new part. Check for marks or scratches on all surfaces of the stem and check the condition of the chroming.
Page 288 Suspension and wheels Insert the pump into the stem and fasten it on with the related screw. 35 N•m Tighten at 35 N•m. Install the stem with the pump in the sleeve, putting the oil seal in place using the required tool. Special tool N.
Page 289 Suspension and wheels Then, put the dust seal in (2) by hand. While holding the sheath in an upright position, insert the spring press spacer; pour in the following oil quan- tities: - BRUTALE 800: 450 cc(*) - DRAGSTER 800: 450 cc(*) (*): approximate quantity calculated in relation to the actual maintenance level...
Page 290 Suspension and wheels Lift the plunger and manually turn the counternut (1) in to the end of the threaded portion. Put the spring in by holding the pump rod in an extend- ed position outside of the sleeve. Insert the 13 mm wrench under the pump nut (1) to stop the rod from falling out.
Page 291 Suspension and wheels Install the cap (2) complete with new o-ring, by hand, and screw it on until it hits the rod and not the nut. Tighten the plug with the prescribed torque. 20 N•m Fork leg plug tightening torque: 20 N•m Insert and screw in the complete cap (1) on the fork slider at the required torque.
Page 292 To ensure proper positioning of the rods, refer to the figure at right, taking care to observe fitting dimension "X": - Brutale 675: X = 220 mm - Brutale 800: X = 224 mm - Dragster 800:...
Page 293 Suspension and wheels Tighten the two screws (1) at the base of the steering. Effectuate the operation several times until the 18 N•m torque wrench does not turn the screw any more. This operation must be carried for both stems. Grease only the first threads.
Page 294 Suspension and wheels Insert the brake hose in the housing on the clamp (3) (Brutale ABS / Dragster excluded). Mount the front wheel and brake calipers according to procedures contained in the page 9. Front suspension adjustment Rebound damper (Brutale 800 / Dragster) After properly fitting the fork assembly, adjust the front suspension so to ensure optimum vehicle geometry.
Page 295: Steering Assembly
Suspension and wheels STEERING ASSEMBLY N·m 16 ÷ 18 Into contact 22 ÷ 24 Torque +10° pressure Kg·m ft·lb Operation - 41 -...
Page 296 Suspension and wheels STEERING ASSEMBLY OvERHAUL To operate on the steering assembly, it is necessary to remove the fork stems as described in this chapter, in the paragraph “Front fork overhaul”, or lift the front wheel using the specific kickstand . Special tool N.
Page 297 Suspension and wheels Steering base removal Utilising the special tool, slacken the screw ring of the steering pin. Support the motorcycle sufficiently enough so that the front stand can be removed. Ensure that the brake calipers are securely placed. Special tool N. 800091645 Remove the screw ring (1) previously slackened.
Page 298 Suspension and wheels Remove the steering base from the lower part. Assembly steering base Accurately clean all the parts and check the general condition. Before reassembly, grease the internal ring of the bear- ing and the ball bearing ring on the steering pin with Agip Grease 30.
Page 299 Suspension and wheels Steering pin tightening 10° Screw down, without tightening, the screw ring of the steering pin. This operation must be done manually. Ensure that the steering base is at the end of stroke, 30° completely steered to the right. Utilising the special tool, tighten the screw ring (1) by rotating it 10°...
Page 300: Rear Suspension And Swingarm
40 ÷ 44 55 ÷ 60 70 ÷ 75 Torque Kg·m pressure ft·lb Operation Description Brutale 675 Brutale 800 Dragster 800 REAR SUSPENSION Type Progressive, Progressive, single shock absorber with single shock absorber with rebound and compression damping spring preload adjustment...
Page 301 Suspension and wheels Rear shock absorber disassembly Remove the seats, side panels, tank and rear panels as described in Chapter C "Bodyworks". Lift up the rear part of the motorcycle with the specific lifter. Slacken the upper nut (1) of the shock absorber. Using a screwdriver push the screw (2) outwards.
Page 302 Suspension and wheels Remove the bottom nut (2) of the damper and slide the screw out. - Only for Brutale 675: Remove the top fork protection of the shock absorber removing the two 3mm socket-head screws (3), one on each part.
Page 303 (A) or radial (B) play. Check the length of the rear shock absorber spring. Standard spring adjustment (A): - BRUTALE 675 (MY13): A = 174 mm - BRUTALE 675 (MY14): A = 175 mm...
Page 304 Suspension and wheels Rear shock absorber assembly Accurately clean all parts. Grease the screws with Agip Grease 30 before reassembly. Insert the shock absorber from above and lightly screw in the lower screw of the shock absorber using the rel- ative nut.
Page 305 Suspension and wheels SWINGARM REMOvAL AND OvERHAUL Remove the rear damper as described in the previous pages. Rear wheel removal Remove the rubber and the safety spring clip (1) and unscrew the screw ring of the wheel. Attention! The screw ring has a left-handed thread.
Page 306 Suspension and wheels Unscrew the two screws (1) of both footrest supports and remove them. Lower chain guard removal Remove the two socket head screws (1) of the lower chain guard. Remove the lower chain guard, taking care to recover the internal bushes..
Page 307 Suspension and wheels Silencer disassembly Remove the clamping screw on the lh side. Remove the socket head screw on the right side hold- ing the nut still with a 10mm Allen key. Remove the silencers unit from the exhausts. - 53 -...
Page 308: Chain Removal
Suspension and wheels CHAIN REMOvAL Remove the chain utilising the special tool. Special tool N. 800095389. Identify the connecting link. The part of the tool being indicated must operate on the internal part of the crown wheel. NOTE The tool has three functions: •...
Page 309 Suspension and wheels How to fit the chain back in Before reassembling the chain, grease the connecting pins and the O-Rings as shown in the figure, by using the special grease supplied with the chain kit. Utilise only new links. Connect both ends of the chain with the connecting link, and press the connecting plate into the connecting pins by hand.
