MV Agusta Brutale 675 / 800 & Dragster 800 Motorcycle Workshop Manual 2014 – PDF Repair & Service Guide

Description

File Details

• Manual Type: Motorcycle Workshop Manual
• Brand: MV Agusta
• Models Covered: Brutale 675, Brutale 800, Dragster 800
• Language: English
• Page Count: 472
• File Format: PDF
• Year: 2014

Chapters Covered

• General Description
• Maintenance
• Bodywork
• Air Intake Injection System
• Electrical System
• Suspension and Wheels
• Frame
• Brakes
• Cooling System
• Special Tools
• Torque Pressures
• Diagnostics
• Analytical Index

A — General Description

Sets out how to consult the manual, the glossary and symbols used throughout, right-hand and left-hand conventions, comprehensive safety warnings covering carbon monoxide, petrol, engine oil, coolant, brake fluid, thread-locking fluid, nitrogen-charged shock absorbers, battery electrolyte and hot components, plus the operating technical specifications for the Brutale 675, Brutale 800 and Dragster 800 — wheelbase, dry weight, fuel capacity, engine type, bore, stroke, displacement and compression ratios.

B — Maintenance

The largest chapter, covering the full periodical maintenance schedule and every routine operation in sequence. Engine oil and oil filter replacement with torque values for the discharge plug (40 N·m) and filter cover screws (10 N·m). Coolant level checks, top-up through the expansion tank and complete coolant substitution (drain plug torque 35 N·m). Electric cooling fan testing. Valve mechanism adjustment at 12,000 km intervals with tappet cover removal and coil disconnection. Timing chain, mobile guide and tensioner checks. Spark plug removal and gapping (NGK CR9 EKB / CR9 EIB-9, 12 N·m). Fuel filter replacement including fuel pump unit extraction, thermistor change, O-ring and strap renewal. Fuel pipe and fitting checks with quick-coupling procedures. Engine idle diagnostics with expected rpm, lambda, suction pressure and engine load ranges for both the 675 and 800/Dragster. Air filter service. Front and rear brake fluid level checks with AGIP Brake 4 specification and 8–10 N·m bracket torque. Brake pad wear limits (1 mm). Clutch play adjustment (approximately 3 mm). Throttle control inspection. Ignition switch, fuel cap lock and seat lock operation. Steering checks. Transmission chain tension specification (Brutale 675: X = 112 mm; Brutale 800 / Dragster: X = 116 mm), adjustment via eccentric hub (28–32 N·m) and O-ring chain lubrication. Tyre pressures and wear limits. Wheel bearing checks. Rear shock absorber spring length measurement. Side stand switch testing and stand plate torque (40–44 N·m). Front fork oil substitution interval. Battery terminal torque (7–8 N·m). Full instrument and warning light function checks, dashboard display mode selection, speed limiter, traction control levels, chronometer, quick shift, ABS activation, clock setting and custom engine mapping adjustment.

C — Bodywork

Removal and refitting of the front mudguard for both the Brutale and Dragster, headlight, dashboard, handlebar (Brutale) or half-handlebars (Dragster), rearview mirrors, low beam support and ignition switch, fuel tank and tail fairings, radiator side panels, airbox, lower bulkhead, tail light and number plate support, and exhaust protections. Each procedure includes fixing screw locations, clip and pin disengagement sequences, spacer positioning and reassembly torque values.

D — Air Intake Injection System

Complete MVICS injection system technical characteristics including injection time calculation, atmospheric pressure, coolant temperature, air intake temperature, battery voltage and starter signal compensations. Injection arrest control logic. Fuel feed system with pump, filter, pressure regulator (3.5 kg/cm²) and injector construction. Fuel pump control system. ECU location, function and pinout. Sensor testing for atmospheric air temperature, intake air temperature and throttle body position (with voltage output tables and angle specifications). Injector resistance check (11 Ohm ± 10% at 20 °C). Fuel pump continuity and level probe checks. Ignition coil wiring. Diagnostics system overview with TEXA IDC4 software capabilities. Air intake system technical characteristics. Complete engine control unit pinout table.

E — Electrical System

Connector, coupling, fuse and semiconductor handling precautions. Complete electrical diagrams for the Brutale 675 and Brutale 800 (both non-ABS and ABS versions) and the Dragster 800 with parts lists. Battery specification (BS BTZ10S), charging procedure using the supplied charger through the connector under the passenger seat, removal and installation with terminal torque values (7–8 N·m) and polarity sequence. Charging system efficiency checks with voltage regulator diagnostics flowchart. Starter system description with start switch, clutch lever, gear position and stand position logic table. Generator resistance check (0.3 Ohm ± 10% at 20 °C). Starter motor removal, check and assembly. Starter relay resistance check (5 Ohm ± 10%). Tilt sensor operation (60° ± 10° for more than 3 seconds). Gear position switch, side stand switch, fuses (Brutale 675/800 and ABS/Dragster fuse tables with positions and amperage ratings), spark plug resistance check (4.5–5.5 kΩ), main relay (82 Ohm ± 10%), engine pick-up (680–700 Ω), E.A.S. electronically assisted shift check, timing wheel gap (0.6–0.7 mm), run-off safety switch, oil pressure sensor, fuel level warning light switch, water sensor resistance table, turn indicators, rpm sensor, speed sensor, low beam and high beam headlight diagnostics, rear tail light and brake light circuits, tail light diagnosis module (Dragster 800), licence plate light, cooling fan system, horn, ECU disassembly, switch continuity checks, and complete electrical system wire clamp positioning diagrams for all three models.

