Aprilia Mana 850 GT ABS-Shop Manual

SERVICE STATION MANUAL
894171
MSS Mana GT ABS
MSS Mana GT ABS
THE VALUE OF SERVICE Due to the continuous technical updates and specific mechanic training programs for aprilia products, only aprilia Official Network mechanics know this vehicle fully and have the special tools necessary to carry out maintenance and repair operations correctly. The reliability of the vehicle also depends on its mechanical state. Checking the vehicle before riding, its regular maintenance and using only Original aprilia Spare Parts are essential! For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or search directly from the map on our Official Website: www.aprilia.com Only by requesting aprilia Original Spare Parts can you be sure of purchasing products that were developed and tested together with the actual vehicle itself. All aprilia Original Spare Parts undergo quality control procedures to guarantee reliability and durability. The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this booklet remain unchanged, aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions/models shown in this publication are available in all Countries. The availability of individual versions/models should be confirmed with the official aprilia sales network. Copyright 2009 aprilia. All rights reserved. Reproduction of this publication in whole or in part is prohibited. aprilia - After-sales service. Aprilia trademark is property of Piaggio & C. S.p.A.

MSS Mana GT ABS
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS SPECIAL TOOLS MAINTENANCE TROUBLESHOOTING ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE SUSPENSIONS CHASSIS BRAKING SYSTEM COOLING SYSTEM BODYWORK PRE-DELIVERY
CHAR S-TOOLS MAIN TROUBL ELE SYS ENG VE ENG SUSP CHAS BRAK SYS COOL SYS BODYW PRE DE
INDEX OF TOPICS
CHARACTERISTICS
CHAR
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MSS Mana GT ABS
Rules
This section describes the vehicle maintenance operations and general safety regulations.
Safety rules
Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH. Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR. AVOID ANY CONTACT WITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES WHICH MAY CAUSE IGNITION OR EXPLOSION. DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT. KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off. When handling these components, wear insulating gloves or wait until the engine and the exhaust system have cooled down. Coolant The coolant contains ethylene glycol which, under certain conditions, can become flammable. When it burns, ethylene glycol produces an invisible flame which however can cause burns.
CAUTION
TAKE CARE NOT TO SPILL COOLANT ONTO HOT ENGINE OR EXHAUST SYSTEM COMPONENTS; THE FLUID MAY IGNITE AND BURN WITH AN INVISIBLE FLAME. WHEN CARRYING OUT MAINTENANCE, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN THOUGH IT IS TOXIC, CHAR - 6
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COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS THEY MAY DRINK IT. KEEP OUT OF THE REACH OF CHILDREN DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS PRESSURISED AND MAY CAUSE SCALDING. Used engine oil and transmission oil
CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE. THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS. WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL. HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Brake and clutch fluid
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH YOUR EYES, RINSE THEM IMMEDIATELY WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE. KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND, AS IT CONTAINS SULPHURIC ACID, MAY CAUSE BURNING IF IT COMES INTO CONTACT WITH THE SKIN. WHEN HANDLING BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IN THE EVENT OF CONTACT WITH THE EYES, RINSE WITH PLENTY OF WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETABLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY. KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY BEING ACTIVATED.
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MSS Mana GT ABS
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION When repairing, dismantling and reassembling the vehicle, follow the recommendations given below carefully. BEFORE DISASSEMBLING COMPONENTS Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle. Use the special tools designed for this bike, as required. COMPONENTS REMOVAL Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific wrench. Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and identify them with different distinctive symbols. Each component needs to be clearly marked to enable identification during reassembly. Clean and wash the dismantled components carefully using a low-flammability detergent. Keep mated parts together since they have "adjusted" to each other due to normal wear. Some components must be used together or replaced altogether. Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. Only use ORIGINAL Aprilia SPARE PARTS. Comply with lubricant and consumables use guidelines. Lubricate parts (whenever possible) before reassembling them. When tightening nuts and screws, start either from the components with the largest diameter or from the innermost components, proceeding diagonally. Tighten nuts and screws in successive steps before applying the tightening torque. Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins and screws with new parts if the thread is damaged. When assembling the bearings, make sure to lubricate them well. Check that each component is assembled correctly. After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on private grounds or in an area with low traffic. Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand or batch number facing outward (visible side). ELECTRIC CONNECTORS CHAR - 8
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Characteristics
Electric connectors must be disconnected as described below; failure to comply with this procedure causes irreparable damage to both the connector and the wiring harness: Press the relative safety clips, if applicable. Grip the two connectors and disconnect them by pulling them in opposite directions. If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully with a jet of compressed air. Ensure that the cables are correctly fastened to the internal connector terminals. Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you will hear them "click" into place).
CAUTION
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.

NOTE
THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM THE RIGHT WAY ROUND. TIGHTENING TORQUES
CAUTION
REMEMBER THAT THE TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON WHEELS, BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.
Running-in
Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients are ideal to run in engine, brakes and suspensions effectively. Vary your riding speed during the runin. This ensures that components operate under both "loaded" and "unloaded" conditions, allowing the engine components to cool.
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT THE END OF THE RUN-IN PERIOD. Follow the guidelines detailed below: Do not twist the throttle grip abruptly and completely when the engine is working at a low revs, either during or after run-in. During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged braking. That is to permit the adequate adjustment of the pad friction material to the brake discs.
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MSS Mana GT ABS
AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official aprilia Dealer FOR THE CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
Vehicle identification
Write down the chassis and engine number in the specific space in this booklet. The chassis number is handy when purchasing spare parts.
CAUTION
THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISHABLE CRIME. HOWEVER, THE LIMITED WARRANTY FOR NEW VEHICLES WILL BE VOID IF THE VEHICLE IDENTIFICATION NUMBER (VIN) HAS BEEN MODIFIED OR NOT PROMPTLY DETERMINED. This number consists of numbers and letters, as in the example shown below. ZD4RCA000YMXXXXXX KEY: ZD4: WMI (World manufacturer identifier) code; RC: model; A00: version variation; 0: digit free Y year of manufacture M: production plant (M= Mandello del Lario); XXXXXX: progressive number (6 digits); CHASSIS NUMBER The chassis number is stamped on the right side of the headstock. ENGINE NUMBER The engine number is printed on the base of the engine crankcase, left hand side. Engine No. ....................
CHASSIS NUMBER The chassis number is stamped on the right hand side of the headstock. Chassis No. ....................
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Dimensions and mass

DIMENSIONS
Specification Max. length Max. width Max. height Saddle height Wheelbase Kerb weight (full fuel tank) Desc./Quantity 2180 mm (85.83 in) 800 mm (31.50 in) 1350 mm (53.15 in) (with the windscreen adjusted in the top position) 810 mm (31.89 in) 1465 mm (57.68 in) 238 kg (524 lb)
Engine
ENGINE
Specification Model Type Number of cylinders Overall cylinder capacity Bore / stroke Valve clearance Compression ratio Ignition Engine speed at idle TIMING SYSTEM MAX. torque Clutch Lubrication system Lubrication pressure Minimum lubrication pressure (100 C - 212 F) Air filter Cooling Desc./Quantity M290 Duel 90 longitudinal V-twin, 4-stroke, 4 valves per cylinder, single overhead camshaft. 2 839.3 cm (51.22 cu.in) 88 x 69 mm (3.46 x 2.72 in) Inlet: 0.15 mm (0.0059 in) Outlet: 0.15 mm (0.0059 in) 10 - 10.6 : 1 electronic 1400 100 rpm 4 valves, single overhead camshaft, chain-driven. 71 Nm at 4,500 rpm Automatic Dry sump system with separate oil tank 3.5 4 bar 0.8 bar With dry cartridge filter Forced-circulation coolant system.
GEARBOX
Specification Type Desc./Quantity aprilia sport gear with electrically-controlled variator, double mode: sequential and autodrive
OIL PUMP
Specification Type Rotor shim washers Fitting clearances External rotor radial clearance Flatness Desc./Quantity Trochoidal pressure pump: 12 mm (0.47 in) scavenge pump: 22 mm (0.87 in) Lobe ends: 0.04 - 0.1 mm (0.0016 - 0.0039 in) 0.05 - 0.12 mm (0.0020 - 0.0047 in) 0.015 mm (0.00059 in)
BY-PASS
Specification Type Piston diameter Unloaded spring length Calibration pressure Desc./Quantity with piston 13.984 - 13.957 mm (0.5505 - 0.5495 in) 52 mm (2.05 in) 4.5 bar (450 kPa) (65 PSI)
OIL FILTER
Specification Type Desc./Quantity paper filter with pressure relief and anti-drain by-passes
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MSS Mana GT ABS
OIL MINIMUM PRESSURE INDICATOR SWITCH

Specification Calibration Desc./Quantity 0.3 0.6 bar
HEAD LUBRICATION CONTROL JET

Specification Diameter * Tightening torque 57 Nm Desc./Quantity 1 0.05 mm *
PISTON COOLING NOZZLE

Specification Diameter Desc./Quantity 0.95 - 1.05 mm (0.037 - 0.041 in)
CRANKCASE VENTILATION CHECK

Specification Device Desc./Quantity metal reed valve and decantation chamber
Transmission
GEAR RATIO
Specification Primary drive gear ratio Secondary drive gear ratio Final drive gear ratio Desc./Quantity Belt primary drive (2.079 - 0.831) Gear secondary drive (23/59) 18/40
Capacities
CAPACITY
Specification Fuel (reserve included) Fuel reserve engine oil Fork oil quantity (for each stem): Coolant Seats Vehicle max. load (rider + passenger + luggage) Desc./Quantity 16 l (3.52 UKgal; 4.23 USgal) 3.3 l (0.73 UKgal; 0.87 USgal) 2.5 l (without oil filter change) (0.55 UKgal; 0.66 USgal) 2.6 l (with oil filter change) (0.57 UKgal; 0.69 USgal) 498 cm (30.39 cu.in) 2.5 l (0.55 UK gal; 0.66 USgal) 2 210 kg (463 lb)
Drive chain
DRIVE CHAIN
Specification Type Model Desc./Quantity Endless (without master link) and with sealed links. No. of links 100 525 ZRPK
Electrical system
ELECTRICAL SYSTEM
Specification Battery Desc./Quantity 12V - 12 Ah
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Characteristics
Specification Main fuses Auxiliary fuses ABS fuses (Permanent-magnet) Alternator Ignition Ignition Ignition advance Pick-up air gap
Desc./Quantity 30A - 40A 3A, 10A, 15A, 20A 20 A 13.5 V - 450 W at 6000 rpm electronic Electronic, inductive, high efficiency, integrated with the injection system, with variable advance separate HV coil. Three-dimensional map managed by control unit front: 0.1 - 3.17 mm (0.004 - 0.124 in) rear: 0.1 - 2.0 mm (0.004 - 0.078 in)
SPARK PLUGS
Specification Standard spark plugs Spark plug electrode gap Resistance Desc./Quantity NGK CR7EKB 0.6 - 0.7 mm (0.024 - 0.028 in) 5 kOhm
BULBS
Specification Low-beam light High-beam light Front daylight running light Turn indicator lights License plate light Rear running light / stop light Rpm indicator lighting Multifunction display lighting Desc./Quantity 12 V - 55 W H11 12 V - 55 W H11 12V - 5W 12V - 10W 12V - 5W LED LED LED
WARNING LIGHTS
Specification High-beam light Right turn indicator Left turn indicator General warning Fuel reserve RPM 1 RPM 2 RPM 3 RPM 4 Desc./Quantity LED LED LED LED LED LED LED LED LED
Frame and suspensions

CHASSIS
Specification Type Steering inclination angle Trail Desc./Quantity High strength steel tubular perimeter frame. 24 103 mm (4.05 in)
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MSS Mana GT ABS
CHASSIS HEIGHTS
Specification A1 A2 B1 B2 Desc./Quantity 386.4 0.5 mm (15.21 0.02 in) 702.6 0.5 mm (27.66 0.02 in) 225.5 0.6 mm (8.88 0.02 in) 187.2 0.6 mm (7.37 0.02 in)
SUSPENSIONS
Specification Front Travel Rear Wheel travel Desc./Quantity Upside-down hydraulic action telescopic fork, 43 mm (1.69 in) stems 120 mm (4.72 in) Oscillating swingarm and single adjustable hydraulic shock absorber 120 mm (4.72 in)
Brakes
BRAKES
Specification Front Desc./Quantity Double floating disc, 320 mm (12.60 in), radially-mounted callipers with four plungers- two of them 27 mm (1.06 in), the other two 32.03 (1.26 in) and 4 pads 260 mm (10.24 in) disc brake, 25 mm (0.98 in) twin-plunger calliper
Rear
Wheels and tyres

WHEEL RIMS
Specification Type Front Rear Desc./Quantity Light alloy wheel rims with extractable bolt 3.50 x 17" 6.00 x 17"
TYRES
Specification Tyre type (standard) Front Inflation pressure Rear Inflation pressure Desc./Quantity DUNLOP SPORTMAX QUALIFIER - PIRELLI SCORPION SYNC 120/70 ZR17" (58W) 1 passenger: 2.3 bar (230 kPa) (33.36 PSI) 2 passengers: 2.5 bar (250 kPa) (36.26 PSI) 180/55 ZR17" (73W) 1 passenger: 2.5 bar (250 kPa) (36.26 PSI) 2 passengers: 2.8 bar (280 kPa) (40.61 PSI)
Supply
FUEL SYSTEM
Specification Type Throttle diameter Fuel Desc./Quantity Electronic injection (Multipoint) 38 mm (1.50 in) Premium unleaded petrol, minimum octane rating of 95 (NORM) and 85 (NOMM)
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Characteristics
Tightening Torques
LUBRICATION
Name Engine oil drainage plug Oil pump compartment cover bulkhead screws Engine oil filter Chain tensioner slider - oil pump Oil pump screws By-pass scavenge pipe fixing screws Lubrication circuit upper bulkhead Oil pump crown gear screw Screws fixing oil pump to crankcase Minimum oil pressure sensor Water pump gear fixing screws Torque in Nm 21 29 3-4 12 16 23 56 11 - 13 34 10 14 56 12 14 56
THERMAL GROUP AND TIMING SYSTEM

Name Spark plug Head fixing stud bolts Head fixing nuts Exhaust/ intake head fixing nuts Head lubrication control jet Tensioner pad fixing screw injector fixing screw Inlet manifold fixing screws Tappet cover fixing screws Throttle body fixing screws Camshaft retaining bracket fixing screws Head fixing screws Coolant temperature sensor Rpm-timing sensor fixing screw Timing system chain tensioner screw Timing system crown screw on camshaft Torque in Nm 12 - 14 *** 10 - 12 10 - 12 5-7 10 - 14 34 11 - 13 7-9 11 13 4-6 10 - 12 21 23 7.5 8.5 11 13 12 14
*** First, apply a preliminary torque of 10 Nm in a criss-crossed sequence. - tighten to a torque of 13 Nm + 90 in a criss-crossed sequence. - tighten again by 90 in a criss-crossed sequence.
TRANSMISSION COVER
Name Driving pulley screw Driven pulley nut Clutch ring nut External transmission cover screws Internal transmission cover screws Air deflector screws Air outlet grid screws Torque in Nm 175 195 153 187 65 - 75 57 11 13 34 34
FLYWHEEL COVER
Name Flywheel fixing nut Stator clamps Screws fixing freewheel to flywheel Flywheel cover screws Torque in Nm 116 - 128 8 - 10 13 - 15 11 - 13
CRANKCASE AND CRANKSHAFT

