S.A.T.
area

304 MV
n°

Service Bulletin
Service Bulletin - Technisches Rundschreiben - Circulaire Technique - Circular Tecnica

Date:

5th January 2023

Subject:

Headlight wiring harness

Product:

Brutale 800 RR \ RC \ SCS \ ROSSO Euro 5
Dragster 800 RR \ RC \ SCS \ ROSSO Euro 5 fino a
BRUTALE 1000 RR Euro 4
BRUTALE 1000 RR Euro 5
BRUTALE 1000 RS Euro 5
BRUTALE 1000 NURBURGRING Euro 5

until VIN NV007262
until VIN NV007124
All VIN
until VIN NV001427
until VIN NV001435
until VIN NV001398

As a result of continuous monitoring of our product quality, it has been found that on the models specified above, is necessary
the repositioning of the headlight cable. In the event that anomalies are detected on it, an update will be necessary.
We ask you to update the vehicles according to the instructions in this Service Bulletin BEFORE handing over the vehicle to
the end customer, during a maintenance service or at the first convenient opportunity at your workshop.

Element to be modified/added
Headlight wiring harness

Type of operation to be performed
Wiring repositioning\ wiring repair

Reason for update
Optimisation of the harness curve
to better distribute the forces
applied through steering

WARRANTY CLAIM AND LABOUR REFUND (STEP 1)
Per ottenere il rimborso della manodopera, oltre ai dati completi del motociclo occorre inviare una Richiesta di Garanzia
utilizzando le seguenti indicazioni:
•

•
•

•
•
•
•

Warranty type = 3 options available:
o New motorbikes in stock NOT YET REGISTERED = GX
o Motorcycles sold with activated warranty = GS
o Motorcycles sold with expired warranty = GS
Special warranty number: 2853 (to be used with all warranty claim’s types)
Operation code for labour refund: U999 with labour time of:
o 0.1 h for harness check and repositioning (no spare parts involved)
o 0.50 h for the application of the additional cable (see upgrade kit codes)
Problem code: 099
Problem date: warranty claim insertion date.
It is mandatory to include the reference "CT 304" in the warranty claim’s notes.
Spare part codes only for warranty claims requiring the application of the additional cable:
o W000W1528 for D3\B3 ROSSO, Qty 1 Pcs.
o W000W1529 for D3\B3 RR, Qty 1 Pcs.
o W000W1530 for B4, Qty 1 Pcs.

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WARRANTY CLAIM AND LABOUR REFUND (STEP 2)
When the Warranty claim (see step 1) is validated by MV Agusta Technical Service, the process must be completed by entering
the repair date.
Please note that the insertion of the date of repair in the Warranty claim represents certification that the motorbike has been
repaired by the dealer, and also allows payment of labour for the work carried out.
NOTE: We remind you that according to the new functions and procedures of warranty management, the insertion of the
date of repair is fundamental and mandatory as per technical communication no. 004/17.

MATERIAL INCLUDED IN THE UPGRADE KITS:
MODEL B3\D3 ROSSO cod. W000W1528:
• Headlight wire L300 cod. 8B00D1816, 1pcs.
• Plastic tie cod. 800056444, 2pcs.
MODEL B3 \ D3 RR -RC – SCS cod. W000W1529:
• Headlight wire L300 cod. 8000D18161, 1pcs.
• Plastic tie X20 cod. 800056444, 2pcs.
MODEL B4 (ALL) cod. W000W1530:
• Headlight wire L300 cod. 8A00D1816, 1pcs.
• Plastic tie X20 cod. 800056444, 1pcs.
• Rubber tie L 39 cod. 800053724, 2 pcs.
NOTE: Each cable has an identification label with the part number on it.

INDEX OF OPERATIONS:
PART 1: headlight wiring check and repositioning
PART 2A: application of the additional wiring harness - Models Brutale 800 RR\ROSSO - Dragster RR\ROSSO
PART 2B: application of the additional wiring harness - Brutale 1000 RR E4 \ RR E5 models
PART 2C: application of the additional wiring harness - Models Brutale 1000 RS E5

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INTERVENTION PROCEDURE
PART 1 - Checking the headlight wiring and repositioning
MODEL B3 RR \ D3 RR \ B3 ROSSO \ D3 ROSSO \ B3 RR SCS \ D3 RR SCS
•

Locate the final branch of the wiring harness leading to the headlight (left side of the motorbike):

•

Remove the protective cap from the headlight connector and check the integrity of the cables in the connector area
and up to a distance of 10 cm from the connector by removing the protective sleeve.
If there is damage to the wiring of any kind, proceed directly to part no. 2
Check that the layout is the same as in figure 2 below; if the cable has different positions, modify it by disconnecting
the connector and positioning the wiring as in figure 2:

•

2

1
The headlamp wiring must be positioned inside the branch of the harness leading to the handlebar controls.
•
•

If the wiring is already correctly positioned (fig. 2), no intervention will be necessary.
Perform tests by moving the handlebar in both directions to check that the headlamp harness does not have too
pronounced bends and that it maintains sufficiently large bends even under stress.