Page 310 Suspension and wheels Suspension and wheels Mount the tool onto the chain as shown in the figure and align the punch on «A». 30÷35 N•m Turn the pin holder by hand until the plate holder con- tacts with the connecting link plate. Tighten at the specified torque.
Page 311 Suspension and wheels Removing the rear brake caliper Loosen the two screws (1) and remove brake caliper (2). Speed sensor cable disassembly Remove the speed sensor cable holding clamp (3). Disconnect the speed sensor cable connector (1). - 57 -...
Page 312 Suspension and wheels Swingarm pin removal Before removing the swingarm pin, loosen the suspen- sion rocker pin (1) and the two engine pins (2). (See chapter G “Frame”). Also loosen the pin for the pads. Remove the screw (1) on the left side of the vehicle. Remove the washer and push out the pin (2) manual- - 58 -...
Page 313 Suspension and wheels Suspension and wheels At this point slide out the rocker arm pin (3). Support the swing arm to avoid it from falling on the ground and slide it towards the rear part of the motor- cycle. Upper chain guide removal Remove the 2 screws (1) and relative plates and the screw (2) on the front.
Page 314 Suspension and wheels Slide out in a forward position as shown in the figure. During re-assembly, proceed in reverse order making sure that the two front and rear reference elliptical ele- ments are in the correct position. Lower chain guide removal Remove the 3 screws (1) with their relative spacers.
Page 315 Suspension and wheels Utilising the special tool press on both ball bearings and extract them. Operate in the same way for the bearings on the left side. Special tool N. 800092860 RIGHT SIDE Extract the spacer from the right side. Check the condition of both bearing seats and the seat of the spacer.
Page 316 Suspension and wheels Complete the assembly by fitting the two bushings relating to the tool Part No. 800092866 on the right side of the swingarm. Special tool no. 800092866 Utilising a press fit the bearings and the roller bearing units (see figure). - 62 -...
Page 317: Rear Wheel Hub
REAR WHEEL HUB N·m 30÷35 20÷22 200÷220 28÷32 220÷240 140 10 18÷20 5÷7 Torque Kg·m pressure ft·lb Operation Description Brutale 675 Brutale 800 Dragster 800 REAR WHEEL Material Aluminium alloy Aluminium alloy Aluminium alloy Dimensions 5,50” x 17” 5,50” x 17”...
Page 318 Suspension and wheels Before checking and overhauling the rear wheel hub assembly it is necessary to carry out the following pre- liminary operations: Place the motorcycle on the rear stand. Special tool no. 800092642 Remove the rear wheel by removing the polygonal nut. Utilise the following tools: •...
Page 319 Suspension and wheels Slacken the nut of the flange by rotating it in an anti- clockwise direction as shown in the figure. Utilise the following tools: • Torque wrench • 55 mm polygonal spanner Remove the nut (1) with the shim (2) underneath. Slacken the fixings (1) of the wheel hub.
Page 320 Suspension and wheels With the special spanner mounted on the extension tube, pull forward the eccentric adjuster and slacken the chain. Special tool: Eccentric adjuster spanner N. 800092854 Spanner extension N. 800092855 Remove the rear sprocket unit (3) and the spacer ring (5) underneath.
Page 321 Suspension and wheels Slacken the two screws (6) and remove the brake caliper (7). Disassembly of the wheel pin Remove the wheel spindle complete with the brake disc, extracting it from the right side of the motorcycle as shown in the figure. At the same time, support the ring gear unit with one hand.
Page 322: Wheel Hub Disassembly
Suspension and wheels Wheel hub disassembly Extract the wheel hub from the left side of the fork. Carefully wash all parts. Check the condition of the roller bearing and the ball bearing. If there is excessive play (even only one of the bear- ings) or chamferings during rotation, substitute the wheel hub, complete with bearings with a new unit.
Page 323 Suspension and wheels Wheel spindle unit check Check the condition of the wheel drive engagement splines. If it is worn, substitute as follows. Disassemble the phonic wheel by acting on the 4 screws (1). Remove the four clamping screws (1) of the brake disc holder flange, as they are usually assembled with threadlocker fluid, after having heated them with a heat gun.
Page 324 Suspension and wheels Check the extra-smooth parts of the wheel spindle for wear (A). Utilising a press with an adequate punch for both the 20÷22 N•m removal and assembly of the pins of the wheel drive engagement. When assembling, apply force on the crown of the peg not on the point.
Page 325: Flexible Coupling Check
Suspension and wheels Evaluate the state of wear of the ring gear. If it appears to be too worn, proceed as described in the following operation. Flexible coupling check Extract the 5 spring drives (2) from the gear flange sup- port (3) and assess its condition.
Page 326: Reassembly Wheel Hub
Suspension and wheels If the bushes are excessively worn, replace the entire set of flanges. When the ring gear unit is being re-assembled with the drive flange unit, grease the coupling areas. Bushes coupling area (1): Grease AGIP GR SM Bushes coupling area (2): Grease AGIP GREASE 30 Do not apply grease to the threads of the pins.
Page 327 Suspension and wheels To assemble the brake caliper-carrying flange, carry out the following operations: Grease the O-rings and insert them into their respec- tive seats on the flange. Assemble the rear spacer ring in contact with the hub, then the brake caliper-carrying flange, the second spacer ring and the Seeger retaining ring (1).
Page 328 Suspension and wheels Reassemble the brake caliper (1) and tighten the fixing screws (2) at the specified torque. 18 N•m Special product: Loctite 243 Torque pressure: 18 N•m Reinsert the rubber clamp (1) around the rear brake pipe. Reposition the nut of the flange (1) with the relative washer (2) without tightening.
Page 329 Suspension and wheels Using the special spanner, bring the eccentric back into position by rotating in an anti-clockwise direction to tighten the chain. Special tool: Spanner for eccentric hub N. 800092854 Extension for spanner N. 800092855 Tighten the two fastening elements (1) of the wheel hub.
Page 330 Suspension and wheels Rear wheel assembly In the case of substitution of the rear tyre it will be necessary to effectuate the balancing of the wheel before assembling it. Follow the instructions indicated in page 82. Insert 1st gear. Reassemble the rear wheel. Tighten the wheel axis nut to the prescribed torque pressure.