F — Suspension and Wheels

Front wheel removal and installation with caliper screw torque (42–46 N·m), wheel spindle torque (60 N·m) and fork foot screw torque (16–18 N·m). Front wheel bearing check, extraction and reassembly using special tools. Wheel spindle eccentricity limit (0.05 mm). Front fork overhaul for the Brutale 675 (right and left stem, spring length 288 mm, oil quantities 510 cc right / 540 cc left, SAE 7.5 oil, air gap X = 100 mm), Brutale 800 and Dragster 800 (spring length 288 mm, oil quantity 450 cc, air gap X = 65 mm). Fork leg plug torque (20 N·m), damping piston screw torque (35 N·m), left rod cartridge ring nut torque (40 N·m). Steering assembly overhaul with steering pin tightening procedure (10° rotation using special tool), steering head torque (16–18 N·m) and fork leg fitting dimensions (Brutale 675: X = 220 mm; Brutale 800 and Dragster 800: X = 224 mm). Front suspension adjustment tables for the Brutale 800 and Dragster 800 with spring preload, rebound and compression damping settings. Rear suspension and swingarm removal, rear shock absorber test with spring length specifications (Brutale 675 MY13: 174 mm; MY14: 175 mm; Brutale 800 / Dragster: 162 mm), damper nut torque (40–44 N·m), swingarm bearing overhaul with replacement part numbers and special tools, chain removal and refitting with riveting torque values (plate press 30–35 N·m, pin riveting 45–50 N·m, pin head diameter 5.5 mm). Rear wheel hub overhaul with crown flange nut torque (200–220 N·m), wheel hub fastening elements, caliper holder pin torque (30–35 N·m), brake disc carrier plate screw torque (20–22 N·m with Loctite 270), ring gear nuts (25 N·m), rear wheel RH nut torque (220–240 N·m), pinion disassembly with retaining nut torque (140 N·m with Loctite 270). Motorcycle set-up adjustment with static sag values (Brutale 675: 12 mm; Brutale 800: 15 mm; Dragster 800: 16 mm) and wheel balancing procedures with eccentricity and flatness limits (0.5 mm).

G — Frame

Battery cable removal sequence with negative-first instruction. Side stand removal with switch screw torque (8–10 N·m), plate screw torque (40–44 N·m) and spring removal tool. Foot peg removal. Exhaust silencer and exhaust tube removal. Frame removal preliminary operations, control unit removal, expansion tank removal, horn disconnection, solenoid starter removal, throttle body removal with tightening sequence (10 N·m in specified order), seat lock removal, main cabling removal, fuse panel mounting plate removal, clutch control transmission removal, frame removal from the engine with front and rear fixing screw identification, frame checks and inspection including steering bearing housing ovalisation measurement, frame assembly on the vehicle with complete torque table for all frame-engine fixing screws (M12x1.25 at 55–60 N·m, M10x1.25 at 45–50 N·m, M15x1.25 at 70–75 N·m, M8x1.25 at 24–28 N·m), rear frame disassembly and assembly for both Brutale and Dragster with sub-frame screw torque (24–28 N·m), engine removal and re-assembly procedures including plate widening, centring bush removal, gear rod disconnection, rear brake pump protection removal and speed sensor disconnection.

H — Brakes

Front brake system specifications (dual floating disc 320 mm, radial 4-piston calipers Ø 32 mm, disc thickness 5 mm, minimum pad thickness 1 mm). Front mudguard removal. Front brake pad substitution with split pin and pad cover removal. Front brake fluid substitution and bleeding procedure with AGIP Brake 4 specification, bleed screw torque (6 N·m) and approximately 250 cc fluid quantity. Front brake caliper substitution with union torque (23–26 N·m) and caliper screw torque (42–46 N·m). Front brake pump removal with brake hose fitting torque (16–18 N·m). Front brake lever removal with nut torque (8–10 N·m). Front brake disc inspection with minimum thickness (4.5 mm) and oscillation limit (0.3 mm), disc removal with screw torque (23–25 N·m and Loctite 243). Rear brake system specifications (single steel disc 220 mm, 2-piston caliper Ø 34 mm). Rear brake pad substitution. Rear brake fluid substitution and bleeding with reservoir bracket torque (8–10 N·m). Rear brake caliper substitution with caliper screw torque (18 N·m and Loctite 243), union torque (23–26 N·m). Rear brake pump removal with pump union torque (16–18 N·m) and pump support torque (8–10 N·m). Rear brake disc inspection with minimum thickness (4.7 mm) and planarity limit (0.3 mm), disc nut torque (18–20 N·m with Loctite 270) and phonic wheel screw torque (3 N·m with Loctite 243).