Name Starting ring gear retaining plate Crankcase-engine coupling screws (M6) Crankcase-engine coupling screws (M8) Torque in Nm 34 11 13 25 28
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MSS Mana GT ABS
FRAME
Name hex headflanged screw fixing coil support - M6x20 (2) Lower self-locking M4 nut fixing coils (8) Self-locking M10 nut fixing shock absorber (1) DAX M14 nut fixing engine to chassis (2) TBEI screw fixing rubber rings with groove for saddle - M6x30 (2) TCEI screw fixing tank front rubber rings - M8x20 (2) Screw fixing ABS control unit (1) - M6x25 Nut fixing ABS control unit (2)- M6 Torque in Nm 10 Nm (7.38 lbf ft) 3 Nm (2.21 lbf ft) 50 Nm (36.88 lbf ft) 80 Nm (59 lbf ft) 10 Nm (7.38 lbf ft) 25 Nm (18.44 lbf ft) 10 Nm (7.37 lbf ft) - Loctite 243 10 Nm (7.37 lbf ft)
FOOTPEGS
Name Non-slip bolt on driver footrest (2) hex headflanged screw for footrest finish - M6x12 (8) TBEI flanged screw fixing heelrests - M5x16 (4) TCEI screw fixing footrest support to fork pin - M10x63 (2) Lower self-locking flanged M10 nut fixing footrest support to stand bolt (2) Lower screw fixing rider footrest Torque in Nm 25 Nm (18.44 lbf ft) 10 Nm (7.38 lbf ft) 6 Nm (4.42 lbf ft) 50 Nm (36.88 lbf ft) 30 Nm (22.13 lbf ft) 25 Nm (18.44 lbf ft)
STAND
Name Bolt fixing screwed stand to fork (1) Stand bolt safety lock nut - M10x1.25 (1) Self-locking nut fixing centre stand front bolt (1) TCEI screw fixing switch - M5x25 (2) Torque in Nm 10 Nm (7.38 lbf ft) 30 Nm (22.13 lbf ft) 50 Nm (22.13 lbf ft) 6 Nm (4.42 lbf ft)
SWINGARM
Name Rear wheel bolt nut fixing fork pin (1) Chain tensioner pad set screw (2) Serpress M8 nut fixing chain tensioner screws (2) M5x15 TBEI screw with washer fixing chain crankcase (4) M5x12 TBEI screw fixing chain slider (2) Rear brake calliper support lock pin (1) Torque in Nm 90 Nm (66.38 lbf ft) manual manual 6 Nm (4.42 lbf ft) 3 Nm (2.21 lbf ft) - Loctite 243 50 Nm (36.88 lbf ft) - Loctite 243
FRONT WHEEL UNIT

Name Brake disc fixing screw on wheel M8x20 (12) Torque in Nm 30 Nm (22.13 lbf ft) - Loct. 243
FRONT SUSPENSION
Name Stainless steel TCC M8x30 screw fixing stanchions on upper plate (2) Stainless steel TCC M8x30 screw fixing stanchions on lower plate (4) Headstock ring nut - M25x1 (1) Headstock cap - M22x1 (1) Screw fixing fork feet on wheel pin - M8x40 (4) TCEI screw fixing handlebar U-bolts to upper plates - M10x60 (2) Front 3-way pipe pivot fixing screw on bottom fork plate (1) Nut for fixing sensor on the plate M5 (1) TCB screw for fixing the cable grommet on the RH fork foot M4x6 (1) Torque in Nm 25 Nm (18.44 lbf ft) 25 Nm (18.44 lbf ft) tighten to 20 Nm (14.75 lbf ft) - unscrew and tighten to 7 Nm (5.16 lbf ft) 100 Nm (73.76 lbf ft) 25 Nm (18.44 lbf ft) 50 Nm (36.88 lbf ft) 10 Nm (7.38 lbf ft) 6 Nm (4.42 lbf ft) 6 Nm (4.42 lbf ft)
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Characteristics
REAR WHEEL UNIT

Name Brake disc fixing screw on wheel M8x20 (5) Screw for fixing the cush drive mounting on the wheel - M10x30 (5) Nut for fixing the crown on sprocket carrier M10 (5) Wheel pin fixing nut (1) Screw fixing the pinion cover on the engine M5x25 (3) Pinion nut (1) Torque in Nm 30 Nm (22.13 lbf ft) - Loct. 243 50 Nm (36.88 lbf ft) - Loctite 2701 50 Nm (36.88 lbf ft) 120 Nm (88.51lbf ft) 6 Nm (4.42 lbf ft) 170 Nm (125.38 lbf ft)
REAR SUSPENSION
Name Self-locking M10 nut fixing shock absorber to fork (1) Mounting plate adjustment knob fixing screw - M6x40 (2) Screw fixing the mounting plate to the engine crankcase M6x40 (2) Torque in Nm 50 Nm (36.88 lbf ft) 10 Nm (7.38 lbf ft) 10 Nm (7.38 lbf ft)
ENGINE
Name TEF screw fixing gear control unit - M6x16 (4) TBEI screw with washer fixing micro-switch bracket - M5x9 (1) TCEI screw fixing pin lever to gearshift lever - M6x16 (1) TCEI screw fixing gearshift lever to engine pin - M6x16 (1) Self-tapping screw fixing air deflector cover on air deflector (4) Self-tapping screw fixing mesh filter on air deflector (2) Self-tapping screw fixing filter cover to air deflector (1) TCCIC screw with shank fixing air deflector to engine (4) hex headflanged screw fixing voltage regulator on bracket M6x30 (2) Torque in Nm 10 Nm (7.37 lbf ft) 6 Nm (4.42 lbf ft) 10 Nm (7.38 lbf ft) 10 Nm (7.38 lbf ft) - knurled washer 1 Nm (0.74 lbf ft) 1 Nm (0.74 lbf ft) 1 Nm (0.74 lbf ft) 7 Nm (5.16 lbf ft) 10 Nm (7.38 lbf ft)
FILTER BOX
Name SWP screw assembling filter support to filter box - M5x19 (6) SWP screw fixing filter box cover - M5x19 (3) hex headflanged screw fixing filter box to chassis - M6x25 (2) Torque in Nm 2 Nm (1.47 lbf ft) 2 Nm (1.47 lbf ft) 10 Nm (7.37 lbf ft)
EXHAUST SYSTEM
Name Self-locking flanged nut tightening exhaust manifolds to heads (4) TBEI flanged screw fixing exhaust front protection (4) M8 flanged self-locking nut fixing silencer (1) M10 screw fixing compensator on footrest support (2) Manifolds fixing clamp (2) Torque in Nm 25 Nm (18.44 lbf ft) 8 Nm (5.9 lbf ft) 25 Nm (18.44 lbf ft) 30 Nm (22.13 lbf ft) 18 Nm (13.28 lbf ft)
COOLING SYSTEM
Name Radiator TCEI fixing screw - M6x35 (2) Heat protection fixing screw - M5x10 (1) Heat protection fixing screw - M6x16 (3) Expansion tank TCEI fixing screw - M6x25 (1) Electric fan fixing screw (3) Radiator cover TBEI fixing screw - M5x12 (4) Torque in Nm 10 Nm (7.38 lbf ft) 6 Nm (4.42 lbf ft) 10 Nm (7.38 lbf ft) 10 Nm (7.38 lbf ft) 0.3 Nm (0.22 lbf ft) 6 Nm (4.42 lbf ft)
FRONT BRAKE
Name hex headflanged screw fixing calliper - M10x1.25x55 (4) Union with breather fixing pipe to callipers - M10x1 (2) Union fixing pipe to pump - M10x1 (1) TEF screw fixing braking system to lower plate - M6x16 (1) Screw tightening ABS sensor (1) - M5 Torque in Nm 50 Nm (36.88 lbf ft) 25 Nm (18.44 lbf ft) 25 Nm (18.44 lbf ft) 10 Nm (7.38 lbf ft) 6 Nm (4.42 lbf ft)
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MSS Mana GT ABS
Name Screw fixing ABS sensor plate (2) - M5x12
Torque in Nm 6 Nm (4.42 lbf ft)
REAR BRAKE
Name Screw fixing pin on brake lever - M6x16 (1) Screw fixing lever on footrest support (1) Brake pipe union on pump and calliper - M10x1 (1) Hydraulic stop switch (1) M6 Lock nut for fork (1) Parking brake calliper retainer - M8x21 (2) Hydraulic calliper retainer - M8x29 (2) hex headscrew fixing pump on footrest plate - M6x25 (2) Oil tank hex head fixing screw - M6x15 (1) Upper TCEI screw fixing parking lever unit - M6x30 (2) Lower TCEI screw fixing parking lever unit - M6x20 (1) Brake pipe support bracket fixing screw (2) Parking brake cable guide fixing screw (1) Screw tightening ABS sensor (1) - M5 Torque in Nm 10 Nm (7.38 lbf ft) 25 Nm (18.44 lbf ft) - Loctite 243 25 Nm (18.44 lbf ft) 25 Nm (18.44 lbf ft) 10 Nm (7.38 lbf ft) 25 Nm (18.44 lbf ft) - Loctite 243 25 Nm (18.44 lbf ft) - Loctite 243 10 Nm (7.38 lbf ft) - Loctite 243 10 Nm (7.38 lbf ft) 10 Nm (7.38 lbf ft) 10 Nm (7.38 lbf ft) 25 Nm (18.44 lbf ft) 10 Nm (7.38 lbf ft) 6 Nm (4.42 lbf ft)
HANDLEBAR / CONTROLS / TRANSMISSION

Name Anti-vibration weights fixing screw - M6x40 (2) Anti-vibration weight terminal - M8x1 (2) Front brake pump screw (2) Mirror support screw (2) Rear-view mirrors Light switch (2) TCC stainless steel screw fixing upper U-bolt on lower U-bolt M8x25 (4) Screw fixing gearshift switch on handlebar- M4x10 (1) Torque in Nm 10 Nm (7.38 lbf ft) 35 Nm (25.81 lbf ft) 10 Nm (7.38 lbf ft) 10 Nm (7.38 lbf ft) manual 1.5 Nm (1.11 lbf ft) 25 Nm (18.44 lbf ft) 2 Nm (1.47 lbf ft)
ELECTRICAL COMPONENTS
Name Hex head flanged screw fixing horn - M8x16 (1) TBEI flanged screw fixing multiple relay support - M6x16 (2) Self-locking M5 nut fixing single relay support (1) Voltage regulator hex head flanged fixing screw - M6x30 (2) Shear head screw fixing ignition lock - M8x40 (2) TCEI screw fixing ignition lock - M8x40 (1) Torque in Nm 25 Nm (18.44 lbf ft) 10 Nm (7.38 lbf ft) 6 Nm (4.42 lbf ft) 10 Nm (7.38 lbf ft) up to the breaking point 25 Nm (18.44 lbf ft)
LIGHTS / INSTRUMENT PANEL

Name Self-tapping screw 3.9x14 (4) Self-locking nut fixing light to light support - M6 (1) TCEI screw fixing light support to upper plate - M6x10(2) Self-locking M6 nut fixing light support to upper plate (2) TBC screw fixing instrument panel clamp - M5x20 (2) hex headscrew fixing instrument panel clamp - M5x15 (1) Self-tapping screw fixing front light to cover - 3.9x14 (4) TEF screw fixing light support to lower plate - M6x16 (2) Rear light self-tapping fixing screw - 5x14 (4) Self-locking flanged M5 nut fixing licence plate lamp retainer (1) Turn indicator TCEI fixing screw - M6x20 (4) Light rim self-tapping fixing screw - 3.9x14 (4) Torque in Nm 1 Nm (0.74 lbf ft) 10 Nm (7.38 lbf ft) 10 Nm (7.38 lbf ft) 10 Nm (7.38 lbf ft) 1.5 Nm (1.11 lbf ft) 1.5 Nm (1.11 lbf ft) 1 Nm (0.74 lbf ft) 10 Nm (7.38 lbf ft) 1.5 Nm (1.11 lbf ft) 6 Nm (4.42 lbf ft) 1.5 Nm (1.11 lbf ft) 1 Nm (0.74 lbf ft)
TANK
Name Fuel pump fixing ring nut (1) Torque in Nm 20 Nm (14.75 lbf ft)
CHAR - 18
MSS Mana GT ABS
Characteristics
SADDLE
Name hex headflanged screw fixing saddle rotation bracket - M6x20 (2) Countersunk head, self-tapping screw fixing saddle hinges to saddle bottom - 5 (4) Driver saddle rear hex headflanged fixing screw - M6x20 (2) Driver saddle lateral TCB fixing screw - 4.2x16 (2) Torque in Nm 10 Nm (7.38 lbf ft) 1.5 Nm (1.11 lbf ft) 10 Nm (7.38 lbf ft) 1 Nm (0.74 lbf ft)
FRONT BODYWORK
Name Front mudguard TBEI fixing screw - M5x12 (4) Right/left SWP crosshead flanged screw fixing helmet compartment - M5x20 (9) Battery cover TBEI fixing screw - M5x12 (2) Screw fixing shock absorber to helmet compartment - M6x20 (1) Self-locking M8 nut fixing shock absorber to helmet compartment (1) Door switch TCB fixing screw - 3.9x14 (1) Lock TBEI fixing screw - M6x16 (2) Self-locking M6 nut fixing injection ECU to support (2) hex headflanged screw fixing cable harness ground cable on injection ECU - M6x12 (2) Self-tapping screw fixing ECU support to compartment - 4.2x12 (2) hex headflanged screw fixing helmet compartment to chassis - M6x20 (4) Right air deflector TBEI flanged fixing screw - M5x12 (2) TBEI flanged screw fixing right air deflector to expansion tank - M5x9 (1) Left air deflector TBEI flanged fixing screw - M5x12 (3) Fairing TBEI flanged fixing screw - M5x12 (10) Steering lock housing TBEI fixing screw - M6x30 (2) Latch support TCB fixing screw - 4.2x16 (2) Stainless steel self-tapping screw for plast. fixing helmet compartment (14) Rear cover TBEI fixing screw - M5x12 (2) Rear cover TCB fixing screw - 4.2x16 (2) TBEI screw with front washer for fixing the instrument panel to the side and top fairing elemnts M5x12 (6) Self-tapping screw to fix the instrument panel to the panel Diam.5x14 (3) TBEI screw for fixing the steering lock protection to the helmet compartment - M6x35 (2) Allen screw for fixing the turn indicator to the side fairing M6x16 (1) TBEI screw with front washer for fixing the air deflector to the helmet compartment and top fairing elements to the shield M5x12 (2) Screw for fixing top fairing element, air deflector and deflector to the side fairing - Diam.3.9x10 (9) Allen screw for fixing the turn indicator to the side fairing M6x16 (1) TBEI screw for fixing the air deflector to the helmet compartment and top fairing elements to the shield - M5x12 (2) Screw for fixing top faring element air deflector and deflector to the side fairing - Diam.3.9x10 (9) TBEI screw with front washer for fixing the shield to the side fairings - M6x25 (2) Screw for fixing the shield and lamp mounting to the front frame - M6x25 (2) Screw to fix the front cover to the shield - Diam.5x14 (2) Screw to fix the lamp to the lamp mounting - 3.9x14 (4) Torque in Nm 6 Nm (4.42 lbf ft) 1.5 Nm (1.11 lbf ft) 6 Nm (4.42 lbf ft) 10 Nm (7.38 lbf ft) 25 Nm (18.44 lbf ft) 1 Nm (0.74 lbf ft) 10 Nm (7.38 lbf ft) 10 Nm (7.38 lbf ft) 10 Nm (7.38 lbf ft) 1 Nm (0.74 lbf ft) 10 Nm (7.38 lbf ft) 6 Nm (4.42 lbf ft) 4 Nm (2.95 lbf ft) 6 Nm (4.42 lbf ft) 6 Nm (4.42 lbf ft) 6 Nm (4.42 lbf ft) 1 Nm (0.74 lbf ft) 1 Nm (0.74 lbf ft) 6 Nm (4.42 lbf ft) 1 Nm (0.74 lbf ft) 6 Nm (4.42 lbf ft) 3 Nm (2.21 lbf ft) 10 Nm (7.38 lbf ft) 1.5 Nm (1.11 lbf ft) 6 Nm (4.42 lbf ft)
1 Nm (0.74 lbf ft) 1.5 Nm (1.11 lbf ft) 6 Nm (4.42 lbf ft) 1 Nm (0.74 lbf ft) 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) 3 Nm (2.21 lbf ft) 1 Nm (0.74 lbf ft)
CHAR - 19
Characteristics
MSS Mana GT ABS
REAR BODYWORK
Name Grab handle hex headflanged fixing screw - M8x45 (2) Left tail section self-tapping fixing screw - 3.8 (3) hex headflanged screw fixing license plate holder frame M6x20 (2) License plate holder TBEI fixing screw - M5x12 (4) License plate holder TBEI fixing screw - M5x9 (2) License plate holder self-tapping fixing screw - 5 (2) License plate holder self-tapping fixing screw - 4.2 (5) Tank cover TCEI fixing screw - M6x16 (4) Countersunk head screw fixing mesh stud bolt - M8x35 (2) Tank protection TBEI fixing screw - M5x12 (1) Torque in Nm 25 Nm (18.44 lbf ft) 1 Nm (0.74 lbf ft) 10 Nm (7.38 lbf ft) 6 Nm (4.42 lbf ft) 6 Nm (4.42 lbf ft) 1.5 Nm (1.11 lbf ft) 1 Nm (0.74 lbf ft) 10 Nm (7.38 lbf ft) 25 Nm (18.44 lbf ft) 6 Nm (4.42 lbf ft)
ENGINE MAIN RETAINERS

Name hex headscrew fixing transmission cover on engine crankcase - M6x35 (13) Central crankcases hex headfixing screw - M8x60 (11) hex headscrew fixing flywheel cover on engine crankcase M6x35 (16) Torque in Nm 12 Nm (8.85 lbf ft) 25 Nm (18.44 lbf ft) 12 Nm (8.85 lbf ft)
Overhaul data Assembly clearances Cylinder - piston assy.