Page 331 Suspension and wheels Remove the 3 clamping screws (2) and remove the pinion cover (1). Straighten the metal tongue with a flat-head drift and hammer. Put it in first gear by moving the lever clockwise by hand. Heat the nut with a heat gun. - 77 -...
Page 332 Suspension and wheels Unscrew the pinion wheel retaining nut. Now cut and remove the chain as described on page Using the specially designed spanner, remove nut (1) and washer (2). Remove the pinion and replace it with a new pinion. For reassembly, insert the pinion to end stroke.
Page 333 Suspension and wheels Hammer the new washer down onto the two opposite faces of the hexagon. Remove the chain as described on pages 45-46. Reassemble the pinion wheel cover after having cleaned the support base. 10 N•m Proceed with the tightening, screwing down respec- tively on the three screws M6 (1) Torque pressure (M6 Screws): 10 N·m...
Page 334: Motorcycle Set-Up Adjustment
Two persons must carry out this opera- NOTE tion. Check that dimension X1 is equal to: Brutale 675: = 316 mm Brutale 800: = 317 mm Dragster 800: = 311 mm...
Page 335 (2) using the required tool, in either one direction or the other depending on the calculated value of Δ static sag. Special tool: No. 75 mm hook wrench (Code no. 8000B7038) - Brutale 675: < 12 mm: Turn counterclockwise > 12 mm: Turn clockwise Δ...
Page 336 Suspension and wheels WHEEL BALANCE CHECK If the tyres are substituted, it is necessary to effectuate the following operations balancing and checking the wheels. Front wheel balancing Mount the wheel onto an adequate support similar to that shown in the figure, utilising a ground pin of 35 mm diameter.
Page 337 Suspension and wheels Insert the polygonal nut of the balancing tool from the opposite side and screw it onto the threaded part of the tool so that the tool can be fixed to the wheel. Mount the wheel onto an adequate support similar to that shown in the figure, utilising the special tool cod.
Page 338 Suspension and wheels When effectuating balancing on certain makes of tyres, it is necessary to refer to the yellow mark (1) present on the side of the tyre as shown in the figure. It indicates the lightest point of balancing and must be situated close to the tyre valve when the tyre is mounted onto the wheel rim.
Page 339 Frame SECTION Revision 1 - 1 -...
Page 340 REAR FRAME DISASSEMBLY (BRUTALE 675 / 800) ........
Page 341: Battery Cables
Frame BATTERY CABLES It is a good rule to disconnect the battery cables before removing components from the motorcycle. Remove the cowl and tank as described in chapter C "Bodywork". Remove the screw (1) indicated in the figure Disconnect the negative pole of the battery. When removing the battery, it is necessary to remove the negative pole cable first and then the positive pole cable.
Page 342 Frame Remove the battery from its compartment. Remove the two central fixing buffers of the tank. Remove the battery mounting by unscrewing the 3 screws. - 4 -...
Page 343 Frame Pull off the support and remove the 4 Relays (2 per side). If it is necessary to remove the engine power and earth cables, once the battery has been removed as described above, remove the screws as shown in the figure.
Page 344: Side Stand Removal
Frame SIDE STAND REMOVAL If the side stand needs to be replaced, use the follow- ing procedure: Place the motorcycle on the rear stand (special tool). Special tool N.800092642 Disconnect the electrical connector of the safety switch (1). Remove the side stand safety switch by unscrewing the screws (2) indicated in the figure.
Page 345 Frame For reassembly, proceed in the reverse order of removal tightening the screws to the prescribed torque pressure. 40÷44 N•m Side stand plate screws tightening torque: 40 ÷ 44 N·m Recommended thread-locking fluid: Loctite 243 Side stand switch screw tightening torque: 8 ÷...
Page 346: Foot Peg Removal
Frame FOOT PEG REMOVAL Before disassembling the left foot peg remove the clamping screw (1) from the gear extension. On the right foot peg, also remove the silencer clamping screw (2). Act on the 2 screws (1) of both foot peg mountings and remove them.
Page 347: Exhaust Silencer Disassembly
Frame EXHAUST SILENCER DISASSEMBLY Remove the clamping screw (1) on the lh side. Remove the socket head screw (2) on the right side holding the nut still with a 10mm wrench. Pull the silencer unit out from the exhausts. - 9 -...
Page 348: Exhaust Tubes Removal
Frame EXHAUST TUBE REMOVAL This operation is not necessary for disas- NOTE sembly of the engine or frame. Proceed as described below for exhaust manifold replacement. Disassemble the water radiator and oil radiator before- hand, as described in chapter L "Cooling system". Disassemble the exhaust protections as described in chapter C “Superstructures”...
Page 349 Frame Disassemble the metal sealing gasket (3) in the head. Apply sufficiently adequate wadding to the exhaust ports to stop the entry of dirt and dust into the cylin- ders. If the engine has to be removed from the frame, it will be necessary to remove the chain as described in chapter F “Suspension and wheels”.
Page 350: Frame Removal Preliminary Operations
Frame FRAME REMOVAL PRELIMINARY OPERATIONS Support the motorcycle with the aid of the following stands: - Cod. 800092642: Rear stand - Cod. 800095807: Front stand - Cod. 8000B7340: Front stand pin - Cod. 8000B6789: Engine support Remove the following components in order: - Front mudguard - Front brake callipers - Front wheel:...
Page 351: Control Unit Removal
Frame CONTROL UNIT REMOVAL Pull off the control unit together with the rubber support from its seat. Disconnect the two connections acting on the safety flaps with a flat screwdriver. Turn the bayonet connector anti-clockwise to remove wiring from the control unit. Remove the control unit from the motorcycle.
Page 352: Expansion Tank Removal
Frame If the battery support box has not yet been removed, do so as described on page 4. EXPANSION TANk REMOVAL Remove the three fixing screws (1) of the expansion tank. Push the expansion tank out of the frame and remove it from the vehicle.
Page 353: Disconnecting The Horn