L — Cooling System

Complete cooling system assembly diagram. Cooling system leakage check using pressure tester at approximately 120 kPa (1.2 kg/cm²). Expansion tank cap seal check. Water radiator cap release pressure check (110 ± 15 kPa). Engine coolant extraction with drain screw location and tilting procedure. Expansion tank removal. Water radiator disassembly including fan connector, hose clamps (CLIC R 205 pliers), thermostat hose, water radiator to oil radiator fixing screws and clutch hose release. Water radiator component disassembly including electric fan, conveyor, silent blocks and liquid temperature sensor with resistance table (20 °C: 3.747 kΩ; 50 °C: 1.150 kΩ; 80 °C: 0.377 kΩ; 110 °C: 0.153 kΩ; 125 °C: 0.102 kΩ). Cooling fan motor check with 12 V supply and amperage draw (7–8 A maximum). Water radiator group assembly with fan screw torque (5–6 N·m) and coolant temperature sensor torque (18 N·m with Loctite 577). Thermostatic valve removal and testing (opening temperature 60 °C, lift more than 7.0 mm at 90 °C) and assembly. Oil radiator disassembly, component disassembly and assembly with O-ring renewal and silicone grease. Filling the cooling system with expansion tank level check. Motor oil system filling with oil level between MIN and MAX on the filler cap rod. System function verification with fan operation check.

M — Special Tools

Complete illustrated list of maintenance tools with part numbers, quantities and model applicability. Includes front and rear stands, steering bearing pin wrench, rear suspension tie rod bearing mounting tool, fork bearing puller and bushing, front wheel bearing puller, rear wheel balancing tool, CLIC R clamp pliers, fork pack assembly tool, dust cover and oil splash guard tool, eccentric hub wrench and extension, equaliser pack tool, chain tool and riveting pin, rear damper adjusting tool, steering pin bearing tools, gear change mounting tool, clutch blocking tool, valve installation/removal plate, piston assembling tool, cylinder head and engine block gasket kits, valve seal mounting punch, valve guide broach, valve rubber cap removal tool, engine removal/installation support, starter motor idler gear pin mounting tool, crank shaft installation/removal tool, gauge pad, base plate, cone installation tool, half-cone removal tool and tube.

N — Torque Pressures

Frame tightening torque tables for the Brutale 675/800 and Dragster 800, covering all major fasteners with part numbers, descriptions, dimensions and torque values in N·m and kgm.

O — Diagnostics

Comprehensive troubleshooting guide organised by system. Battery charging system diagnostics with battery warning light, power supply, electric starter, cooling system, lights and indicators, E.A.S., traction check, speed limiter, horn, instrument panel, injection, ignition system, ABS system (Brutale MY14 ABS / Dragster 800 with TEXA diagnostic software), and dashboard instructions covering pressure sensor, phase error, air temp, H2O sensor, throttle position, lambda sensor, injector, gas position, fuel pump relay, rpm sensor, coil, fan relay, speed sensor, battery voltage, ECU, starter relay, DBW, sensor supply, clutch switch, safety, low beam relay, tip over and gear sensor. Frame diagnostics covering steering, front wheel, front suspension, rear wheel, rear suspension, brakes, exhaust system and cooling system with symptom, cause and remedy for each fault.

P — Analytical Index

Complete alphabetical index with page references to every topic covered in the manual, organised by section A through O.

Why This MV Agusta Workshop Manual Matters

The Brutale 675, Brutale 800 and Dragster 800 are high-performance Italian motorcycles with advanced three-cylinder engines, ride-by-wire throttle systems and complex electronics. Working on them without the correct procedures and specifications is a fast route to damaged components, poor running and unnecessary expense. This manual gives you the exact torque values, service limits, adjustment figures, diagnostic parameters and reassembly sequences that MV Agusta authorised workshops use. From a simple oil and filter change to a full fork overhaul, swingarm bearing replacement, valve clearance adjustment or injection system diagnosis, every operation is documented with clear instructions and supporting illustrations.

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This MV Agusta Brutale 675 / 800 and Dragster 800 workshop manual is delivered as an instant PDF download. There is no physical book to ship, no courier to wait for and no postage to pay. As soon as payment is confirmed, you can download the file and start working. The PDF can be viewed on any device — laptop, tablet, smartphone or desktop computer — and specific pages can be printed for use in the workshop. Whether you are a professional motorcycle technician, a dedicated home mechanic or an owner who wants to understand and maintain their own machine, this manual gives you the complete technical reference in one searchable document.