- Pistons and cylinders are classified according to their diameter. This coupling is carried out in pairs (A-A, B-B, C-C, D-D).
COUPLING CATEGORIES
Name Cylinder - Piston Cylinder - Piston Cylinder - Piston Cylinder - Piston Initials A B C D Cylinder 87.990 87.997 87.997 87.004 88.004 88.011 88.011 88.018 Piston 87.954 87.961 87.961 87.968 87.968 87.975 87.975 87.982 Play on fitting 0.029 0.043 0.029 0.043 0.029 0.043 0.029 0.043
Rod small end - pin - piston

ROD SMALL END - PIN COUPLING CLEARANCE - Calculate the rod small end - pin coupling clearance.
Characteristic
Standard clearance: 0.015 0.029 mm
CHAR - 20
MSS Mana GT ABS
Characteristics
PIN - PISTON COUPLING CLEARANCE - Calculate the pin - piston coupling clearance.
NOTE THE PIN HOUSINGS HAVE TWO LUBRICATION CHANNELS FOR THIS REASON MEASURE THE DIAMETER ACCORDING TO THE PISTON AXIS
Characteristic
Standard clearance: 0.001 0.010 mm PISTON BEARINGS DIAMETER - Measure the diameter of the bearings on the piston.
Characteristic
Standard diameter: 22 + 0.006 +0.001 mm
Piston rings
* Fit piston rings 2 and 3 with the mark TOP facing up. ** Position the port in the piston rings as shown in this figure. *** Value A of the sealing ring inside the cylinder. Check the size of the sealing ring opening: Compression ring: 0.15 0.35 mm. Max. value: 0.5 mm Oil scraper ring: 0.25 0.50 mm. Max. value: 0.65 mm CHAR - 21
Characteristics
MSS Mana GT ABS
Oil scraper ring: 0.25 0.50 mm. Max. value: 0.65 mm Rings/slots coupling clearances: Carefully clean the sealing ring housings. Check coupling clearances by placing a thickness gauge between the ring and the slot as shown in the figure. Top ring: Standard coupling clearance: 0.010.06 mm Maximum clearances allowed after use: 0.10 mm Middle ring: Standard coupling clearance: 0.020.07 mm Maximum clearances allowed after use: 0.10 mm Oil scraper ring: Standard coupling clearance: 0.010.06 mm Maximum clearances allowed after use: 0.10 mm If clearances measured exceed the maximum values specified in the table, the piston should be replaced with a new one.
Crankcase - crankshaft - connecting rod

Crankshaft bearing diameter. Measure the diameters as indicated in the figure by positions A and B, on both x and y axes.
CHAR - 22
MSS Mana GT ABS
Characteristics
CRANKSHAFT
Specification Cat. 1 Cat. 2 Desc./Quantity Standard diameter: 45.010 45.016 Standard diameter: 45.016 45.022
CRANKSHAFT / CONNECTING ROD AXIAL CLEARANCE

Name Half shaft, transmission side Half shaft, flywheel side Description Dimensions 23.8 +0.1 23.8 + 0.1 Initials A B Quantity D = 0.20 0.55 D = 0.20 0.55
CHAR - 23
Characteristics
MSS Mana GT ABS
Name Connecting rod Complete crankshaft
Description
Dimensions 22 -0.10 - 0.15 91.8 +0.05
Initials C E
Quantity D = 0.20 0.55 D = 0.20 0.55
Characteristic
Crankshaft-crankcase axial clearance (H) 0.1 0.45 mm (when cold) - Measure the inside diameter of the rod small end using a bore meter.
NOTE IF THE ROD SMALL END DIAMETER EXCEEDS THE STANDARD DIAMETER, SHOWS SIGNS OF WEAR OR OVERHEATING, REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.
Characteristic
Standard diameter: 22 + 0.025 +0.015 mm Depending on the type of crankshaft/crankcase coupling, the following types of bushings listed in the table should be used.
CHAR - 24
MSS Mana GT ABS
Characteristics
KEY X = Crankshaft category Y = Crankcase half-shells category A = Red B = Blue C = Yellow
Recommended products chart

RECOMMENDED PRODUCTS
Product AGIP RACING 4T SAE 5W-40 Description Engine oil Specifications Use top-brand oils that meet or exceed the requirements of CCMC G-4 specifications. SAE 5W As an alternative to the recommended product, use top brand grease for roller bearings with an operating temperature range of -30C to +140C (-22F to +284 F), a drop point between 150C and 230 C (302F and 446F), high corrosion protection qualities and good water and rust resistance. Grease Biodegradable coolant, ready for use, with "long life" technology and characteristics (pink). Freezing protection up to -40C (-104F). Compliant with CUNA 956-16 standard.
AGIP FORK 5W AGIP MP GREASE
Fork oil Grease for bearings, joints, couplings and linkages
AGIP CHAIN GREASE SPRAY AGIP BRAKE 4 / BRAKE 5.1 AGIP PERMANENT SPEZIAL
Recommended CHAIN oil Recommended BRAKE FLUID Recommended ENGINE COOLANT
CHAR - 25
INDEX OF TOPICS
SPECIAL TOOLS
S-TOOLS
MSS Mana GT ABS
Special tools
SPECIFIC TOOLS
Stores code 020183Y Description 30 mm guide
020193Y
Gauge for oil pressure check
020262Y
Crankcase splitting strip
020306Y
Punch for fitting the valve sealing rings
020330Y
Stroboscopic light for timing checking
S-TOOLS - 27
Special tools
MSS Mana GT ABS
Stores code 020331Y
Description Digital multimeter
020335Y
Dial gauge magnetic support
020357Y
32 x 35 mm adaptor
020358Y
37 x 40-mm adaptor
020359Y
42 x 47-mm adaptor
S-TOOLS - 28
MSS Mana GT ABS
Special tools
Stores code 020360Y
Description 52 x 55-mm adaptor
020362Y
12 mm guide for oil seal in kick start pedal
020363Y
20 mm guide for oil seal
020364Y
25-mm Guide
020365Y
22 mm (0.87 in) guide
020375Y
28x30 mm punch
S-TOOLS - 29
Special tools
MSS Mana GT ABS
Stores code 020376Y
Description Adapter handle
020408Y
72x75-mm (2.83x2.95 in) adaptor
020412Y
15-mm Oil seal guide
020414Y
28 mm punch
020424Y
Punch for fitting driven pulley roller casing
020434Y
Fitting for oil pressure check
S-TOOLS - 30
MSS Mana GT ABS
Special tools
Stores code 020439Y
Description 17-mm guide for oil seal
020431Y
Valve oil seal extractor
020441Y
Oil seal punch
020455Y
10-mm guide for oil seal on water pump shaft
020456Y
24 mm punch
020470Y
Pin snap ring fitting tool
S-TOOLS - 31
Special tools
MSS Mana GT ABS
Stores code 020477Y
Description 37-mm Adaptor
020478Y
Punch for roller casing
020480Y
Fuel pressure check set
020481Y
Adaptor cable harness
020481Y004
Adaptor cable
020483Y
30 mm guide
S-TOOLS - 32
MSS Mana GT ABS
Special tools
Stores code 020527Y
Description Engine support base
020621Y
HV cable extraction adaptor
020629Y
8 mm (0.31 in) guide
020648Y
Single battery charger
020654Y
35-mm Guide
020655Y
62x68 mm Adaptor
S-TOOLS - 33
Special tools
MSS Mana GT ABS
Stores code 020658Y
Description Engine plate
020659Y
Tool to remove clutch and repl. belt
020660Y
Driving pulley check ring
020661Y
Water pump overall seal replacement kit
020662Y
50 mm guide
020663Y
Water pump shaft oil seal punch
020664Y
Flywheel side crankshaft fitting tip
S-TOOLS - 34
MSS Mana GT ABS
Special tools
Stores code 020665Y
Description Transmission side crankshaft fitting tip
020709Y
Engine support
020713Y
Flywheel extractor
020714Y
Dial gauge mounting
020716Y
Connecting rod locking
AP0276474
Valve spring compressor adaptor
AP8140146
Weight
S-TOOLS - 35
Special tools
MSS Mana GT ABS
Stores code AP8140147
Description Spacer tool
AP8140148
Spacer-pumping element separating plate
AP8140149
Protection for fitting operations
AP8140150
Perforated rod for pumping member air bleed
AP8140179
Support for valve fitting/removal
AP8140180
Extractor for bushings
AP8140189
Oil seal fitting tool for 43 mm (1.69 in) orifices
S-TOOLS - 36
MSS Mana GT ABS
Special tools
Stores code AP8140302
Description Piston fitting ring
AP8140595
Axone + battery charger (230V 50Hz)
AP8140187
Engine support stand
AP8106702
Flywheel lock calliper spanner
AP8202311
Axone + battery charger (110V 60Hz)
S-TOOLS - 37
INDEX OF TOPICS
MAINTENANCE
MAIN
MSS Mana GT ABS
Maintenance
Maintenance chart
Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum functionality and performance. For this purpose, Aprilia has formulated a series of checks and scheduled services (at the owner's expense), are summarised in the table given in the following page. We recommend having any minor faults resolved immediately by an Authorised Aprilia Dealer, without waiting until the next scheduled service interval. All scheduled services must be carried out at the specified intervals and mileage, as soon as the predetermined mileage is reached. Carrying out scheduled services on time is essential for the validity of your warranty. For further information regarding Warranty procedures and ''Scheduled Maintenance'', please refer to the ''Warranty Booklet''.
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Replace every 24 months. ** Check and replace if necessary every 2,000 km. *** Replace every 4 years
ROUTINE MAINTENANCE TABLE

km x 1,000 Drive chain Final drive Transmission cables and controls Diagnosis for engine control unit and transmission ECU Brake discs Brake pads ** Brake fluid * Braking systems Vehicle general operation Parking brake calliper Suspension and setting Fork oil * Fork oil seals Wheels and transmission cush drive Tyres Tyre pressure Steering bearings and steering clearance Tightening bolts, nuts and screws Coolant * Light circuit Safety switches Battery Fuel pipes *** Engine oil Engine oil filter Air filter Transmission air filter 1 I I I I I I I I I I I I I A I I I I I I 10 I I I I I I I I I I I I I A I I I I I I R R C C 20 R I I I I I I I I I I I I A I I I I I I R R C 30 I I I I I I I I I I I I I A I I I I I I R R R C C 40 I I I I I I I I I I I I I A I I I I I I R R C 50 R I I I I I I I I I I I I A I I I I I I R R C C 60 I I I I I I I I I I I I I A I I I I I I R R R C 70 I I I I I I I I I I I I I A I I I I I I R R C C 80 I I I I I I I I I I I I I A I I I I I I R R C
MAIN - 39
Maintenance
MSS Mana GT ABS
km x 1,000 Wheel bearings Tightening transmission nuts and bolts Drive belt Variator sliders Spark plug Throttle body Tappet clearance
1 -
10 I I -
20 I I R R R -
30 I I I I
40 I I R R R -
50 I I -
60 I I R R R I I
70 I I -
80 I I R R R I
Spark plug
At regular intervals, remove the spark plug and clean off any carbon deposits or replace as required.
CAUTION
ALWAYS REPLACE BOTH SPARK PLUGS, EVEN IF ONLY ONE NEEDS REPLACING. In order to reach the spark plugs:
CAUTION
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS, LEAVE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE. Working from both sides, remove the two spark plug tubes. With the specific supplied wrench, unscrew and remove the spark plugs (two per cylinder).
Check the gap between the electrodes with a feeler feeler gauge.
CAUTION
DO NOT ATTEMPT TO READJUST THE ELECTRODE GAP.
MAIN - 40
MSS Mana GT ABS
Maintenance
The gap between the electrodes should be between 0.7 - 0.8 mm (0.027 - 0.031 in). Otherwise, replace the spark plug (2). Make sure the washer is in good conditions. Installation: Once the washer is fitted, screw the spark plug (2) carefully to avoid damaging the thread. Tighten using the spanner supplied in the tool kit. Make each spark plug (2) complete 1/2 of a turn to compress the washer.
CAUTION
IT IS ESSENTIAL TO TIGHTEN THE SPARK PLUG (2) PROPERLY. A LOOSE SPARK PLUG MAY CAUSE ENGINE OVERHEATING AND RESULT IN SEVERE DAMAGE.
Locking torques (N*m)

Spark plug (2) 13 Nm (9.59 lbf ft)
Engine oil Check

Check the engine oil level frequently.
NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. CAUTION CHECK ENGINE OIL LEVEL WHEN THE ENGINE IS WARM, WITH THE VEHICLE PERFECTLY UPRIGHT, WITH BOTH WHEELS ON THE GROUND, ON A SOLID AND LEVEL SURFACE. NOTE DO NOT LET THE ENGINE IDLE WHEN THE VEHICLE IS AT STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER A TRIP OR AFTER TRAVELLING APPROXIMATELY 15 km (10 mi), OUT OF TOWN (ENOUGH TO WARM UP ENGINE OIL TO OPERATING TEMPERATURE). IT IS IMPORTANT TO MEASURE THE ENGINE OIL MINIMUM LEVEL USING THE DIPSTICK (1), AND THE ENGINE OIL MAXIMUM LEVEL THROUGH THE CRANKCASE SIGHT GLASS (2).
MAIN - 41
Maintenance
MSS Mana GT ABS
Shut off the engine. Keep the vehicle upright with both wheels on the ground. Unscrew and remove the filler cap (1) and check the oil level through the dipstick. The level should be above the minimum level marked on the cap-dipstick (1). Top up if the oil level is close to or below the reference mark on the dipstick.
Replacement
CHANGING ENGINE OIL AND ENGINE OIL FILTER CAN PROVE DIFFICULT IF YOUR ARE INEXPERIENCED. CONTACT AN OFFICIAL APRILIA DEALER IF REQUIRED. IF YOU WISH TO PERFORM THESE OPERATIONS YOURSELF, FOLLOW THESE INSTRUCTIONS. Check the engine oil level frequently. To change the oil:
CAUTION HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY; IDEAL TEMPERATURE IS REACHED AFTER THE ENGINE HAS RUN FOR ABOUT TWENTY MINUTES.
OIL BECOMES VERY HOT WHEN THE ENGINE IS HOT; BE CAREFUL NOT TO GET BURNED WHEN CARRYING OUT THE OPERATIONS DESCRIBED BELOW.
MAIN - 42
MSS Mana GT ABS
Maintenance
Use a cloth to wipe off any mud deposit on the area next to the filler plug (1). Place a container with + 4000 cm (244 cu.in) capacity under the drainage plug (2).
Unscrew and remove the drainage plug (2). Unscrew and remove the filler plug (1). Drain the oil into the container; allow several minutes for oil to drain out completely.
Replace the sealing washer of the drainage plug and the O-ring of the cap (2).
Screw and tighten the drainage plug (2) paying attention that the O-ring is adequately fitted so there are no oil leaks from the tank to the sump.
CAUTION IF THE O-RING IS NOT CORRECTLY FITTED, THIS RESULTS IN LACK OF SEALING AND CAN CAUSE OIL LEVEL TO INCREASE IN THE SUMP IN STATIC CONDITIONS.