Frame DISCONNECTING THE HORN Disconnect the 2 horn fastons (1). REMOVING THE SOLENOID STARTER Remove the fixing screw (1) of the contactor protection (2) and remove the protection. Remove the fixing screw (3) of the contactor support plate. - 15 -...
Page 354: Throttle Body Removal
Frame THROTTLE BODY REMOVAL Protect the frame by applying adhesive tape as shown in figure. Remove the 2 cable-retaining clamps (1). Disconnect the pressure sensor (2). - 16 -...
Page 355 Frame Disconnect the 3 injector connectors (3). Disconnect the 6 clamping screws (4) of the throttle body to the intake flange. Remove the throttle body first lifting it from the left as shown in figure. - 17 -...
Page 356 Frame Disconnect the DBW control connection (5). Protect the air intake lines using adhesive tape in order to avoid dirt from getting into the cylinders. For reassembly proceed the opposite order as disas- sembly, applying the following procedure to tighten the throttle body screws: - Tighten the 6 fixing screws of the throttle body at a tightening torque of 10 Nm, respecting the tightening...
Page 357: Removing The Seat Lock
Frame Remove the following components in order: - Steering head - Handlebar - Right/left front forks - Steering base as described in chapter F - "Suspension and Wheels". REMOVING THE SEAT LOCk Remove the M5 nuts (1) fixing the lock support to the frame.
Page 358: Removing The Main Cabling
Frame REMOVING THE MAIN CABLING To remove the main cabling it is necessary to discon- nect all of the connections and remove the clamps. Free up the connection for the direction indicators. Remove the engine rpm pick-up. Remove the current generator connection. - 20 -...
Page 359 Frame Remove the gear position sensor. Remove the engine coolant temperature sensor. Remove the rear wheel speed sensor. - 21 -...
Page 360: Removing The Fuse Panel Mounting Plate
Frame Position all of the cabling over the engine. REMOVING THE FUSE PANEL MOUNTING PLATE Remove the screw that clamps the fuse panel mount- ing plate to the frame. REMOVING CLUTCH CONTROL TRANSMISSION Loosen the nut on the clutch cable. - 22 -...
Page 361: Frame Removal From The Engine
Frame Unhook the transmission from the lever. Unscrew the counter-nut to free up the transmission from the plate. FRAME REMOVAL FROM THE ENGINE Operating as shown in the figure, unscrew and remove the front screw (1) fixing the engine to the frame from the left side, recovering the nut and spacer (2) from the right side.
Page 362 Frame Unscrew and remove the upper screws fixing the frame to the plate from both sides. Unscrew and remove the engine fixing nut (3) from the right side of the frame. Take the engine clamping pin out from the lh side of the frame.
Page 363: Frame Checks And Inspection
Frame Supporting the front part of the frame, shift it towards the front. Remove the frame from the engine by lifting. FRAME CHECkS AND INSPECTION Clean thoroughly and check the housings of the steer- ing bearings. - 25 -...
Page 364 In this case, remove the following components: - Rubber elements and springs WARNING: If any damage occurs to the motorcycle frame structure, MV Agusta recommends the immediate replacement of the frame, while advising against and, in any case, not authorizing since now any kind of...
Page 365 Frame FRAME MEASUREMENTS CONTROL DIAGRAM - 27 -...
Page 366: Steering Bearings Housing Check
Frame Steering bearings housing check Check the diameter and for any ovalisation on the stearing beerings as shown in the drawing here to the side. Measure ovalisation in different points as shown in the diagram. - 28 -...
Page 367: Frame Assembly On The Vehicle
These components can be assembled on the new frame after having carried out a careful inspection. Contact MV AGUSTA spare parts service for approval punching and decals on the new frame. Carefully clean the frame-engine head and frame- rear suspension plates coupling planes.
Page 368 Frame Carry out the sequence of operations of assembly in reverse order to removal for the correct assembly of the frame to the motorcycle. Tighten the various fixings to the torque pressure shown in the following diagram. PART. DESIGN NO. DESCRIPTION DIM.
Page 369 Frame - 31 -...
Page 370: Rear Frame Disassembly (Brutale 675 / 800)
Frame REAR FRAME DISASSEMBLY (BRUTALE 675 / 800) After having carried out the removal of all the neces- sary components described in the previous paragraph, perform the following operations. Remove the 5 wire retaining rubber clamps (1). Disconnect the voltage regulator connector.
Page 371 Frame Rewind the seat lock transmission (1) on the rear seat rail. Unscrew the 4 fixing screws of the rear platform sup- port frame and remove the support. Unscrew and remove on both sides the two lower screws fixing the rear sub-frame to the union plates taking care to recuperate the nuts.
Page 372: Rear Frame Disassembly (Dragster 800)
Frame At this point it is possible to remove the complete sub- frame assembly from the motorcycle. REAR FRAME DISASSEMBLY (DRAGSTER 800) As a preliminary operation, carry out the removal of the following components according to the procedures described in chap. C - Superstructures: •...
Page 373: Rear Frame Assembly
Frame Keep the fuel tank lifted by leaning it on an adequate support. Unscrew and remove on both sides the two lower screws fixing the rear sub-frame to the union plates taking care to recuperate the nuts. Unscrew and remove the two upper fixing screws tak- ing care, in this case also, to support the sub-frame and recuperate the nuts.
Page 374: Engine Removal
Frame ENGINE REMOVAL Cut the chain as described in chapter F "Suspension and Wheels." Remove the brake oil tank in the inside of the right plate Operating as shown in the figure, remove the plate fix- ing screw from the left side. Remove the lower screw fixing the plates to the engine from the left side.
Page 375 Frame Loosen the swing arm pin to widen the plates respect to the engine. Operating as shown in the figure, loosen the lower screw fixing the plates to the rocker arm to widen the plates respect the engine. Using a rubber mallet, slightly widen the plates as shown in the figure to be able to push the engine towards the front part.
Page 376 Frame Using a flat screwdriver, move aside the centring bush- es (1) between the plates and engine (one on each side) and remove them by hand. Insert a support to bear the plates. Disconnect the gear rod (2) removing the screw (3). - 38 -...