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MODEL B4 RR EURO 4
•

Locate the final branch of the wiring harness leading to the headlight (left side of the motorbike):

•

Remove the protective cap from the headlight connector and check the integrity of the cables in the connector area
and up to a distance of 10 cm from the connector by removing the protective sleeve.
If there is a damage to the wiring of any kind, proceed directly to part no. 2
Locate the front L39 clamp and remove it to free the headlight wiring branch (FIG. 1); then reposition the L39 clamp at
the same height, taking care NOT to include the headlight wiring in the fixing (FIG. 2):

•

2

1
•
•

If the wiring is already correctly positioned (fig. 2), no intervention will be necessary.
Perform tests by moving the handlebar in both directions to check that the headlamp harness does not have too
pronounced bends and that it maintains sufficiently large bends even under stress.

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MODEL B4 RR \ RS \ NURBURGRING EURO 5
•

Locate the final branch of the wiring harness leading to the headlight (left side of the motorbike):

•

Remove the protective cap from the headlight connector and check the integrity of the cables in the connector area
and up to a distance of 10 cm from the connector by removing the protective sleeve.
If there is damage to the wiring of any kind, proceed directly to part no. 2
Locate the front L39 clamp and remove it to free the headlight wiring branch (FIG. 1); then reposition the L39 clamp at
the same height, taking care NOT to include the headlight wiring in the fixing (FIG. 2):

•

2

1
•
•

If the wiring is already correctly positioned (fig. 2), no intervention will be necessary.
Perform tests by moving the handlebar in both directions to check that the headlamp harness does not have too
pronounced bends and that it maintains sufficiently large bends even under stress.

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PART 2A: Application of the additional wiring
Model Brutale 800 RR \ ROSSO – Dragster RR \ ROSSO
EQUIPMENT REQUIRED FOR THE OPERATION:
•
•
•
•
•
•

Allen key 4 mm
Allen key 2.5 mm
Cutters
Soldering iron
Insulating tape
Heat gun

WIRING MODIFICATION PROCEDURE:
1.
2.
3.

Locate and disconnect the starter relay.
Disconnect the previously located headlight relay.
Cut and remove the plastic clamp if present (models B3\D3):

4.
5.

Remove the left radiator cover using a 4 mm Allen key and protect the area underneath adequately.
Move the headlight cable to an area suitable for manipulating, cut the cable leading to the headlight at a distance of
20 cm from the connector.
Remove the protective cap on the front light connector by pulling it off the previously cut area.
Remove the tape from the area of the harness next to the cut for a length of 5 cm.
Strip all wires on the harness side for a length of 5 mm:

6.
7.
8.

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9.

Take the additional cable from the kit and insert the protective cap previously removed from the harness
And apply it to the new connector.
10. Take the 6 heat-shrink sleeves from the kit and fit one on each wire.
11. Solder the additional cable to the vehicle's wiring harness, taking care to follow the following wiring diagram:

B3\D3 RR-RC-SCS E5

B3\D3 ROSSO E5

NOTE: Ensure that all wires are sheathed and that the connector protection cap is fitted.
12. Solder the cables, taking care to smooth out any ridges on the filaments with pliers in order not to damage the heatshrink sleeve that will be placed later.
13. Place the heat-shrink sleeves in the centre of the cable solderings and heat them with a heat gun:

14. Group the cables without twisting them and apply insulating tape over the entire uncovered length, taking care to
connect correctly with the existing sheats on both sides.
15. Connect the connector to the headlight.

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16. Position the headlight cable as shown in the figure; include the cable in the rubber clamp already fitted onto the
frame in the area behind the left intake duct (shown in the figure);
NOTE: the soldered section must be positioned in the area under the left intake duct, in the position indicated by
the box:

17. Take the clamp from the kit and place it in the area indicated in the picture:

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18. Take the second plastic cable tie from the kit and re-attach it to the system as shown in the figure, taking care NOT to
include the cable to the headlight:

18. Perform tests by moving the handlebar in both directions to check that the headlamp harness does not have too
pronounced bends and that it maintains sufficiently large bends even under stress.
19. Reassemble the previously removed components.
20. Reconnect the starter relay.
21. Check that the headlight works properly and perform a dynamic test of the vehicle.