Engine oil drainage plug - M16x1.5 (1) 21 - 29 Nm
(15.49 - 21.39 lbf ft)
MAIN - 43
Maintenance
MSS Mana GT ABS
Engine oil filter

ENGINE OIL FILTER REPLACEMENT Replace the engine oil filter (1) at the intervals specified in the routine maintenance table. Remove the engine oil filter (1).
Never reuse an old filter. Screw the new engine oil filter (1).

Engine oil filter (1) 16 Nm (11.80 lbf ft)
Air filter
Undo and remove the six screws fixing the filter casing cover. Remove the filter casing cover. Undo and remove the three screws fixing the air filter. Remove the air filter.
COVER THE HOLE WITH A CLEAN CLOTH SO THAT NO FOREIGN ELEMENTS GET INTO THE INLET DUCTS.
MAIN - 44
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Troubleshooting
MSS Mana GT ABS
Engine The engine does not start

CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
CAUTION
AXONE SHOULD BE WORKING PROPERLY AND UPGRADED TO THE 5.1.6 VERSION MINIMUM.
CAUTION
BEFORE ANY TROUBLESHOOTING, MAKE SURE THAT: 1) BATTERY VOLTAGE IS ABOVE 12V; 2) THE MAIN 30A FUSE IS NOT DAMAGED AND IS ADEQUATELY FITTED; 3) AUXILIARY FUSES ARE NOT DAMAGED AND ARE ADEQUATELY FITTED.
NOTE
THE RELAY NUMBER SPECIFIED REFERS TO THE WIRING DIAGRAM. THE POSITION OF THE RELAY ON THE VEHICLE IS INDICATED IN THE "ELECTRICAL SYSTEM/COMPONENT LAYOUT/ RELAY LAYOUT" CHAPTER. 1 - WITH THE KEY TURNED TO "ON", THE INSTRUMENT PANEL LIGHTS UP BUT NO FAILURE INDICATION IS SHOWN. 2 - IS THE FUEL PUMP ACTIVATED? YES, go to 3; NO, go to 7. 3 - DOES THE MOTOR TURN WHEN THE STARTER BUTTON IS PRESSED? YES, go to 4; NO, go to 12. 4 - SEE THE "ELECTRICAL SYSTEM/ CHECKS AND CONTROLS/ ENGINE REVOLUTION SENSOR" CHAPTER: SEE THE WARNING RELATED TO THE TROUBLESHOOTING AT THE END OF THE PARAGRAPH 5 - HAS THE MALFUNCTION BEEN IDENTIFIED? YES, END; NO, go to 6. 6 - CHECK INJECTORS AND ENGINE FOR CORRECT MECHANICAL OPERATION, CHECK FUEL CIRCUIT PRESSURE. IN CASE OF A FAULTY SECONDARY CIRCUIT OF A COIL, THE ENGINE STARTS BUT WITH ONE CYLINDER - END 7 - CHECK THE FUEL PUMP CONNECTOR AND CHECK IF THERE IS CONTINUITY IN THE RED/BROWN CABLE FROM THE CONNECTOR TO RELAY 29 (INJECTION LOAD) AND ITS GROUND INSULATION: IS EVERYTHING OK? YES, go to 8; NO, go to 11. 8 - IS THERE CONTINUITY BETWEEN THE BLUE/GREEN CABLE OF THE PUMP CONNECTOR AND THE GROUND CONNECTION? YES, go to 10; NO, go to 9.
TROUBL - 46
MSS Mana GT ABS
Troubleshooting
9 - RESTORE THE CABLE HARNESS - END 10 - CHECK THE ELECTRICAL SPECIFICATIONS OF THE FUEL PUMP - END 11 - RESTORE THE CABLE HARNESS - END 12 - CONNECT TO AXONE BY SELECTING "PETROL INJECTION": WHAT DOES THE "IGNITION" STATUS INDICATE IN THE DEVICE STATUS (ICON 0/1) SCREEN PAGE? ENABLED, go to 13; DISABLED, go to 25
13 - CONNECT TO AXONE BY SELECTING "AUTOMATIC GEARSHIFT": WHAT DOES THE "IGNITION" STATUS INDICATE IN THE DEVICE STATUS (ICON 0/1) SCREEN PAGE? ENABLED, go to 14; CONDITIONAL, go to 31
14 - IF THE FRONT BRAKE IS OPERATED, DOES THE STOP LIGHT TURN ON? YES, go to 15; NO, go to 32.
15 - IF THE REAR BRAKE IS OPERATED, DOES THE STOP LIGHT TURN ON? YES, go to 16; NO, go to 37.
16 - IS THERE CONTINUITY BETWEEN THE YELLOW/GREEN CABLE FROM PIN 1 OF RELAY No. 3 (START-UP CONTROL) TO PIN 23 OF CONNECTOR B OF THE ECU? YES, go to 44; NO, go to 42.
19 - IS THERE VOLTAGE AT PIN 28 B WHEN THE KEY IS SET TO ON ? THAT IS, IS THERE VOLTAGE ON THE YELLOW/RED CABLE OF (RETENTION) RELAY No. 65, AND IS THERE CONTINUITY IN THE CABLE UP TO PIN 28 OF CONNECTOR B OF THE ECU AND IS THE CABLE GROUND INSULATED? YES, go to 20; NO, go to 48.
20 - DOES THE VOLTAGE IN THE YELLOW/RED CABLE OF (RETENTION) RELAY No. 65 DROP TO APPROXIMATELY 0 WHEN THE KEY IS SET TO ON AND THE START-UP SWITCH IS PRESSED? YES, go to 21; NO, go to 49.
21 - CHECK CORRECT GROUND CLOSING OF PIN 1 OF CONNECTOR B BY THE ECU: WHEN TRYING TO START UP THE ENGINE (BY PRESSING THE STARTER BUTTON AND OPERATING THE BRAKES), IS VOLTAGE PULSE DETECTED ON THE ORANGE/ YELLOW CABLE OF THE RETENTION RELAY (No. 65)? YES, go to 22; NO, go to 52.
22 - WHEN TRYING TO START UP THE ENGINE (BY PRESSING THE STARTER BUTTON AND OPERATING THE BRAKES), IS VOLTAGE PULSE DETECTED ON THE RED CABLE TOWARDS THE STARTER MOTOR OF RELAY No. 64 (START-UP REMOTE CONTROL)? YES, go to 23; NO, go to 55. TROUBL - 47
Troubleshooting
MSS Mana GT ABS
23 - IS THE STARTER MOTOR CORRECTLY CONNECTED TO THE VEHICLE GROUND CONNECTION? YES, go to 24; NO, go to 60.
24 - PROBABLE ELECTRIC MOTOR MALFUNCTION: CHECK ITS SPECIFICATIONS END 25 - WHAT DOES THE FALL SENSOR STATUS INDICATE? NORMAL, go to 26; TIP OVER, go to 28
26 - WHAT DOES THE RUN/STOP SWITCH STATUS INDICATE? RUN, go to 13; STOP, go to 27
27 - SEE THE "ELECTRICAL SYSTEM, CHECKS AND CONTROLS, RUN/STOP SWITCH" CHAPTER: INDICATION ON AXONE ALWAYS "STOP" - END 28 - IS THE FALL SENSOR VERTICAL? YES, go to 29; NO, go to 30.
29 - SEE THE "ELECTRICAL SYSTEM, CHECKS AND CONTROLS, FALL SENSOR" CHAPTER: INDICATION ON AXONE ALWAYS TIP OVER - END 30 - PLACE IT CORRECTLY - END 31 - IT IS NECESSARY TO FOLD THE SIDE STAND (VARIATOR NOT IN 1ST GEAR POSITION) - END 32 - IS THERE VOLTAGE ON THE YELLOW/GREEN CABLE OF THE SWITCH WHEN THE KEY IS SET TO "ON" AND THE FRONT BRAKE SWITCH PRESSED? YES, go to 33; NO, go to 34.
33 - CHECK CONTINUITY AND GROUND INSULATION OF THE YELLOW/GREEN CABLE FROM THE FRONT BRAKE SWITCH TO THE REAR LIGHT AND RESTORE THE CABLE HARNESS- END
34 - IS THERE VOLTAGE ON THE GREEN CABLE OF THE SWITCH? YES, go to 35; NO, go to 36.
35 - REPLACE THE FRONT BRAKE SWITCH - END 36 - RESTORE THE CABLE HARNESS(GREEN CABLE) - END 37 - IS THERE VOLTAGE ON THE YELLOW/GREEN CABLE OF THE SWITCH WHEN THE KEY IS SET TO "ON" AND THE REAR BRAKE SWITCH IS PRESSED? YES, go to 38; NO, go to 39.
38 - CHECK CONTINUITY AND GROUND INSULATION OF THE YELLOW/GREEN CABLE FROM THE FRONT BRAKE SWITCH TO THE REAR LIGHT AND RESTORE THE CABLE HARNESS- END
39 - IS THERE VOLTAGE ON THE GREEN CABLE OF THE SWITCH?
TROUBL - 48
MSS Mana GT ABS
Troubleshooting
YES, go to 40; NO, go to 41 40 - REPLACE THE REAR BRAKE SWITCH - END 41 - RESTORE THE CABLE HARNESS (GREEN CABLE) - END 42 - RESTORE THE CABLE HARNESS (YELLOW/GREEN CABLE) - END 44 - IS THERE VOLTAGE ON THE PINK/BROWN CABLE OF THE START-UP CONTROL RELAY WHEN THE KEY IS SET TO ON AND THE FRONT OR REAR BRAKE SWITCH IS PRESSED? YES, go to 45; NO, go to 46
45 - IS THERE CONTINUITY ON THE PINK/BROWN CABLE FROM PIN 2 OF THE STARTUP CONTROL RELAY TO PIN 5 OF THE RETENTION RELAY AND FROM PIN 2 OF THE START-UP CONTROL RELAY TO PIN 1 OF CONNECTOR B OF THE ECU? YES, go to 19; NO, go to 47
46 - CHECK CONTINUITY BETWEEN PIN 1 AND PIN 2 OF THE RELAY AND CONTINUITY AND GROUND INSULATION OF THE YELLOW/GREEN CABLE AND THE PINK/ BROWN CABLE - END
47 - RESTORE THE CABLE HARNESS(PINK/BROWN CABLE) - END 48 - RESTORE THE CABLE HARNESS(YELLOW/RED CABLE) - END 49 - IS THERE CONTINUITY BETWEEN THE STARTER BUTTON BLUE CABLE AND THE GROUND LEAD? YES, go to 50; NO, go to 51
50 - CHECK THE RIGHT LIGHT SWITCH CONNECTOR, THE CABLES FROM THE CONNECTOR TO THE LIGHT SWITCH AND THE LIGHT SWITCH - END 51 - RESTORE THE CABLE HARNESS (BLUE CABLE) - END 52 - DOES THE START-UP CONTROL RELAY WORK CORRECTLY? YES, go to 53; NO, go to 54 53 - PROBABLE MALFUNCTION OF THE INJECTION ECU - END 54 - REPLACE THE RELAY - END 55 - DISCONNECT THE START-UP REMOTE CONTROL CONNECTOR, WHEN TRYING TO START UP THE ENGINE (BY PRESSING THE STARTER BUTTON AND OPERATING THE BRAKES), IS VOLTAGE PRESENT ON THE ORANGE/YELLOW CABLE? YES, go to 56; NO, go to 58
56 - IS THERE CONTINUITY WITH THE GROUND OF THE BLUE CABLE OF THE STARTUP REMOTE CONTROL? YES, go to 57; NO, go to 59
57 - REPLACE THE RELAY - END 58 - RESTORE THE CABLE HARNESS - END
TROUBL - 49
Troubleshooting
MSS Mana GT ABS
59 - RESTORE THE CABLE HARNESS - END 60 - RESTORE THE CABLE HARNESS - END
FAILURE INDICATIONS ON INSTRUMENT PANEL DISPLAY

WARNING LIGHTS Instrument panel (hardware) identical to that of the vehicle without ABS system (there is no dedicated warning light). Software version must be M2MAN0006 or higher (to check the current version connect/ disconnect battery). The system can not be disconnected (there is no ON/OFF switch). Each time the key is ON, the module performs a check of the system (flashing EFI warning light and ABS word on the display) that is completed when the 5 km/h (3.11 mph) are exceeded and the EFI warning light turns off and the ABS word disappears. In case of an error in the ABS system, the steady EFI warning light turns on and the ABS word appears on the display.
CAUTION
IF THE EFI WARNING LIGHT FLASHES WITH THE ABS WORD STEADY ON THE DISPLAY, THE ABS SYSTEM IS NOT ACTIVATED.
INSTRUMENT PANEL OFF

CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. 1 - KEY ON, THE INSTRUMENT PANEL DOES NOT TURN ON 2 - IS THE FUEL PUMP ACTIVATED? YES, go to 3; NO, go to 4. 3 - CHECK THE INSTRUMENT PANEL CONNECTOR AND CHECK IF THERE IS CONTINUITY IN THE GREEN CABLE FROM AUXILIARY FUSE TO PIN 1 OF THE INSTRUMENT PANEL CONNECTOR - END 4 - DETACH THE MAIN INJECTION RELAY: IS IT ON THE GREEN/BLACK CABLE? YES, go to 8; NO, go to 5. 5 - DETACH THE KEY SWITCH CONNECTOR: IS THERE VOLTAGE IN THE WHITE/RED CABLE? YES, go to 7; NO, go to 6. 6 - CHECK THE KEY SWITCH CONNECTOR AND CHECK IF THERE IS CONTINUITY IN THE WHITE/RED FROM THE 30A FUSE TO THE KEY SWITCH CONNECTOR - END 7 - CHECK CONTINUITY OF THE KEY SWITCH - END
TROUBL - 50
MSS Mana GT ABS
Troubleshooting
8 - IS THERE VOLTAGE IN THE WHITE/RED CABLE? YES, go to 9; NO, go to 12.
9 - SLIDE OFF THE AUXILIARY 15A FUSE: IS THERE VOLTAGE IN THE RED/BLACK CABLE? YES, go to 10; NO, go to 11.
10 - CHECK THE INSTRUMENT PANEL CONNECTOR AND CHECK IS THERE IS CONTINUITY IN THE GREEN CABLE FROM THE AUXILIARY FUSE TO PIN 1 OF THE INSTRUMENT PANEL CONNECTOR - END
11 - CHECK CORRECT OPERATION OF RELAY 28 - END 12 - CHECK THE MAIN INJECTION RELAY CONNECTOR AND CHECK IF THERE IS CONTINUITY IN THE WHITE/RED CABLE FROM THE 30A FUSE TO THE MAIN INJECTION RELAY CONNECTOR - END
Service
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. 1 - "EFI" WARNING LIGHT IS ON AND THE WORD "SERVICE" IS SHOWN ON THE DISPLAY 2 - CONNECT TO AXONE SELECTING "PETROL INJECTION": ARE THERE ANY CURRENT ERRORS? YES, go to 3; NO, go to 9. 3 - FIND THE MALFUNCTION (SEE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS" CHAPTER AND RESTORE THE CORRECT OPERATION. 4 - HAS THE INJECTION ECU BEEN REPLACED? YES, go to 5; NO, go to 6. 5 - WITH AXONE SELECT "THROTTLE POSITIONER AUTODETECTION" - END 6 - HAS THE THROTTLE POSITIONER BEEN REPLACED? YES, go to 7; NO, go to 8. 7 - WITH AXONE SELECT THROTTLE POSITIONER AUTODETECTION 8 - DELETE THE ERROR WITH THE ERROR CLEARING FUNCTION IN THE DEVICES ACTIVATION (INJECTOR ICON) SCREEN PAGE - END 9 - OPEN THE "DIAGNOSIS" FUNCTION OF THE INSTRUMENT PANEL AND SELECT "INSTRUMENT PANEL ERRORS" 10 - FIND THE MALFUNCTION (SEE THE ELECTRICAL SYSTEM/CHECKS AND CONTROLS/INSTRUMENT PANEL/DIAGNOSIS CHAPTER) AND RESTORE THE CORRECT OPERATION.
TROUBL - 51
Troubleshooting
MSS Mana GT ABS
11 - HAS THE INSTRUMENT PANEL BEEN REPLACED? YES, go to 12; NO, go to 13.
12 - STORE ALL THE KEYS THE FIRST TIME THE INSTRUMENT PANEL IS SWITCHED ON - END 13 - DELETE THE ERROR WITH THE "ERROR CLEARING" FUNCTION IN THE "DIAGNOSIS" FUNCTION OF THE INSTRUMENT PANEL - END
Belt
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. 1 - WORD "BELT" SHOWN ON THE DISPLAY 2 - IS THE "EFI" WARNING LIGHT ON AND THE GEARSHIFT IN "AUTOMATIC - RAIN" MODE? YES, go to 4; NO, go to 3. 3 - NOW THE CURRENT BELT CAN BE USED UNTIL THE "EFI" WARNING LIGHT COMES ON AND THERE IS A FORCED SETTING OF THE GEARSHIFT IN "AUTOMATIC -RAIN" MODE 7 - HOWEVER, DO YOU WANT TO REPLACE THE BELT? YES, go to 5; NO, END 4 - CONNECT TO AXONE BY SELECTING "AUTOMATIC GEARSHIFT", THE "BELT WEAR" ERROR, CODE 9011 CURR. (CURRENT) IS PRESENT. 5 - REPLACE THE BELT AND BEFORE STARTING THE ENGINE, REPLACE THE BELT WITH AXONE (SEE ELECTRICAL SYSTEM/CHECKS AND CONTROLS/TRANSMISSION ECU/ADJUSTABLE PARAMETERS). 6 - DELETE THE ERROR WITH THE "ERROR CLEARING" FUNCTION - END
GEAR
CAUTION
CAUTION
BEFORE ANY TROUBLESHOOTING, MAKE SURE THAT: 1) BATTERY VOLTAGE IS ABOVE 12V; 2) THE MAIN 30A FUSE IS NOT DAMAGED AND IS ADEQUATELY FITTED; 3) AUXILIARY FUSES ARE NOT DAMAGED AND ARE ADEQUATELY FITTED. 1 - "EFI" WARNING LIGHT IS ON AND THE WORD "GEAR" IS SHOWN ON THE DISPLAY 2 - CONNECT TO AXONE BY SELECTING "AUTOMATIC GEARSHIFT" AND CHECK WHICH ERROR IS PRESENT: FOR FURTHER INFORMATION ABOUT THE ERROR AND ITS POSSIBLE CAUSES, PUSH BUTTON "?". THE AMBIENT PARAMETERS RELATED TO THE ERROR CAN ALSO TROUBL - 52
MSS Mana GT ABS
Troubleshooting
BE CONSULTED BY SELECTING THE "ACTIVATIONS" SCREEN AND THEN (INJECTOR ICON)/ ERROR AMBIENT PARAMETER READING 3 - FIND THE MALFUNCTION (SEE THE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS" CHAPTER) AND RESTORE THE CORRECT OPERATION 4 - TO SOLVE THE MALFUNCTION, IS IT NECESSARY TO REPLACE OR REMOVE THE DRIVING PULLEY POSITION POTENTIOMETER? YES, go to 5; NO, go to 7. 5 - ONCE THE POTENTIOMETER HAS BEEN REFITTED (SEE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS/POSITION SENSOR/DRIVING PULLEY/FITTING) AND BEFORE STARTING THE ENGINE, CARRY OUT THE "POTENTIOMETER RESET" OPERATION WITH AXONE (SEE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS/DRIVING PULLEY POSITION SENSOR/ADJUSTABLE PARAMETERS) 6 - DELETE THE ERROR WITH THE "ERROR CLEARING" FUNCTION - END 7 - TO SOLVE THE MALFUNCTION, IT IS NECESSARY TO REPLACE THE TRANSMISSION ECU YES, go to 8; NO, GO TO 6 - END 8 - IT IS ALSO NECESSARY TO SOLVE THE BELT PROBLEM, USING AXONE ENTER IN THE ECU THE GEARSHIFT STROKE CATEGORY OR THE DEFAULT VALUE, AND BEFORE STARTING THE ENGINE, CARRY OUT THE "POTENTIOMETER RESET" OPERATION WITH AXONE (SEE ELECTRICAL SYSTEM/CHECKS AND CONTROLS/DRIVING PULLEY POSITION SENSOR/ADJUSTABLE PARAMETERS - END
H-F-M
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. 1 - LETTERS "H"; "F" OR "M" ARE SHOWN ON THE DISPLAY 2 - "H" DISPLAYED? YES, go to 3; NO, go to 4. 3 - IN THE INSTRUMENT PANEL, GO TO "MENU/CONTROL (on handlebar) ENABLING: ARE THEY ENABLED? YES, go to 4; NO, go to 7. 4 - CONNECT TO AXONE BY SELECTING "AUTOMATIC" AND CHECK WHICH "ERROR" IS PRESENT: FOR FURTHER INFORMATION ABOUT THE ERROR AND ITS POSSIBLE CAUSES, PUSH BUTTON "?" THE AMBIENT PARAMETERS RELATED TO THE ERROR CAN ALSO BE CONSULTED BY SELECTING THE "ACTIVATIONS" SCREEN AND THEN (INJECTOR ICON)/ERROR AMBIENT PARAMETER READING
TROUBL - 53
Troubleshooting
MSS Mana GT ABS
5 - FIND THE MALFUNCTION (SEE THE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS" CHAPTER AND RESTORE THE CORRECT OPERATION 6 - DELETE THE ERROR WITH THE "ERROR CLEARING" FUNCTION IN THE "DEVICES ACTIVATION" (INJECTOR ICON) SCREEN PAGE - END 7- ENABLE THE HANDLEBAR CONTROLS - END
ECU AND CABLE DISCONNECTED ICON

CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. 1 - EFI WARNING LIGHT IS ON AND WORD ECU AND DISCONNECTED ECU ICON ARE SHOWN ON THE DISPLAY 2 - CONNECT TO AXONE SELECTING "PETROL INJECTION": DOES AXONE COMMUNICATE WITH THE CONTROL UNIT? YES, go to 3; NO, go to 4. 3 - READ THE ERROR INDICATED AND FOLLOW THE INSTRUCTIONS PRESENT IN THE "ELECTRICAL SYSTEM/CAN LINE" CHAPTER - END 4 - CHECK CONNECTOR B (blue) OF THE INJECTION ECU (PIN 4) AND CHECK IF THERE IS CONTINUITY IN THE ORANGE/GREEN CABLE BETWEEN THE CONNECTOR AND AUXILIARY FUSE BOX.
OIL BULB
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. 1 - EFI WARNING LIGHT IS ON AND THE BULB ICON IS SHOWN IN THE DISPLAY 2 - OPEN THE "DIAGNOSIS" FUNCTION OF THE INSTRUMENT PANEL AND SELECT "INSTRUMENT PANEL ERRORS" 3 - FIND THE MALFUNCTION (SEE THE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS/INSTRUMENT PANEL/DIAGNOSIS" CHAPTER AND RESTORE THE CORRECT OPERATION 4 - HAS THE INSTRUMENT PANEL BEEN REPLACED? YES, go to 5; NO, go to 6. 5 - STORE ALL THE KEYS THE FIRST TIME THE INSTRUMENT PANEL IS SWITCHED ON - END
TROUBL - 54
MSS Mana GT ABS
Troubleshooting
6 - DELETE THE ERROR WITH THE "ERROR CLEARING" FUNCTION IN THE "DIAGNOSIS" FUNCTION OF THE INSTRUMENT PANEL - END
TROUBL - 55
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
MSS Mana GT ABS
Electrical system
Components arrangement
CAUTION
A RELAY CANNOT BE IDENTIFIED BASED ONLY ON THE FOLLOWING INDICATIONS: THIS SHOULD BE DONE ALSO IDENTIFYING THE COLOUR OF THE RELAY CABLES. RELAY LAYOUT ON THE WIRING DIAGRAM AND ON THE VEHICLE START-UP CONTROL RELAY Location on the wiring diagram: 3 Location on the vehicle: under the helmet compartment, to the right in the relay holder.
LIGHTS LOGIC RELAY Location on the wiring diagram: 5 Location on the vehicle: under the helmet compartment, to the right in the relay holder.
MAIN INJECTION RELAY Location on the wiring diagram: 28 Location on the vehicle: under the helmet compartment, to the right in the relay holder.
AUXILIARY INJECTION RELAY Location on the wiring diagram: 29 Location on the vehicle: under the helmet compartment, to the right in the relay holder.
FAN CONTROL RELAY Location on the wiring diagram: 62 Location on the vehicle: under the helmet compartment, to the right in the relay holder.
START-UP RELAY Location on the wiring diagram: 64 Location on the vehicle: under the saddle.
RETENTION RELAY Location on the wiring diagram: 65 Location on the vehicle: under the helmet compartment, to the right in the relay holder.
HIGH-BEAM LIGHT RELAY Location on the wiring diagram: 69 Location on the vehicle: under the helmet compartment, next to the left fork.
RESISTANCE MODULE Location on the wiring diagram: 70 Location on the vehicle: under the helmet compartment, next to the left fork (only if injection control unit mapping is more recent than the 00 version).
ELE SYS - 57
Electrical system
MSS Mana GT ABS
Electrical system installation

Motorcycle division The wiring distribution is subdivided in three essential sections, as indicated in the figure. 1. Front section 2. Central section 3. Rear section
SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES Carry out the checks described below once the electrical system is refitted, connectors reconnected and clamps and retainers restored. For the following connectors, check the connection and the correct tightening of the Secondary Lock and "mark" the connector with an indelible pen. 1. Instrument panel connector: FRONT SECTION, TABLE J. 2. Handgrip sensor connectors: CENTRAL SECTION, TABLE F. 3. Pick Up Connector: CENTRAL SECTION, TABLE Q. 4. Side Stand Switch Connector. 5. Regulator Connector: CENTRAL SECTION, TABLE H. 6. Front cylinder coil and rear cylinder coil connectors: CENTRAL SECTION, TABLE F. 7. Filter Housing Connectors: CENTRAL SECTION, TABLE F. 8. ECU and Ground Lead Connectors for the filter casing: CENTRAL SECTION, TABLE A. 9. Fuel Pump Connector: CENTRAL SECTION, TABLE F. 10.Key Connector - Right Light Switch Connectors - Left Light Switch Connectors: Connectors inside the housing behind the radiator: FRONT SECTION, TABLE I. 11.Pedal gear control connector. 12.Pulley position connector. 13.ABS control unit connector 14.Rear and front ABS sensor connector. THE CONNECTORS LISTED ARE CONSIDERED CRITICAL IN COMPARISON WITH ANY OTHER BECAUSE THE VEHICLE WILL STOP IF THEY ARE ACCIDENTALLY DISCONNECTED. Undoubtedly the connection of the rest of connectors is also important and essential for the correct operation of the vehicle.
Front side
CAUTION
ELE SYS - 58
MSS Mana GT ABS
Electrical system
ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELECTRICAL SYSTEM INSTALLATION" SECTION. TABLE A Turn signal extension (1) 3 Black nylon clamps
TABLE B Turn signal extension (1) 3 Black nylon clamps
TABLE C 4. Clamps
TABLE D 2. Clamps
ELE SYS - 59
Electrical system
MSS Mana GT ABS
TABLE E Clamp that fixes the main cable harness and antenna cable to the support.
TABLE F - Front ABS sensor fitting 3 Black nylon clamps White cable guide
TABLE F1 3. Clamps
TABLE G 6. ABS grommet Pay attention to the front ABS hose guides passage so as not to flatten them.
ELE SYS - 60
MSS Mana GT ABS
Electrical system
TABLE H 7. Rear ABS system oil pipes 8. Front ABS system oil pipes Be very careful when placing the rear pump-control unit pipes, insert the two pipes in the respective lower clamps. 9. Modulator
TABLE I 10. Fan connector 11. Key switch connection
TABLE J 12. Black clamps 178x4 (7x0.16) 13. Clamp to chassis 14. Black clamp 178x4 (7x0.16) 15. Front ABS sensor connector
ELE SYS - 61
Electrical system
MSS Mana GT ABS
TABLE K Clamp that fixes the main cable harness, front lamp output, left light switch output and transmission control output.
TABLE L 16. 2 clamps that fix the left light switch cable and the transmission control cable to the support. 17. Clamp that fixes the air temperature sensor cable, the left light switch cable and the transmission control cable to the support.
Central part
CAUTION
ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELECTRICAL SYSTEM INSTALLATION" SECTION. TABLE A - COILS 1. Part for fitting ground terminals, on coil assembly. 2. Cable guide
ELE SYS - 62
MSS Mana GT ABS
Electrical system
TABLE B - CABLE HARNESS FOR RELAY UNIT The shortest cables must be connected to the three closest relays
TABLE C - FLYWHEEL CABLE HARNESS
TABLE D 3. Fan connector 4. Middle clamp 5. Coil "A" connector 6. Clamp to chassis
TABLE E - Coil assembly connection 1. insert the connectors in both coils; 2. fit coil assembly on chassis; 3. connect H.V. cables 7a. Coil "P" connector 7b. Coil "A" connector 7c. Clamp to chassis
ELE SYS - 63
Electrical system
MSS Mana GT ABS
TABLE F 8. Cable harness laying through the cable guide
TABLE G - Location of front cylinder injector
TABLE H 9. Clamp 178x4 (7x0.16)
TABLE I 10a. Gearbox starter motor connection 10b. Pulley sensor connection 11. Engine ground
ELE SYS - 64
MSS Mana GT ABS
Electrical system
TABLE L 12. Clamp to chassis fastening the three cables 13. Black clamps 98x2 (3.86x0.08)
TABLE M - Locate gear switch on crankcase 14. Switch "D"
TABLE N - Starter motor cable 15. Black clamps 98x2 (3.86x0.08)
ELE SYS - 65
Electrical system
MSS Mana GT ABS
TABLE O 16. Clamp to chassis
TABLE P Procedure for the correct insertion of the ABS control unit connector The initial position of the lever that couples the connector must be as shown in the figure.
TABLE P1 Place the connector on the opposite side of the control unit and lower the driving lever until the "click" that signals the end of the stroke is heard.
TABLE P2 When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm (0.295 in). If the initial positions of the connector and the driving lever are not those described in P1, the connector will not be properly coupled and the distance measured will be greater (12 mm approx. (0.47 in). In this case repeat the operation as described in P, P1, P2. It is advisable to create a template to check the correct connector insertion.
ELE SYS - 66
MSS Mana GT ABS
Electrical system
TABLE P3 Fit the housing.
TABLE Q - FITTING OPTION WITH PICK-UP DIVIDER CABLE HARNESS 1. Pick-up divider cable harness. 2. Fasten the cable harness with a clamp. 3. Signal regulator exit with WHITE tape. 4. Fasten the upper branch of the control unit with a clamp. TABLE Q 17. Big clamp 18. Clamp to chassis
ELE SYS - 67
Electrical system
MSS Mana GT ABS
TABLE R 19. The light switch connections must be placed on the chassis pipe 20. The flywheel cable passes under the main cable harness Note: where indicated, fasten with a 290 black clamp on the reference position.
TABLE S The pick-up sensor cable harness passes around the fuel pipe and the main cable harness 21. Black clamps 178x4 (7.008x0.157)
TABLE T - Start-up relay 22. Start-up relay connections Fasten where indicated with a 178x4 (7.008x0.157) black clamp
TABLE U - Engine control unit Engine control unit fitting: Connect the control unit to the main cable harness; Fit the control unit on the glove-box with AP8150426 screws and AP8201764 clips
ELE SYS - 68
MSS Mana GT ABS
Electrical system
TABLE V - Ground to chassis connection
TABLE Z 22. Clamp to chassis that locks the fuel pipe and the pulley sensor
TABLE ZA 23. Black clamp 178x4 (7.008x0.157)
TABLE ZB
ELE SYS - 69
Electrical system
MSS Mana GT ABS
TABLE ZC
TABLE ZD Red and Blue - Rear cylinder H.V cables laying Yellow - Temperature sensor cable laying
TABLE ZE Red - glove-box light cable harness At the centre of the figure, glove-box light connector Note - fasten the cable harness with a 178x4 (7.008x0.157) black clamp
TABLE ZF 24. Clamp to chassis 25. Rear ABS sensor connector 26. Black nylon clamp
ELE SYS - 70
MSS Mana GT ABS
Electrical system
TABLE ZG The lambda probe and rear stop switch cables must pass BEHIND the braking system pipes
Back side
CAUTION
ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELECTRICAL SYSTEM INSTALLATION" SECTION. TABLE A 1. Clamp to chassis Perform cable taping where indicated by the arrow.
TABLE B - Rear headlight cable harness 2. Rear headlight connector 3. 2 Clamps code
ELE SYS - 71
Electrical system
MSS Mana GT ABS
TABLE C - Rear ABS sensor fitting 4. Black cable guide 5. Black nylon clamp Note - The sensor cable must pass ABOVE the brake pipe.
TABLE D 2 black nylon clamps
ELE SYS - 72
MSS Mana GT ABS
Electrical system
General wiring diagram
KEY 1. MULTIPLE CONNECTORS 2. PULLEY POSITION SENSOR 3. START-UP CONTROL RELAY 4. PULLEY SPEED SENSOR
ELE SYS - 73
Electrical system
MSS Mana GT ABS
5. LIGHT LOGIC RELAY 6. RIGHT LIGHT SWITCH 7. HIGH-BEAM BULB 8. HORN 9. LEFT LIGHT SWITCH 10.AMBIENT AIR TEMPERATURE SENSOR 11.Instrument panel 12.INSTRUMENT PANEL DIAGNOSIS 13.KEY SWITCH 14.IMMOBILIZER AERIAL 15.REAR RIGHT TURN INDICATOR 16.REAR LIGHT ASSEMBLY 17.REAR LEFT TURN INDICATOR 18.CVT CONTROL UNIT 19.REAR STOP SWITCH 20.FRONT STOP SWITCH 21.ECU DIAGNOSIS CONNECTOR 22.AUXILIARY FUSES 23.AUTOMATIC TRANSMISSION FUSE 24.STARTER MOTOR 25.BATTERY 26.VOLTAGE REGULATOR 27.GENERATOR 28.INJECTION MAIN RELAY 29.INJECTION LOAD RELAY 30.OIL PRESSURE BULB 31.GEARSHIFT SWITCH ON HANDLEBAR 32.LAMBDA PROBE 33.SIDE STAND SWITCH 34.FUEL RESERVE SENSOR (PIC) 35.FUEL PUMP 36.INTAKE AIR TEMPERATURE SENSOR 37.WATER TEMPERATURE SENSOR 38.AUTOMATIC AIR 39.THROTTLE SENSOR 40.FRONT CYLINDER INNER SPARK PLUG 41.FRONT CYLINDER OUTER SPARK PLUG 42.REAR CYLINDER INNER SPARK PLUG ELE SYS - 74
MSS Mana GT ABS
Electrical system
43.REAR CYLINDER OUTER SPARK PLUG 44.FRONT CYLINDER DOUBLE COIL 45.REAR CYLINDER DOUBLE COIL 46.FRONT CYLINDER INJECTOR 47.REAR CYLINDER INJECTOR 48.PINION SPEED SENSOR 49.FALL SENSOR 50.PICK-UP 51.PICK-UP WIRE SHIELDING 52.ECU 53.FRONT LEFT TURN INDICATOR 54.TAIL LIGHT BULB 55.LOW-BEAM BULB 56.HEADLIGHT 57.RIGHT FRONT TURN INDICATOR 58.CVT MOTOR 59.GEAR DOWNSHIFT PEDAL SWITCH 60.GEAR UPSHIFT PEDAL SWITCH 61.FAN 62.FAN CONTROL RELAY 63.ELECTRIC LOCK 64.START-UP REMOTE CONTROL 65.RETENTION RELAY 66.LICENSE PLATE LIGHT 67.MAIN FUSE 68.PLUG SOCKET 69.HIGH-BEAM LIGHT RELAY 70.RESISTANCE MODULE 71.HEATED HAND GRIP CONNECTOR 72.GLOVE-BOX LIGHT 73.GLOVE-BOX LIGHT SWITCH 74.HEATED HAND GRIPS (OPTIONAL) 75.HEATED HAND GRIPS (OPTIONAL) 76.HAND GRIP CONTROL LIGHT SWITCH (OPTIONAL) 77.ABS CONTROL UNIT 78.FRONT ABS SENSOR 79.REAR ABS SENSOR 80.ABS CONTROL UNIT FUSE ELE SYS - 75
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81.HEATED HANDGRIP UNIT