Page 377 Frame Remove the rear brake pump protection (1) removing the two fixing screws (2). Then remove the two screws fixing the pump support to the engine. Disconnect the rear wheels speed sensor and hydrostop connector (1). - 39 -...
Page 378: Re-Assembly Of The Vehicle
Frame Slip the engine forwards. RE-ASSEMBLY OF THE VEHICLE To re-assemble the vehicle in an easy fashion, do the following: - position the engine on tool 8000B6789 - assemble the following parts: 1) engine earth cable 2) electrical system protection 3) engine oil vapour vent pipe - proceed in the reverse order of the engine removal.
Page 379 Brakes SECTION Revision 1 - 1 -...
Page 380 Brakes SUMMARY FRONT BRAKE SYSTEM ............PAGE 3 REMOVING FRONT MUDGUARD .
Page 381: Front Brake System
8 ÷ 10 16 ÷ 18 42 ÷ 46 23 ÷ 26 23 ÷ 25 Torque Kg·m pressure ft·lb Operation Description BRUTALE 675 BRUTALE 800 DRAGSTER 800 FRONT BRAKE Type Dual floating disc with steel braking band Ø discs (mm) Disc flanges Aluminium...
Page 382: Removing Front Mudguard
Brakes REMOVING FRONT MUDGUARD To facilitate replacement of the front brake pads, remove the front mudguard as described in Chapter C “Upper structures”. FRONT BRAKE PADS SUBSTITUTION Using pincers, position the pin (1), in such a way as to facilitate split pins removal. Remove the two split pins (2), one for each pin.
Page 383 Brakes Remove the two pins (1) and remove the pad cover (3). NOTE: Re-assemble the pad cover with the stamp of the arrow turned upwards. Widen the pads before taking them out. Remove the two pads from the caliper. Repeat the same disassembling procedure for the other caliper.
Page 384: Substitution And Bleeding Of The Front Brake Fluid
Brakes Every 6000 kilometres, check the wear of the pads. The pad thickness must not be less than 1 mm. If the pads are excessively worn, substitute them. Brake Disc Brake Wear limit 1 mm For setting up front brake pads, carry out the opera- tions described above in reverse order.
Page 385 Brakes Remove the protection cap of the bleed valve of the front right caliper. Apply a rubber tube to the bleed valve (the valve is placed on the summit of the brake caliper). Put the other end of the rubber tube in a suitable con- tainer.
Page 386 Brakes Fill the system by pulling the front brake lever 3-4 times (see figure). Repeat the above drain operations until the fluid reach- es the minimum level in the reservoir. Top up with fresh fluid and carry on with the operation until fluid of a dif- ferent colour (fresh) flows out.
Page 387 Brakes Pour new brake fluid into the chamber until it reaches the maximum level. Brake fluid: AGIP Brake 4 Utilise only the prescribed brake fluid from sealed containers. NEVER use old or used brake fluid. Top-up the level of the fluid until it reaches the maxi- mum mark (upper).
Page 388: Front Brake Calipers Substitution
Brakes Accurately clean the three elements of the brake fluid chamber cap with alcohol and dry with compressed air. Position and screw on the top brake fluid tank cap and tighten the two lateral fixing screws. FRONT BRAKE CALIPERS SUBSTITUTION Slightly move the front brake lever towards the right handgrip and hold it in position with a strap to limit the outflow of brake fluid during subsequent operations.
Page 389 Brakes Unscrew the fitting with a 12mm key, being careful to avoid spilling any brake fluid. Brake liquid can corrode painted surfaces. Clean immediately any spilt brake liquid. Remove the 3 sealing washers, and change them in the assembly phase with new ones. Remove the two caliper fixing screws indicated in the figure.
Page 390: Front Brake Pump Removal
Brakes To fit the front brake calipers, follow these steps: 23÷26 N•m 42÷46 N•m - Insert the caliper fixing screws and turn them it until they make contact. Only grease the first threads of the brake caliper fixing screw. - Refit the caliper connection after replacing the sealing washers.
Page 391 Brakes Remove the two faston (2) of the electrical system. Remove the union (3) indicated in the figure. Brake fluid is extremely corrosive. Avoid contact with the eyes, skin and nose. Wash abundantly with water and call a doc- tor if accidental contact occurs. During the following operations, avoid con- tact with painted surfaces.
Page 392: Front Brake Lever Removal
Brakes To replace the front brake switch, remove the screw shown in the figure. After having carried out the overhaul of the front brake pump assembly, carefully wash and bleed the front brake system as previ- ously described in this chapter. When reassembling, pay attention to the position of the brake hose fitting and use two newly supplied washers.
Page 393: Front Brake Discs
Brakes Unscrew the pin and remove it; then remove the brake lever. When reassembling take care to insert the lever into its seat. Grease the pin: Recommended grease: Agip Grease 30 Insert the pin into the seat and screw it in until the beat is reached, then tighten the nut by using a screwdriver.
Page 394: Front Brake Disc Removal
Brakes FRONT BRAKE DISC REMOVAL Take down the front wheel as described in chapter F "Suspensions and Wheels". Place the wheel in a horizontal position and remove the five screws of each disc proceeding in a star-like mode for the removal. Visually check the discs for lines or score marks.
Page 395 Brakes The following operation is to be carried out on all mod- els. If newly supplied screws are being used they already have threadlocker on them. Apply thread-locking fluid to the five fixing screws of the disc. Recommended thread-locking fluid: Loctite Screw in the screws lightly, proceeding in a star-like mode.
Page 396: Rear Brake System
8 ÷ 10 18 ÷ 20 16 ÷ 18 8 ÷ 10 Torque Kg·m pressure ft·lb Operation Description BRUTALE 675 BRUTALE 800 DRAGSTER 800 REAR BRAKE Type Single steel disc Single steel disc Single steel disc Ø disc (mm) Caliper (Ø pistons mm) With 2 pistons (Ø...
Page 397: Rear Brake Pads Substitution
Brakes REAR BRAKE PADS SUBSTITUTION Remove the safety retainer and unscrew the rear ring nut by turning it clockwise (see figure). Remove the wheel. Utilising circlip pincers as shown in the figure, widen the pads so that the pistons are pushed back into their seats.