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PART 2B: Application of the additional wiring
Model Brutale 1000 RR E4 \ RR E5 \ NURBURGRING
EQUIPMENT REQUIRED FOR THE OPERATION:
•
•
•
•
•

Allen key 4 mm
Cutters
Soldering iron
Insulating tape
Heat gun

WIRING MODIFICATION PROCEDURE:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Locate and disconnect the starter relay.
Remove the left air intake using a 4 mm Allen key and protect the area underneath appropriately.
Disconnect the previously identified headlight connector.
Move the headlight cable to an area suitable for manipulating, cut the cable leading to the headlight at a distance of
60 mm from the connector
Remove the protective cap from the headlight connector by pulling it off the previously cut area.
Remove the tape from the area of the harness next to the cut to the first branch present (recommended 40 mm).
Strip all wires on the harness side for a length of 5 mm:
Take the additional cable from the kit and insert the protective cap previously removed from the harness
and apply it to the new connector.
Take the 6 heat-shrink sleeves from the kit and fit one on each wire:

10. Solder the additional cable to the vehicle's wiring harness, taking care to follow the following wiring diagram:

B4 1000 RR E4 \ RR E5 \ RS E5

NOTE: Ensure that all wires are sheathed, and that the connector protection cap is fitted.
11. Solder the wires, taking care to smooth out any ridges on the filaments with pliers in order not to damage the heatshrink sleeve that will be placed later.

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12. Place heat-shrink sleeves in the centre of the cable solderings and heat them with a heat gun:

13. Group the cables without twisting them and apply insulating tape over the entire uncovered length, taking care to
correctly connect them with the existing sheaths on both sides.
14. Connect the connector to the headlight, taking care to run the wiring EXTERNALLY to the clutch hose:

15. Take the two rubber ties L39 from the kit and position the headlight cable as shown in the figure below; the cable must
be secured.
• To the wiring harness leading to the left electronic fork.
• To the wiring branch leading to the handlebar including all cables:

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16. Position the headlight cable as shown:

17. Ensure that the cable runs without excessive or excessively pronounced folds, especially in the area affected by the
welding previously performed.
18. Perform tests by moving the handlebar in both directions to check that the headlamp harness does not have too
pronounced bends and that it maintains sufficiently large bends even under stress.
19. Reassemble the previously removed components.
20. Reconnect the starter relay.
21. Check that the headlight works properly and perform a dynamic test of the vehicle.

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PART 2C: Application of additional wiring
Model Brutale 1000 RS E5
EQUIPMENT REQUIRED FOR THE OPERATION:
•
•
•
•
•

Allen key 4 mm
Cutters
Soldering iron
Insulating tape
Heat gun

WIRING MODIFICATION PROCEDURE:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Locate and disconnect the starter relay.
Remove the left air intake using a 4 mm Allen key and protect the area underneath appropriately.
Disconnect the previously identified headlight connector.
Move the headlight cable to an area suitable for manipulating, cut the cable leading to the headlight at a distance of
60 mm from the connector
Remove the protective cap from the headlight connector by pulling it off the previously cut area.
Remove the tape from the area of the harness next to the cut to the first branch present (recommended 40 mm).
Strip all wires on the harness side to a length of 5 mm:
Take the additional cable from the kit and insert the protective cap previously removed from the harness
and apply it to the new connector.
Take the 6 heat-shrink sleeves from the kit and fit one on each wire:

10. Solder the additional cable to the vehicle's wiring harness, taking care to follow the following wiring diagram:

B4 1000 RR E4 \ RR E5 \ RS E5 \ NURBURGRING

NOTE: Ensure that all wires are sheathed, and that the connector protection cap is fitted.

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11. Solder the wires, taking care to smooth out any ridges on the filaments with pliers in order not to damage the heatshrink sleeve that will be placed later.
12. Place heat-shrink sleeves in the centre of the cable solderings and heat them with a heat gun

13. Group the cables without twisting them and apply insulating tape over the entire uncovered length, taking care to
correctly connect them with the existing sheaths on both sides.
14. Connect the connector to the headlight, taking care to run the wiring EXTERNALLY to the clutch hose

15. Take the rubber tie L39 from the kit and place it at a distance of 50 mm from the previous rubber tie (area indicated by
the yellow arrow):

50 mm

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Tie the clutch hose and the wiring branch to the handlebar up together as shown in the figure below; DO NOT TIE THE
HEADLIGHT CABLE:

16. Take the plastic cable tie part no. 800056444 supplied in the kit and position it at the L39 cable tie closest to the intake
manifold, including the headlight cable, taking care to ensure that the cable is not bent sharply:

17. Perform tests by moving the handlebar in both directions to check that the headlamp harness does not have too
pronounced bends and that it maintains sufficiently large bends even under stress.
18. Reassemble the previously removed components.
19. Reconnect the starter relay.
20. Check that the headlight works properly and perform a dynamic test of the vehicle
Thanking you in advance for your cooperation, we remain at your disposal for any technical/commercial support.
Kind regards,
MV AGUSTA MOTOR S.p.A.
Technical Assistance Service

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