CAUTION
THE ELECTRICAL SYSTEM IN THIS VEHICLE CAN BE SLIGHTLY DIFFERENT, DEPENDING ON THE SERIAL NUMBER, SPECIFICALLY IN THE LAYOUT OF THE GLOVE-BOX LIGHT SWITCH CONNECTIONS. THE DIFFERENCES ARE HIGHLIGHTED ON THE DIAGRAM BY TWO TYPES OF LINES, DIFFERENT AND ALTERNATE BETWEEN THEM: IF THERE IS A WHITE/RED CABLE ON THE VEHICLE, REFER TO THE PATH MARKED WITH long/short dashes IF THERE IS A GREEN CABLE ON THE VEHICLE, REFER TO THE PATH MARKED WITH A UNIFORM DOTTED LINE.
Checks and inspections

GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING PROCEDURE ON THE VEHICLE, CHECK THAT THE BATTERY VOLTAGE IS ABOVE 12V. CONNECTOR CHECK PROCEDURE The procedure includes the following checks: 1. Observation and check of the connector position on the component or on the coupling connector, making sure that the locking catch is released. 2. Observation of the terminals on the connector: no rust marks or dirt should be present and it is important to check terminal correct positioning on the connector (i.e., all terminals aligned at the same depth) and terminal integrity (i.e., that terminals are not loose, open/bent, etc.). For connectors whose terminals are not visible (e.g. Marelli control unit) use a metal cable of suitable diameter and introduce it carefully in the connector slot at the same depth as for the other terminals of the connector.
CAUTION IN CASE OF TEMPORAL MALFUNCTIONING, CARRY OUT ALL DUE CHECKS LOOKING FOR FAULT BY MOVING SLIGHTLY THE CABLE HARNESS BEING INSPECTED.
3. Pulling the cables slightly from the back of the connector in order to check the correct position of the terminals on the connector and of the cable on the terminal. ELE SYS - 76
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CONTINUITY check Check goal: this control is to check that there are not any circuit interruptions nor excessive resistance, for instance caused by rust, on the two terminals being inspected. Tester: set the tester on the "continuity" symbol and place the tester probes on the two circuit ends: the tester emits a sound signal only if there is continuity; the tester can also be set to the Ohm symbol to check that the circuit resistance is null or a few tenths of an Ohm. CAUTION: THE CIRCUIT SHOULD NOT BE ENERGISED, OTHERWISE THE TEST IS IRRELEVANT. GROUND CONNECTION check Check goal: this control is to check if a cable or a circuit is in contact with the vehicle ground (-) connection. Tester: set the tester on the "continuity" symbol and place one tester probe on the vehicle ground connection (or on the battery - terminal) and the other probe on the cable being inspected: the tester sends out a sound signal only if there is continuity. The tester can also be set to the Ohm symbol to check that the circuit resistance is null or a few tenths of an Ohm. CAUTION! IF THERE IS A GROUND CONNECTION COMING FROM THE CONTROL UNIT, MAKE SURE THAT DURING THE TEST THE CONTROL UNIT IS GROUND CONNECTED TO THE CIRCUIT. VOLTAGE check Check goal: this control is to check if a cable is energised, i.e. if it receives power supply from the battery or the control unit. Tester: set the tester on the direct current symbol and place the tester red probe on the cable being inspected and the black probe on the vehicle ground connection (or on the battery - terminal).
CAUTION
IN CASE OF TEMPORAL MALFUNCTIONING, CARRY OUT ALL DUE CHECKS LOOKING FOR FAULT BY MOVING SLIGHTLY THE CABLE HARNESS BEING INSPECTED.
Dashboard
In case of failure, a different icon is displayed according to the cause at the bottom of the display. SERVICE ALARM In case of failure found in the instrument panel or in the electronic control unit, the instrument panel signals the failure by displaying the SERVICE icon and the red general warning light comes on. Given this, and for some kinds of problems, the engine can be started only if the side stand is up.
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If there is an immobilizer failure at ignition, the instrument panel requests you to enter a user code. If the code is entered correctly, the instrument panel signals the failure by displaying the SERVICE icon and the red general warning light comes on. Air temperature sensor failure In case of air temperature sensor failure, the instrument panel signals the problem by displaying the "--" symbol steadily at the position where the temperature value is generally displayed. In this case the red general warning light does not turn on. Oil failure In case of failing oil pressure or oil pressure sensor failure, the bulb and the red general warning light turn on the instrument panel. Engine overheating alarm The engine overheating alarm is activated when the temperature is higher than or equal to 110 C (230 F). The red general warning light turns on and the thermometer icon flashes on the display to signal this condition. Electronic control unit disconnected alarm In case no connection is detected, the disconnection icon is displayed on the instrument panel and the red general warning light turns on to signal this condition.
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Turn indicator malfunction When the instrument panel detects a failing turn indicator, the turn indicator warning light flashes twice as fast and the problem is signalled on the digital display.
Alarms - transmission In case of alarms for gearshift controls and mode control connected to the transmission control unit, three kinds of symbols are shown on the display, according to the nature of the alarm: F, H and M. F stands for "foot" (foot pedal), H stands for "handlebar" (handlebar control) and M is for "mode" (gear mode selection). In case of alarms related to the transmission control unit, the general alarm warning light is lit and the display shows the word GEAR.
CAUTION IN CASE THE HANDLEBAR CONTROLS ARE DISABLED, THE H SYMBOL WILL BE ALSO SHOWN ON THE DIGITAL DISPLAY.
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Worn belt alarm The alarm for a worn belt indicates excessive wear for that belt. There are two priority levels: Low-priority alarm: the display shows the word BELT but the alarm warning light is off. High-priority alarm: the display shows the word BELT and the alarm warning light comes on simultaneously. For high-priority alarms, the RAIN mode is automatically set (see the Transmission chapter). ABS alarm (for vehicles fitted with this device) For alarms related to the ABS control unit, the general alarm warning light is lit and the display shows the word ABS
Side stand alarm If the side stand is down, the display shows the stand icon.
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Electrical system
Diagnosis
An access code is required to enter this menu which controls the diagnosis function: ENTER SERVICE CODE
This is a 5-digit code, fixed for each vehicle. For these vehicles, the code is: 12321 If the code is incorrect, the following message is displayed: INCORRECT CODE
and the instrument panel goes back to the main menu. Otherwise, the following menu is displayed: EXIT ECU DIAGNOSIS INSTRUMENT PANEL ERRORS ERROR CLEARING VEHICLE SERVICING RESET UPDATE CHANGE KEYS KM / MILES
ECU diagnosis In this mode a chart is displayed showing potential errors in the control unit. IT IS NECESSARY REFER TO THE ERROR INDICATIONS GIVEN BY AXONE FOR THIS VEHICLE.
The instrument panel does not keep all previous errors stored in its memory. INSTRUMENT PANEL ERRORS In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connected to it.
INSTRUMENT PANEL errors In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connected to it. DSB 01 - Immobilizer failure: key code read but not recognised. ELE SYS - 81
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DSB 02 - Immobilizer failure: key code not read (key not present or transponder not working) DSB 03 - Immobilizer failure: aerial not working (open or short-circuited) DSB 04 - Internal controller failure DSB 05 - DSB 06 - Ambient air temperature sensor Error cause An oil sensor failure is signalled when it is detected that the sensor circuit is open or shorted to positive. DSB 07 - Oil pressure sensor Error cause An oil sensor failure is signalled when, with engine off, it is detected that the sensor circuit is open. Troubleshooting The test is performed only once when the key is set to ON. This error is signalled by the bulb icon, and the general warning light turns on as well. DSB 08 - Oil pressure sensor Error cause An oil sensor failure is signalled when, with engine running, it is detected that the sensor circuit is closed. There is an error when the general warning light turns on. Troubleshooting This error is signalled by the bulb icon, and the general warning light turns on as well. The instrument panel must keep all previous errors stored in its memory. DELETE ERRORS This option deletes all instrument panel errors; a further confirmation is requested. Use Axone to reset ECU errors. VEHICLE SERVICING RESET This function is used to reset vehicle servicing. Using this function, the odometer can be reset only once within the first 200 km (124 mi) of the vehicle, provided this has not been done by the Quality Check. UPDATE This function is used to program the instrument panel again. This screen page shows the software version currently loaded; the LCD reads: INSTRUMENT PANEL DISCONNECTED. NOW CONNECT THE DIAGNOSIS INSTRUMENT. The instrument panel will restart to work normally after the key is inserted-extracted. Modify Keys With this function the instrument panel can update the keys. Up to 4 keys can be stored. The user code is first requested to be entered:
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ENTER THE CODE
After entering the correct code, the following message should be shown on the display: INSERT THE X KEY INSERT THE X+1 KEY
At least one key must be programmed for the next start-ups. If no other key is inserted within 20 seconds or if there is no power or after the fourth key is programmed, the procedure finishes and all the functions of the vehicle and the instrument panel must be enabled (even if only one key has been programmed). Km / miles This menu selects the unit of measurement, either for the speed or the total or partial odometers. KM MILES
LANGUAGES Select the user interface language from this menu. ITALIANO ENGLISH FRANCAIS DEUTSCH ESPAOL
Service warning light reset

VEHICLE SERVICING RESET This function is used to reset vehicle servicing. Using this function, the odometer can be reset only once within the first 200 km (124 mi) of the vehicle, provided this has not been done by the Quality Check. In order to activate this function follow the instructions in the DIAGNOSIS section.
See also
Diagnosis
Start-up system check

Function Operate the engine start-up through the INJECTION ECU Operation / Operating principle The start-up switch, the brake switches, start-up control relay No. 3, retention relay No. 65, start-up relay No. 64 and the injection ECU through PINS 1; 23 and 28 of connector B are involved. Level in wiring diagram:Start-up ELECTRICAL ERRORS Starter diagnosis P0170 - shorted to positive Error cause ELE SYS - 83
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If shorted to positive: excessive voltage has been detected at PIN 1 of connector B (BLUE).
Troubleshooting If shorted to positive: the malfunction is detected with an activated brake (12 V voltage detected at PIN 23 of connector B) and the start-up switch is pressed, if the battery voltage is not reduced (due to the absorption by the drive coil of the start-up control relay No. 3) now the ECU reads that the pink/brown cable is shorted to battery. Restore the cable harness (if the short circuit is in the cable harness) or the relay (if the short circuit is inside the relay).
NOTE
IN CASE OF SHORTED TO GROUND/ OPEN CIRCUIT, NO ERROR IS DISPLAYED: SEE ENGINE DOES NOT START IN THE TROUBLESHOOTING CHAPTER.
Checking the idle speed adj.system