Page 398 Brakes Slide the pad supporting pin (1) off with a screwdriver until it comes out from the opposite side, freeing up the circlip as well (2). Remove the caliper from the support by removing the 2 fixing screws. Remove the brake pads. Carry out the check every 6000 kilometres.
Page 399: Substitution And Bleeding Of The Rear Brake Fluid
Brakes SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID The operation described herewith must be carried out with the engine cold because of the nearness of the exhaust tubes that could cause grave burns. To carry out this operation it is necessary to remove the tank (1) along with the supporting bracket (2) from the frame plate, and then detach it from the bracket.
Page 400 Brakes Connect a rubber tube to the bleed valve, empty the system in an appropriate container by slackening the bleed valve as shown in the figure. Be careful not to let the liquid fall below the minimum level before topping it up with new brake oil, to avoid getting air into the system.
Page 401: Rear Brake Calipers Substitution
Brakes REAR BRAKE CALIPER SUBSTITUTION To facilitate the operation, remove the brake pads as described previously. Empty the rear brake system as previously described in the paragraph “SUBSTITUTION AND BLEEDING OF THE REAR BRAKE FLUID”. Loosen the tubing by unscrewing the union indicated in the figure.
Page 402 Brakes Assemble the union tightening to the prescribed torque. 23÷26 N•m Torque pressure: 23 ÷ 26 N·m NOTE Substitute the gaskets with new ones. Proceed with the filling and bleeding of the rear brake system (see page 21). Rear brake pump removal Carry out the emptying of the brake system as previ- ously described.
Page 403 Brakes Disconnect the rear stop switch connector (1) once you have removed the clamp (2). Disengage the switch cabling by removing the two marked rubber clamps. Unscrew connection (1) as shown in the figure so as to disengage the pump from the brake line. - 25 -...
Page 404: Rear Brake Disc
Brakes Loosen the retaining clamp (2) sliding it off the work zone and slip off the brake fluid hose (3). After having carried out a check on all components and substituted those used, damaged or defective proceed 16÷18 N•m with the assembly by following the procedure in reverse order of removal.
Page 405: Rear Brake Disc Removal
Brakes REAR BRAKE DISC REMOVAL Before proceeding with the removal of the rear brake disc, it is necessary to carry out certain operations described below: - Remove the rear wheel. - Remove the rear wheel pin from the motorcycle (See chapter F).
Page 406 Brakes Check the thickness of the rear brake disc by utilising a micrometer gauge and measuring at least at three points with 120° between them. The minimum thickness of the disc must not be less than 4,7 mm. Utilise a micrometer gauge for this check. Before fitting the rear brake disc, check the condition of the four pins.
Page 407 Cooling system SECTION Revision 0 - 1 -...
Page 408: Cooling System
Cooling system SUMMARY COMPLETE COOLING SYSTEM ASSEMBLY ..........PAGE 3 COOLING SYSTEM LEAKAGE CHECK .
Page 409: Complete Cooling System Assembly
Cooling system COMPLETE COOLING SYSTEM ASSEMBLY Before proceeding with the disposal or overhaul of any component relative to the cooling system, carry out cer- tain preliminary operations: 1) Let the engine cool down. 2) Remove the side fairings, the underfairing, the fairings push rod, the headlight fairing, the suction duct covers and suction ducts as described in the chapter "Superstructures."...
Page 410: Cooling System Leakage Check
Cooling system COOLING SYSTEM LEAKAGE CHECK Before removing the radiator and discharging the engine coolant, check that the cooling system does not have leakages. Remove the fuel tank, the seat and the underseat pan- els (see chap. C “Upper structures”). Remove the water radiator cap and connect the tester (of the type shown in the diagram) to the filler hole.
Page 411: Water Radiator Cap Check
Cooling system WATER RADIATOR CAP CHECK Check the release pressure of the radiator cap by util- ising the appropriate tester as follows: Apply the cap to the tester as indicated and slowly cre- ate a pressure by activating the tester. Make sure that the increase in pressure is interrupted at 110±15 kPa (1.1±0.15 kg/cm ) and check that with the tester held steady, the pressure is maintained for at...
Page 412 Cooling system • Tilting the motorcycle ∼30° on its right side, let the liq- uid flow out paying attention to where it pours; • Using a funnel and tilting the motorcycle further, have all the coolant empty into the collection container; •...
Page 413 Cooling system • Release the direction indicator connector and remove the panel; • To make sure coolant has completely emptied, remove the radiator plug. - 7 -...
Page 414: Removing Expansion Tank
Cooling system REMOVING EXPANSION TANK After having emptied the cooling system, as described in the previous paragraph, in order to remove the expansion tank you must first remove the seat, the tank panels, the fuel tank, the right and left intake ducts, the air filter and the radiator panels (right and left) as described in Chapter C "Upper structures".
Page 415 Cooling system Operating on the right side of the vehicle, remove the CLIC R 66-100 clamp connecting the water radiator vent hose to the expansion tank using the special pli- ers CLIC R 205. Special CLIC R 205 pliers tool. When performing reassembly, check the NOTE conditions of the clamp and replace it if it...
Page 416: Water Radiator Disassembly
Cooling system WATER RADIATOR DISASSEMBLY After having emptied the cooling system, proceed as follows to remove the radiator: 1) Remove the right and left air outlet panels by remov- ing the screw (1) and disengaging them from the two upper pins on the frame. 2) Disconnect the water temperature sensor.
Page 417 Cooling system 4) Operating on the left side of the vehicle, remove the sleeve clamp of the hose from the radiator to the pump using the special pliers CLIC R 205. Special CLIC R 205 pliers tool. 5) Slip the hose from the sleeve leaving a collection container underneath the vehicle to recover any liq- uid left in the hose.
Page 418 Cooling system 7) Disconnect the sleeve clamp of the hose from the thermostat to the radiator using the special pliers CLIC R 205 and pull the hose off. Special CLIC R 205 pliers tool. 8) Remove the three screws fixing the water radiator to the oil radiator.
Page 419 Cooling system 9) Release the water radiator from the frame by remov- ing the screw on the left side of the vehicle. 10) Free the water radiator from the frame, disengag- ing it from the pin on the right side of the vehicle, pushing the radiator from left to right.
Page 420 Cooling system 12) Disengage the water radiator from the oil radiator, releasing it from the seat of the pin located on the oil radiator, pushing the water radiator from right to left. 13) Remove the water radiator from the vehicle, pulling it out from the right part.
Page 421 Cooling system DISASSEMBLY OF THE WATER RADIATOR PARTS Disassembly of the electric fan Remove the 2 screws that clamp the conveyor to the radiator. Lift the conveyor and slide it from the retaining pins. Turn the conveyor by 180° and unscrew the 4 screws that clamp the fan to the conveyor.
Page 422 Cooling system Remove the fan. Disassembly of the radiator clamping elements Slide off the 2 threaded circlips. - 16 -...
Page 423 Cooling system Pull the spacer from the lower support bracket. Remove the silent block from the lower fixing bracket. Remove the 2 silent blocks from the fan conveyor brack- - 17 -...
Page 424 Cooling system Slide the spacer off of the top left supporting bracket. Slide the anti-vibration elements off of the 2 top sup- porting brackets. Disassembly of the liquid temperature sensor Whenever it is necessary to check whether the liquid temperature sensor is operating efficiently proceed as described below.
Page 425 Cooling system Remove the coolant liquid temperature sensor. Check Check that the resistance of the coolant liquid temper- ature sensor varies with the temperature, as specified. Carry out the control in accordance with the instruc- tions below: connect the coolant liquid temperature sensor to an ohmmeter and immerse it in the oil contained in a heat- ed recipient;...
Page 426 Cooling system Assembly of the liquid temperature sensor Before assembly apply the stated type of threadlocker 18 N•m fluid to the threaded section of the sensor. Types of applicable threadlocker: Loctite 577 Tighten the coolant liquid temperature sensor to the specified torque pressure.
Page 427 Cooling system Position the complete electric fan on the radiator. Position the electric fan wiring as indicated in the fig- ure, verifying the correct positioning of the anchoring clamps. Tighten the 2 screws to the prescribed tightening torque. Torque pressure: 5 ÷ 6 N·m Replace the previously removed components following the disassembly procedures inversely.
Page 428 Cooling system THERMOSTAT REMOVAL Remove the 2 fixing screws of the thermostat cover. Remove the cover of the thermostat (1). Remove the thermostat (2). - 22 -...
Page 429 Cooling system Check Check to see if the thermostat pad is damaged. Check the functioning of the thermostat as follows: • Suspend the thermostat by a piece of string threaded through the flange as indicated in the figure. • Immerse the thermostat in water contained in a labo- ratory glass as indicated in the figure.
Page 430 Cooling system THERMOSTAT ASSEMBLY Insert the O-ring (1) in its appropriate seat on the cover of the thermostat. Check the condition of the O-ring previously utilised. If the O-ring is not in good condition, substi- tute it with a new one. Apply a thin layer of silicone grease.
Page 431: Water Radiator Vehicle Unit Assembly
Cooling system Insert the thermostat cover on the engine. Tighten the 2 fixing screws to the prescribed torque pressure. Torque pressure: 8 N·m 8 N•m WATER RADIATOR VEHICLE UNIT ASSEMBLY Reassemble the radiator unit in the opposite order of disassembly. - 25 -...
Page 432: Oil Radiator Disassembly
Cooling system OIL RADIATOR DISASSEMBLY To disassemble the oil radiator together with the hoses, the water radiator must be disassembled as well. To avoid oil leakage during disassembly, lift the motor- cycle with specific tools. Specific tool front stand: 800095807 Specific tool pin: 8000B7340 Position an oil collecting basin under the pipes.
Page 433 Cooling system If necessary, disconnect the drain manifold from the engine by removing the six M6 nuts and placing the drain manifold on the oil radiator hoses. It is recommended to remove the drain NOTE manifold to facilitate disassembly of the support plate which otherwise is difficult to access.
Page 434 Cooling system Pull off the connection pipes from the engine block one at a time and let leftover oil empty into the tray. Remove the oil radiator. Check the integrity of the component and if needed straighten the bent fins using a screwdriver or tweezer. - 28 -...
Page 435: Oil Radiator Component Disassembly
Cooling system OIL RADIATOR COMPONENT DISASSEMBLY Removing the connecting pipes Take the retaining screw off of the plate. Slide the pipe off. Do the same with the other one. Removal of spacers and silent blocks Pull the two spacers from the upper support brackets anchoring the water radiator.
Page 436: Oil Radiator Assembly
Cooling system Slip the three silent blocks from the three upper support brackets. OIL RADIATOR ASSEMBLY Before reassembly, check the integrity of the oil tubes and replace if necessary. Change the sealing rings for the oil pipe fittings every time they are disassembled. Grease O-rings with silicone grease.
Page 437 Cooling system Insert the fixing screws of the supply and return radia- tor hose retaining plate but do not tighten them. Insert the supply and return pipes in their housing on the motor block. Position the hose support plate and insert the three fix- ing screws without tightening them.
Page 438 Cooling system Put the oil support plate back in place inserting the two screws without tightening them. Before tightening the entire unit, wait for the oil radia- tor to be mounted on the water radiator in order to pro- vide the oil hoses inside the drain manifolds with the right orientation.
Page 439 Cooling system One screw is placed on the right side of the vehicle; - tighten the three fixing screws of the hose support plate; - tighten the two screws fixing the supply and return pipe retaining plate to the oil radiator; - 33 -...
Page 440 Cooling system - tighten the two screws fixing the radiator support plate to the engine; When you have finished tightening the unit, make sure the hoses respect the orientation shown in the figure. ATTENTION: The oil hoses must be the right distance from the drain pipes to keep oil from overheating.