IDLE REGULATION SYSTEM CHECK Function It checks the air flow in the inlet manifolds bypassing the throttle valve. Operation / Operating principle The opening position is set by the injection control unit and is performed by means of a Stepper electrical motor. Level in wiring diagram:Throttle and idle motor Location: on the vehicle: on throttle body connector: on throttle body
Electrical characteristics: between PIN A and PIN D: 50 Ohm +/10 % between PIN B and PIN C: 50 Ohm +/10 % Pin-out: A - 17 B - 19 C-9 D - 18
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT. ELE SYS - 84
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CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM PARAMETERS Stepper base Example value: 70 - 50 Steps corresponding to the idle motor reference position: approx. 70 when cold; approx. 50 when hot. CL Stepper Example value: 120 - 70 Steps set by the control unit for the idle motor. Steps at idle are so that the engine keeps the target engine Revs set by the control unit: approx. 90 - 120 steps when cold; approx. 70 - 90 when hot. Stepper regulator Difference between current steps of idle motor and those at the reference position. Virtual throttle angle from Stepper Example value: 0 If the engine is not at idle speed, this value indicates the motor air flow by the idle motor in throttle degrees. ACTIVATION Stepper control: For 4 s, advancement command of 32 steps; for the next 4 s, retrocession command of 32 steps and so on for 30s ELECTRICAL ERRORS Idle check P0505 - shorted to positive / shorted to negative / open circuit Error cause If shorted to positive: excessive voltage has been detected at PINS 17 and 18 or PINS 9 and 19 of connector A (BROWN). If shorted to negative: no voltage has been detected. If the circuit is open: an interruption has been detected
Troubleshooting If shorted to positive: with the key set to key ON disconnect the idle motor connector and check if there is a voltage different from zero at the ends of one of the PINS on the cable harness side: if there is voltage, restore the cable harness. If shorted to negative: with the key set to key ON disconnect the idle motor connector and check which pin on the cable harness side is in continuity with the ground connection and restore the cable harness. If the circuit is open: disconnect the idle motor connector and check the continuity towards the motor between PINS A and D and between PINS B and C: if there is an interruption, ELE SYS - 85
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replace the throttle body; if its OK, check the connectors of both idle motor and ECU: if they are not OK, restore; if OK, check continuity of the 4 cables and once the interrupted cable is found, restore the cable harness.
Fuses
AUXILIARY FUSES A - Tail lights, Stop lights, License place light, Horn, Electric lock, Instrument panel power supply, Transmission ECU power supply, Resistance module (15A). B - Low-/high-beam lights, Heated hand grips (OPT) (15 A). C - Fuel pump, Coils, Injectors, Electric fan, Lambda probe, Start-up control relay (20A). D - Injection load relay, Electric fan relay, Injection control unit power supply, Engine Stop (10A). E - Injection control unit permanent power supply (3A). F - Plug socket (15A). G - Spare fuses (10 - 15 - 20A). MAIN FUSES H - Instrument panel, Turn indicators, Glove-box light, Injection main relay (30A). E - Transmission ECU permanent power supply (40A). ABS FUSE The ABS fuse is placed inside the helmet compartment. J - ABS fuse (20 A)
FUSES SUBDIVISION Each time the key is set to ON, the ABS module is activated by means of a: 15A auxiliary fuse (NA 850 Mana ABS); 10A auxiliary fuse (SL 750 Shiver ABS / Dorsoduro 750 ABS)
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The hydraulic pump, the solenoid valves and the sensors are activated by a 20A main fuse.
Control unit
MARELLI CONTROL UNIT Function It manages injection/ignition, the system safety checks and the self-diagnosis function. Location: Right side, under helmet compartment.
Pin-out: see the CONNECTORS section THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM PARAMETERS Target idle rpm STATUSES Engine status Example value:ON/run/power-latch/stopped. Immobilizer signal Example value: yes/no Indicates whether the control unit has received the consent by the instrument panel regarding the immobilizer: coded key or user code entered manually. Potential errors will be shown on the Instrument Panel Errors screen page, on the DIAGNOSIS section of the instrument panel. Ignition Example value: Enabled/Disabled Indicates whether the control unit will enable start-up when requested: in case the safety measures are not respected, for example the fall sensor is inverted or if the immobilizer does not send the start-up consent to the control unit, the status is DISABLED. ACTIVATIONS Error clearing ELECTRICAL ERRORS ELE SYS - 87
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P0606 Microprocessor - circuit not operational. Error cause Possible internal control unit error. Also check the control unit supply and ground connections. Troubleshooting If the power supply and ground connections are connected correctly, replace the injection control unit. CONTROL UNIT REMOVAL Remove the right lower protection. Disconnect the connectors.
Undo and remove the ground cable fixing screw.
Undo and remove the two control unit fixing screws.
Remove the control unit.
NEW CONTROL UNIT ACTIVATION PROCEDURE After installing a new control unit, it is necessary to carry out the Throttle positioner autodetection function using the diagnosis instrument
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Speed sensor
VEHICLE FRONT SPEED SENSOR FUNCTION:To indicate the vehicle speed by reading the front wheel turning speed. OPERATION / OPERATING PRINCIPLE:Magnetoresistive sensor: a square-wave pulse is generated with voltage approx. between 11.55 V and 11.25 V WIRING DIAGRAM Level in wiring diagram: ABS. REMOVAL LOCATION ON THE VEHICLE:on the fork, right stem, next to the brake calliper support. CONNECTOR LOCATION (if available): under the helmet compartment. PINS PIN 1- Ground connection (white) PIN 2 - Power supply voltage/Output signal (white/brown) AXONE Parameters: Speed (km/h) - Vehicle speed. ELECTRICAL ERRORS Speed sensor 5D90 electric malfunction: Electrical fault in sensor or cable harness. Troubleshooting: Check the sensor connector and the ABS control unit connector. If they are not OK, restore the connectors. If they are OK, check continuity of the white/brown cable between PIN 2 of the sensor on the cable harness side and PIN 14 of the ABS control unit connector. If there is no continuity, restore them. If there is, PIN 2 of the sensor on the cable harness side, with the sensor disconnected and key set to ON, must have 12V voltage approximately: if there is no voltage, check PIN 2 for continuity with the vehicle ground connection: if it is grounded, restore the cable harness. If OK, replace the control unit. If PIN 2 has approx. 12 V, check the continuity of the white cable between PIN 1 of the sensor on the cable harness side and PIN 13 of the ABS control unit connector. If there is no continuity, restore the cable harness. If there is, replace the logic errors sensor. LOGIC ERRORS Speed sensor 5D91 the signal works irregularly: faulty sensor or signal interferences.
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Troubleshooting: Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone wheel is dirty, deformed or wrongly fixed. If any of this happens, replace the tone wheel. Otherwise, replace the speed sensor. 5D92 the signal decreases periodically: Possible tone wheel fault due to deformations or dirt; possible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel vibrations. Troubleshooting: Check if the tone wheel is dirty, deformed or wrongly fixed. If the tone wheel is not OK, replace it. If it is OK, check for possible faults in the wheel bearings and if it is not OK, replace the bearings. 5D93 missing signal or speed measured too low in relation to the rear wheel: faulty sensor or missing sensor/tone wheel. Or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth. Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer. If it is not, restore it. If it is, check if the tone wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace the tone wheel and if it is OK, replace the speed sensor. 5D94 no acceleration after pressure reduction: Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone wheel. Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer. If it is not, restore it. If it is, check if the tone wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace the tone wheel and if it is OK, replace the speed sensor. 5D95 excessive speed measured: Faulty sensor or tone wheel, or tone wheel with wrong number of teeth or wrong tyre size. Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace the tone wheel and if it is OK, check that the tyre size is the correct one. If it is not OK, replace it. If it is OK, check that the tyre pressure is the correct one. If it is not OK, restore it; if it is OK, replace the speed sensor.
VEHICLE REAR SPEED SENSOR FUNCTION:To indicate the vehicle speed by reading the rear wheel turning speed. OPERATION / OPERATING PRINCIPLE:Magnetoresistive sensor: a square-wave pulse is generated with voltage approx. between 11.55 V and 11.25 V WIRING DIAGRAM Level in wiring diagram: ABS. ELE SYS - 90
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REMOVAL LOCATION ON THE VEHICLE:on the fork, left side, under the parking brake calliper support. CONNECTOR LOCATION (if available): under the saddle, right side. PINS PIN 1- Ground connection (yellow) PIN 2 - Power supply voltage/Output signal (yellow/brown) AXONE Parameters: Speed (km/h) - Vehicle speed. ELECTRICAL ERRORS Speed sensor 5DA0 electric malfunction:Electrical fault in sensor or cable harness. Troubleshooting:Check the sensor connector and the ABS control unit connector. If they are not OK, restore the connectors. If they are OK, check continuity of the yellow/brown cable between PIN 2 of the sensor on the cable harness side and PIN 11 of the ABS control unit connector. If there is no continuity, restore them. If there is, PIN 2 of the sensor on the cable harness side, with the sensor disconnected and key set to ON, must have 12V voltage approximately: if there is no voltage, check PIN 2 for continuity with the vehicle ground connection: if it is grounded, restore the cable harness. If OK, replace the control unit. If PIN 2 has approx. 12 V, check continuity of the yellow cable between PIN 1 of the sensor on the cable harness side and PIN 12 of the ABS control unit connector. If this is not OK, restore the cable harness. If it is OK, replace the sensor. LOGIC ERRORS Speed sensor 5DA1 the signal works irregularly:faulty sensor or signal interferences. Troubleshooting:Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone wheel is dirty, deformed or wrongly fixed. If any of this happens, replace the tone wheel. Otherwise, replace the speed sensor. 5DA2 the signal decreases periodically: Possible tone wheel fault due to deformations or dirt; possible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel vibrations. Troubleshooting: Check if the tone wheel is dirty, deformed or wrongly fixed. If the tone wheel is not OK, replace it. If it is OK, check for possible faults in the wheel bearings and if it is not OK, replace the bearings. 5DA3 no signal or speed measured too low in relation to the front wheel: Faulty sensor or missing sensor/tone wheel. Or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth.
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Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer. If it is not, restore it. If it is, check if the tone wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace the tone wheel and if it is OK, replace the speed sensor. 5DA4 missing acceleration after pressure reduction: Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone wheel. Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer. If it is not, restore it. If it is, check if the tone wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace the tone wheel and if it is OK, replace the speed sensor. 5DA5 excessive measured speed: Faulty sensor or tone wheel, or tone wheel with wrong number of teeth or wrong tyre size. Troubleshooting:Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace the tone wheel and if it is OK, check that the tyre size is the correct one. If it is not OK, replace it. If it is OK, check that the tyre pressure is the correct one. If it is not OK, restore it; if it is OK, replace the speed sensor.
Engine rpm sensor

ENGINE REVOLUTION SENSOR Function It tells the crankshaft position and speed to the Marelli control unit. Operation / Operating principle Inductive sensor: sinusoidal-type generated voltage; two teeth are missing on the flywheel for the reference position. Level in wiring diagram:Revolution sensor Location: on the vehicle: rear cylinder, internal side connector: right side, under helmet compartment, along upper frame. Electrical specifications: Resistance at ambient temperature: 0.7-1.1 kOhm ELE SYS - 92
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Pin-out: 1. Negative signal 2. Positive signal THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM PARAMETERS Engine rpm (rpm) Engine revolutions per minute: the minimum value is set by the control unit and cannot be adjusted. STATUSES Synchronisation Example value:Synchronised / Not synchronised It indicates if the control unit detects the revolution sensor signal correctly. ELECTRICAL ERRORS Engine revolution sensor P0335 - open circuit Error cause: An interruption in the sensor circuit has been detected, from PIN 25 to PIN 35 of connector A (BROWN). Troubleshooting: Check the sensor connector and the injection control unit connector A (BROWN): if it is not OK, restore; if it is OK, check continuity of the two cables: if there is no continuity, restore the cable harness; if there is continuity, check the interruption on the sensor and replace it
CAUTION
IF THE ELECTRIC CIRCUIT IS SHORT-CIRCUITED, NO ERROR IS DISPLAYED. CHECK THE SENSOR ELECTRICAL SPECIFICATIONS: IF IT IS NOT THE CORRECT ONE, REPLACE THE SENSOR. IF IT IS THE CORRECT ONE, CHECK INSULATION FROM POWER AND GROUND CONNECTION OF BOTH CABLES OF PINS 1 AND 2. PERFORM THE TESTS FROM THE SENSOR CONNECTOR TO THE SENSOR. IF THEY ARE NOT OK, RESTORE THE CABLE HARNESS/REPLACE THE SENSOR. IF OK, PERFORM THE TEST FROM PINS 25 AND 35 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR A (BROWN) TO THE CABLE HARNESS AND REPLACE THE LATTER.
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Engine temperature sensor

ENGINE TEMPERATURE SENSOR Function it tells the engine temperature to the control unit so as to optimise its operation. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in wiring diagram:Temperature sensors Location: on the vehicle: rear cylinder, internal area connector: on the sensor
Electrical characteristics: Pin-out: Orange: 0-5 V signal: PIN B1 Grey: Ground connection: PIN B2 Resistance at 25: 2.05 kOhm +/- 100 Ohm Resistance at 60: 575 Ohm +/- 15 Ohm Resistance at 90: 230 Ohm +/- 5 Ohm
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM PARAMETERS Engine temperature Example value: 75 C In case of recovery, this value is set by the control unit. ELECTRICAL ERRORS engine temperature sensor P0115 - open circuit, shorted to positive / shorted to negative. Error cause ELE SYS - 94
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If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 5 of connector A (BROWN). If shorted to negative: voltage equal to zero has been detected. In both cases, recovery function.
Troubleshooting If the circuit is open, shorted to positive: check the sensor connector and the Marelli control unit connector. If they are OK, check sensor continuity: replace the sensor if not OK; if it is OK, check the continuity between PIN 5 of the connector A (BROWN) and sensor PIN 1: restore cable harness if there is no continuity; if it is OK, reconnect the control unit connector and, with key set to key ON, check the continuity between the sensor connector PIN 2 and the vehicle ground connection: if it is OK, it means that the error cause is that the cable is shorted to positive and it is necessary to restore the cable harness between ENGINE PIN 5 and sensor PIN 1; if there is not continuity with the ground lead, check the sensor connector and the Marelli control unit connector; if they are not OK, restore the cable harness; if they are OK, check continuity between PIN 20 of the connector A (BROWN) and PIN 2 of the sensor connector: restore the cable harness if there is not continuity. If there is, it means that the control unit does not supply the ground connection and therefore should be replaced. If shorted to negative, check sensor correct resistance: if resistance is null, replace the sensor; if resistance is correct, it means that the cable has ground connection: restore the cable harness. NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty: then check through Axone if the temperature indicated is plausible in relation to the engine temperature. Check also that the sensor electrical characteristics are observed: replace the sensor if not OK; if it is OK, check the sensor connector and the Marelli control unit connector
Air temperature sensor