Page 441: Filling The Cooling System
Cooling system FILLING THE COOLING SYSTEM Position the motorcycle on the side stand. Fill the cooling system with the required liquid described in the table (see page B-8) up to the level of the radiator fill cap. Carry out the operation several times until the level of the liquid is stable.
Page 442 Cooling system Close the loading hole with the screw-on cap and tight- en it at the prescribed tightening torque. 7 ÷ 8 N•m Torque pressure: 7 ÷ 8 N·m Start the engine, keeping it running long enough to heat the fluid until the cooling fan begin operating, then turn the engine off.
Page 443: Motor Oil System Filling
Cooling system MOTOR OIL SYSTEM FILLING Unscrew the oil fill cap. Pour in the required quantity of oil.. Make sure that the oil level is between the MIN and MAX level markings on the fill cap control rod. Oil level Before replacing the filler plug, grease O-ring (1) with silicone grease, then reinsert it into its seat (see fig- ure).
Page 444 Cooling system SYSTEM FUNCTIONING CHECK Assemble the following components in order: • Airbox. • Fuel tank. • Rear side panels (n°2 items for each side). • Radiator side panels. • Air intake ducts. • Air outlet side panels. • Saddle. For the assembly operations, assemble in reverse order of removal.
Page 445 Special tools SECTION Revision 1 - 1 -...
Page 446 Special tools MAINTENANCE TOOLS The special tools shown in the following chapter are indispensable for a correct carrying out of the described maintenance operations. To order the special tools, refer to the spare parts catalogue. - 2 -...
Page 447: Special Tools
Special tools Code Q.ty Note Brutale 675 Brutale 800 DRAGSTER Descrizione Description I FRAME I I ENGINE I 800095830 • • • Cavalletto Front stand anteriore 800091645 • • • Chiave ghiera Steering bearing cuscinetti di sterzopin wrench 8000B6920 •...
Page 448 Special tools - 4 -...
Page 449 Special tools Code Q.ty Note Brutale 675 Brutale 800 DRAGSTER Descrizione Description I FRAME I I ENGINE I 8000B6782 • • • Attrezzo montaggio Equaliser pacco bilanciere pack tool 8000B4421 • • • Attrezzo cuscinetti Front wheel ruota anteriore bearings tool 800095389 •...
Page 450 Special tools - 6 -...
Page 451 Special tools Code Q.ty Note Brutale 675 Brutale 800 DRAGSTER Descrizione Description I FRAME I I ENGINE I 8000B7177 • • • Attrezzo montaggio Gear change cambio mounting tool 800079015 • • • Attrezzo bloccaggioClutch blocking frizione tool 800094796 •...
Page 452 Special tools - 8 -...
Page 453 Tightening torques SECTION Revision 2 - 1 -...
Page 454 Tightening torques - 2 -...
Page 455 Tightening torques - 3 -...
Page 456 Tightening torques - 4 -...
Page 457 Tightening torques - 5 -...
Page 458 Tightening torques - 6 -...
Page 459 Diagnostic SECTION Revision 1 - 1 -...
Page 460: Electrical Components
Diagnostic ELECTRICAL COMPONENTS BATTERY CHARGING SYSTEM Battery warning light on Check the condition of the fuse on the remote switch Replace Faulty fuse connection on remote switch Deoxidize/Repair Faulty remote switch connection Deoxidize/Repair Battery connection defective Deoxidize/Repair Battery faulty Replace Alternator broken Replace Alternator connection defective Deoxidize/Repair...
Page 461 Diagnostic Low beam does not work Bulb burnt out Replace Bulb connections faulty Deoxidize/Repair Faulty front light connection Deoxidize/Repair Check condition of fuse 4 Replace Fuse 4 connection faulty Deoxidize/Repair Lights switch broken Replace Lights switch connection faulty Deoxidize/Repair High beam flashing light not working Lights switch broken Replace (with steady high beam function working)
Page 462 Diagnostic Battery warning light does not work (MY13) / ABS warning light does not work (MY14) Instrument panel broken Replace Instrument panel connection faulty Deoxidize/Repair ECU failure Replace Faulty ECU connection Deoxidize/Repair The idle light does not come on Gear position sensor broken Replace Gear position sensor connection faulty Deoxidize/Repair...
Page 463 Diagnostic ABS SYSTEM (BRUTALE MY14 ABS / DRAGSTER 800 - Perform verifications by using TEXA diagnostic software) ABS warning light ON Defective front/rear speed sensor connection Deoxidize/Repair Defective front/rear speed sensor Replace Broken or damaged phonic wheel Repair/Replace Incorrect clearance between sensor and phonic wheel Restore Defective fuse 25A Deoxidize/Repair...
Page 464 Diagnostic COIL N Faulty specified reel connection Deoxidize/Repair Specified coil broken Replace ECU failure Replace Faulty ECU connection Deoxidize/Repair Problem with the electrical system Repair/Replace FAN RELAY Faulty fan relay connection Deoxidize/Repair Fan relay failure Replace ECU failure Replace Faulty ECU connection Deoxidize/Repair Problem with the electrical system Repair/Replace...
Page 465 Diagnostic FRAME STEERING Steering stiff Steering bearings damaged Replace Steering bearings overtightened Adjust Steering pin bent Replace Steering damper action excessive Adjust Steering damper joints damaged Replace Tyre pressure low Adjust Vehicle tends to steer or does not travel on a straight line Fork bent Replace Frame bent Replace...
Page 466 Diagnostic BRAKES Brake lever and pedal soft (“spongy”) Air bubbles in hydraulic circuit Bleed Leaks in hydraulic circuit Repair Caliper seals damaged Replace Pump seals damaged Replace Caliper pistons do not slide freely Check Brake fluid level low Top up Brake discs distorted Replace Brake lever or pedal stiff...
Page 467 Analytical index SECTION Revision 1 - 1 -...
Page 468 Analytical index ANALYTICAL INDEX - BRUTALE 675 / BRUTALE 800 Transmission chain .....B-47 / DRAGSTER 800 WORKSHOP MANUAL Tube fastening bands ....B-55 Tubes / Fuel fittings .
Page 469 – Removing the seat lock ....G-19 – Brutale 675 / 800 ....E-43 –...
Page 470 Cooling system leakage check ... . .L-4 Analytical index - Brutale 675 / Brutale 800 / Dragster Engine coolant extraction ....L-5 800 Workshop Manual .

This manual is also suitable for:

Brutale 800 Dragster 800

MV Agusta Brutale 675 Workshop Manual

General Description a

Section

Superstructures Summary

Air Intake Injection System

Section

Section

Frame

Brakes

Cooling System

Quick Links

Chapters

Related Manuals for MV Agusta Brutale 675

Summary of Contents for MV Agusta Brutale 675