INTAKE AIR TEMPERATURE SENSOR Function It tells the control unit the intake air temperature in order to calculate oxygen presence so as to optimise the petrol quantity necessary for correct combustion. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in wiring diagram:Temperature sensors Location: ELE SYS - 95
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on the vehicle: on throttle body on connector sensor: on throttle body
Electrical characteristics: Pin-out: 1. 0-5 V signal: PIN 1 2. Ground connection: PIN 2 THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
Resistance at 0: 5.9 k 5% Resistance at 10: 3.8 k 5% Resistance at 20: 2.5 k 5% Resistance at 30: 1.7 k 5%
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM PARAMETERS Air temperature Example value: 26 C Temperature of the air taken in by the engine, measured by the sensor in the throttle body. This is not the temperature indicated by the instrument panel. ELECTRICAL ERRORS air temperature sensor P0110 - open circuit, shorted to positive / shorted to negative. Error cause If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 14 of connector A (BROWN). If shorted to negative: voltage equal to zero has been detected. Troubleshooting If the circuit is open, shorted to positive: check the sensor connector and the Marelli control unit connector. If OK, check sensor continuity: replace the sensor if not OK; if it is OK, check continuity between PIN 14 of connector A (BROWN) and sensor PIN 1: restore cable harness if there is not continuity; if it is OK, reconnect the control unit connector and, with key set to key ON, check the continuity between the sensor connector PIN 2 and the vehicle ground connection: if it is OK, it means that the error cause is that the cable is shorted to positive and it is necessary to restore the cable harness between PIN 14 of the connector A (BROWN) and sensor PIN 1; check the sensor connector and the Marelli control unit ELE SYS - 96
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connector. If they are not OK, restore the cable harness. If they are OK, check continuity between PIN 20 of the connector A (BROWN) and PIN 2 of the sensor connector: restore the cable harness if there is not continuity. If there is, it means that the control unit does not supply the ground connection and therefore should be replaced. If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor; if resistance is correct, it means that the cable has ground connection: restore the cable harness. NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty: then check through Axone if the temperature indicated is plausible in relation to the ambient temperature. Check also that the sensor electrical characteristics are observed: replace the sensor if not OK; if it is OK, check the sensor connector and the Marelli control unit connector.
Lambda sensor
LAMBDA PROBE Function It tells the control unit whether combustion is lean or rich. Operation / Operating principle The Marelli injection control unit reads and interprets a voltage generated by the difference in oxygen content between the exhaust fumes and the ambient. It does not require an external supply source but, in order to work properly, it should reach a high operating temperature: that is why there is a heating circuit inside. Level in wiring diagram:Lambda probe Location: on the vehicle: on the silencer connector: near the probe, on the upper metal bracket. Electrical characteristics: Pin-out: 1. Sensor signal + (grey wire) 2. Sensor signal - (black wire) Heater circuit: 7-9 at Ambient temp.
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3. Heater ground connection (white) 4. Heater power supply (white) THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM PARAMETERS Lambda probe Example value: 0 - 1000 mV Signal when energised that the control unit receives from the lambda probe: inversely proportional to the presence of oxygen. Lambda integrator Example value: 0,00 % In closed loop, the value must be close to 0.00 (values not within the interval from -10.0 % to 10.0 % indicate a fault): for example, value 25% corresponds to +25% with respect to the reference injection time; -25% corresponds to -25%. In an open circuit, the lambda probe signal is too low. Therefore, the control unit takes it as a lean mixture condition and will try to enrich it. The value read will be +25%: once this correction has been tried, the value shifts to 0.00 fixed and the Lambda probe error is signalled. STATUSES Lambda Example value:Open loop / Closed loop It indicates if the control unit is using (CLOSED) the lambda probe signal to keep the stoichiometric combustion. At idle CLOSED only if: Air T >10 and engine T > 18 and engine running for at least 1-2 minutes. ELECTRICAL ERRORS Lambda probe P0130 - shorted to positive / open circuit, shorted to negative. Error cause If shorted to positive, excessive voltage has been detected at PIN 22 of connector B (BLUE). If the circuit is open, shorted to negative, no voltage has been detected. In both cases, the recovery function is hardly noticeable for the customer. Troubleshooting
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if shorted to positive: with key set to ON, disconnect the sensor connector and measure PIN 1 voltage on the cable harness side (grey cable): if there is voltage (5 or 12 V), restore the cable harness; if there is not, replace the lambda probe.
Lambda probe heater P0130 - shorted to positive / open circuit, shorted to negative. Error cause If shorted to positive: excessive voltage has been detected at PIN 11 of connector B (BLUE). If the circuit is open, shorted to negative: voltage equal to zero has been detected. Troubleshooting If shorted to positive: disconnect the probe connector and check the sensor correct resistance: replace the sensor if not OK; if it is OK, restore the cable harness. If the circuit is open, shorted to negative: check the sensor connector: if it is not OK, restore; if it is OK, check the continuity towards the sensor from PINS 3 and 4: if it is not OK, replace the sensor; if it is OK, check the continuity of the white cable between the sensor connector and PIN 11 of connector B (BLUE) of the control unit: if it is not OK, restore the cable harness; if it is OK, it means that the white cable is in continuity with the ground cable and it is necessary to restore the cable harness.
Injector
INJECTOR Function To supply the correct amount of petrol at the right timing. Operation / Operating principle Injector coil is excited for the petrol passage to open. Level in wiring diagram:Coils and injectors Location: on the vehicle: on the intake manifolds connector: on injector
Electrical characteristics:14.8 Ohm +/- 5% (at 20 C) Pin-out: 1. Supply 2. Ground connection THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM ELE SYS - 99
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THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM PARAMETERS Injector Injection time ELECTRICAL ERRORS Front injector P0202 - shorted to positive / shorted to negative / open circuit. Error cause If shorted to positive: excessive voltage has been detected at PIN 37 of connector A (BROWN). If shorted to negative: no voltage has been detected. If the circuit is open: an interruption has been detected. Troubleshooting if shorted to positive: disconnect the injector connector, set the key to KEY ON and activate the component with Axone; check if there is voltage at PIN 2 of the injector connector: if there is, restore the cable harness; if there is not, replace the sensor. if shorted to negative: disconnect the injector connector, set the key to KEY ON and check if there is a ground connection on PIN 2: if there is, restore; if there is not, replace the injector. the circuit is open: check the component correct electrical characteristic: if it is not the correct one, replace the component; if it is correct, check the connector on the component and the Marelli control unit connector: if they are not OK, restore; if they are OK, check the continuity of the cable between PIN 37 of connector A (BROWN) and PIN 2 of the component and restore the cable harness. Rear injector P0201 - shorted to positive / shorted to negative / open circuit. Error cause If shorted to positive: excessive voltage has been detected at PIN 28 of connector A (BROWN). If shorted to negative: no voltage has been detected. If the circuit is open: an interruption has been detected.
Troubleshooting
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if shorted to positive: disconnect the injector connector, set the key to KEY ON and activate the component with Axone; check if there is voltage at PIN 2 of the injector connector: if there is, restore the cable harness; if there is not, replace the sensor.
if shorted to negative: disconnect the injector connector, set the key to KEY ON and check if there is a ground connection on PIN 2: if there is, restore; if there is not, replace the injector. the circuit is open: check the component correct electrical characteristic: if it is not the correct one, replace the component; if it is correct, check the connector on the component and the Marelli control unit connector: if they are not OK, restore; if they are OK, check the continuity of the cable between PIN 28 of the connector A (BROWN) and PIN 2 of the component and restore the cable harness.
Fuel pump
Electrical characteristics: 0.7 +/-0.2 Ohm.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM ACTIVATION Fuel pump: Operation for 30 seconds. ELECTRICAL ERRORS Fuel pump relay P0230 - shorted to positive / shorted to negative / open circuit. Error cause If shorted to positive: excessive voltage has been detected at PIN 6 of connector B (BLUE). If shorted to negative: no voltage has been detected. If the circuit is open: an interruption has been detected. ELE SYS - 101
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Troubleshooting If shorted to positive: disconnect the injection load relay (No. 29 on the wiring diagram) and setting the key to KEY ON, measure the voltage read at PIN 1 of the relay connector towards the cable harness: if voltage is equal to 5 or 12 V, restore the cable harness; if voltage is equal to zero, replace the relay. If shorted to negative: disconnect the injection load relay (No. 29 on the wiring diagram) and setting the key to KEY ON (wait for a few seconds), check if there is continuity with the ground cable to PIN 1 of the relay connector towards the cable harness: if there is continuity, restore the cable harness; if there is not continuity, replace the relay. If the circuit is open: check the injection control unit connector and the relay connector: if they are not OK, restore; if they are OK, check the continuity of the grey/blue cable between the two connectors: if there is not continuity, restore the cable harness; if there is continuity, check the continuity of the yellow/grey cable between the relay connector and the auxiliary D fuse: if there is not continuity, restore the cable harness; if there is continuity, check that the relay presents no continuity between PINS 1 and 2, and replace the relay.
Coil
Function It controls the ignition spark plug in order to generate the fuel ignition spark. Operation / Operating principle With inductive discharge: 2 coils with double secondary circuit (Twin spark) Level in wiring diagram:Coils and injectors Location: Under helmet compartment: Right coil (rear cylinder) and Left coil (front cylinder) Electrical specifications: Primary circuit resistance: approx. 0.57 at 20C between PIN 1 and 2 Secondary circuit resistance: approximately 7.3 Ohm at 20C Pin-out: 1. Supply + batt V 2. Activation from control unit
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CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM PARAMETERS Ignition advance ACTIVATION Right coil (rear cylinder): The auxiliary injection relay (No. 29 in the wiring diagram, placed under helmet compartment, right side) is energised for 5 seconds and the grey/red cable of the coil is closed to ground for 2 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation. Left coil (front cylinder): The auxiliary injection relay (No. 29 in the wiring diagram, placed under helmet compartment, right side) is energised for 5 seconds and the orange/green cable of the coil is closed to ground for 2 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation. ELECTRICAL ERRORS Right coil (rear cylinder) P0351 - shorted to positive / open circuit, shorted to negative. Error cause If shorted to positive: excessive voltage has been detected at PIN 38 of connector A (BROWN). If the circuit is open, short circuit to negative: voltage equal to zero has been detected
Troubleshooting ELE SYS - 103
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If shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with Axone and check voltage at connector PIN 1: if there is voltage, restore the cable harness; if voltage = 0, replace the coil
if the circuit is open, short circuit to negative: check the coil connector and the Marelli control unit connector. If they are not OK, restore; if everything is OK, check cable continuity between the two cable terminals. If there is not continuity, restore the cable harness; if there is cable continuity, with key set to ON, check the cable earth insulation (from coil connector or control unit connector). If it is not OK, restore the cable harness; if it is OK, check if there is voltage in the red/brown cable, with key set to ON or activating with Axone. If there is no voltage, check continuity and earth isolation of the red/brown cable from the coil connector to the auxiliary injection relay connector 29. If it is not OK, restore; if everything is OK, disconnect the relay and check if there is voltage in the orange/red cable: if there is voltage, replace the relay; if there is no voltage, check continuity and earth insulation of the orange/ red cable from the relay connector to the auxiliary fuse box and replace the cable harness.
Left coil (front cylinder) P0352 - shorted to positive / open circuit, shorted to negative Error cause If shorted to positive: excessive voltage has been detected at PIN 10 of connector A (BROWN). If the circuit is open, short circuit to negative: voltage equal to zero has been detected.
Troubleshooting If shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with Axone and check voltage at connector PIN 1: if there is voltage, restore the cable harness; if voltage = 0, replace the coil if the circuit is open, short circuit to negative: check the coil connector and the Marelli control unit connector. If they are not OK, restore; if everything is OK, check cable continuity between the two cable terminals. If there is not continuity, restore the cable harness; if there is cable continuity, with key set to ON, check the cable earth insulation (from coil connector or control unit connector). If it is not OK, restore the cable harness; if it is OK, check if there is voltage in the red/brown cable, with key set to ON or activating with Axone. If there is no voltage, check continuity and earth isolation of the red/brown cable from the coil connector to the auxiliary injection relay connector 29. If it is not OK, restore; if everything is OK, disconnect the relay and check if there is voltage in the orange/red cable: if there is voltage, replace the relay; if there is no voltage, check continuity and earth insulation of the orange/ red cable from the relay connector to the auxiliary fuse box and replace the cable harness.
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Throttle body
THROTTLE BODY Function
To tell the position of the throttle to the throttle control unit. Operation / Operating principle The throttle position sensor works as a variable resistance according to the throttle rotation. Level in wiring diagram:Throttle and idle motor Location: on the vehicle: on the intake manifold connector: on the throttle body
Electrical characteristics: PINS A-C: throttle closed approximately 2.5 kOhm; throttle open approximately 1.5 kOhm. Pin-out: A - Ground connection B - Supply voltage + 5V C - Potentiometer signal PINS A-B: approximately 1.1 kOhm.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM PARAMETERS Throttle Example value: 4.9 STATUSES Throttle position Example value:Released/Pressed It indicates if the throttle potentiometer is open or closed in the released position. ADJUSTABLE PARAMETERS ELE SYS - 105
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Throttle positioner autodetection: It allows the control unit to detect the closed throttle position; just press the Enter key. Self-adjustable parameters reset: Lambda probe self-adaptability parameters reset: operation to be carried out after the throttle body is cleaned (every 30,000 km), or in the case a new engine, a new lambda probe or a new injector is fitted, or the correct operation of the injection system or the valves is restored ELECTRICAL ERRORS Throttle actuator position sensor P0120 Example value:open circuit, shorted to positive / shorted to negative. Error cause If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 3 of connector A (BROWN). If shorted to negative: voltage equal to zero has been detected.
Troubleshooting Circuit is open, shorted to positive: check the injection control unit connector and the sensor connector: if they are not OK, restore; if they are OK, check the continuity between PIN 3 of the connector A (BROWN) and PIN C (red cable): if there is not continuity, restore the cable harness; if there is continuity, check continuity of the sensor between PIN A and PIN C: if there is not continuity, replace the throttle body; if there is continuity, check the resistance: if below 1.3 kOhm, replace the sensor; if above 1.3 kOhm, there is a short circuit to positive on the red cable and it is necessary to restore the cable harness. If shorted to negative: disconnect the sensor connector and check the ground insulation of the red cable (from throttle sensor connector or control unit connector): if there is continuity with the ground connection, restore the cable harness; if isolated from ground connection, the resistance between PIN A and PIN C is below 1.3 kOhm; therefore, it is necessary to replace the throttle body. RESET PROCEDURE Once the throttle body or the injection control unit is replaced, it is necessary to connect to the diagnosis instrument selecting FUEL INJECTION and carry out the operation: Throttle position autodetection.
Engine oil pressure sensor

ENGINE OIL PRESSURE SENSOR Function:it indicates the instrument panel if there is enough oil pressure (0.5 +/- 0.2 bar) (7.25 +/- 2.91 PSI) in the engine. Operation / Operating principle: normally closed switch. With oil pressure above (0.5 +/-0.2 bar) (7.25 +/- 2.91 PSI), open circuit. Location on the vehicle: under front cylinder ELE SYS - 106
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Connector location: on the sensor Pin-out: 1. Voltage 5V
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT. Instrument panel Error DSB 07 Error cause An oil sensor failure is signalled when, with engine off, it is detected that the sensor circuit is open. The test is performed only once when the key is set to ON. This error is signalled by the bulb icon and the general warning light turns on as well. Troubleshooting Check the sensor connector and the instrument panel connector (PIN 17): If not OK, restore. If OK, check the continuity of the purple cable between the sensor connector and the instrument panel connector PIN 17: if not OK, restore the cable harness; if OK, replace the sensor. Error DSB 08 Error cause An oil sensor failure is signalled when, with engine running, it is detected that the sensor circuit is closed. This error is signalled by the bulb icon and the general warning light turns on as well. Troubleshooting Check if oil pressure is low with the specific gauge.
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Side stand sensor

SIDE STAND SENSOR Function It tells the side stand position to the control unit. Operation / Operating principle If vehicle speed is equal to zero and with the stand down, start-up is attempted, a restriction to engine revolutions is activated. If the vehicle is moving and the stand is extended, the ECU injection stops the engine. Level in wiring diagram:start-up enabling switches Location: on the vehicle: on the side stand connector: under the fuel tank (inside the rubber protection housing) Electrical specifications: Side Stand Up: closed circuit (continuity) Side Stand Down: open circuit (infinite resistance) Pin-out: 1. Ground connection 2. Voltage 12V THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM STATUSES Side stand Example value:up/down Troubleshooting ELE SYS - 108
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Indication on Axone always down: check the connector: if not OK, restore; if it is OK, disconnect the two terminals from the sensor and check continuity to ground of PIN 1: if there is no continuity, restore the cable harness; if there is, replace the sensor
Indication on Axone always up: disconnect the terminals from the sensor and check if there is continuity between the two PINS, with stand down: if there is continuity, replace the sensor; if the circuit is open, it means that on the brown/green cable from sensor PIN 2 to PIN 38 of connector B (BLUE) there is a short circuit to ground: restore the cable harness
Bank angle sensor

FALL SENSOR Function it tells the vehicle position to the control unit. Operation / Operating principle When the sensor is inverted, the circuit is closed to ground: When the Marelli control unit detects this ground connection, it does not enable start-up or shuts off the engine. Level in wiring diagram:Start-up enabling switches. Location: on the vehicle: under the saddle, front area near the control unit connector: near the sensor
Electrical characteristics: Sensor in vertical position: open circuit (resistance: 62 kOhm) Sensor inverted: closed circuit (continuity) Pin-out: 1. Ground connection 2. Voltage 5V THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
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BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM PARAMETERS Fall sensor Example value: Normal / Tip over Troubleshooting Indication on Axone always Normal, even when the sensor is inverted: disconnect the connector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: if there is no continuity, replace the sensor; if there is, check the connector. If not OK, restore the cable harness; if OK, check continuity to ground of PIN 2: if there is no continuity, restore the cable harness; if there is, with key set to KEY ON, check if there is 5V voltage at PIN 1. If there is not, check the Marelli control unit connector (PIN 35 of connector B "BLUE") Indication on Axone always Tip over: disconnect the connector and check if there is continuity between the two PINS when the sensor is in vertical position: if there is continuity, replace the sensor; if there is not, it means that, with key set to KEY ON, there is no 5V voltage at PIN 1: restore the cable harness whose pink/yellow cable will be shorted to ground
Air temperature sensor - instrument panel

INSTRUMENT PANEL AIR TEMPERATURE SENSOR Function It tells the ambient air temperature to the instrument panel. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in wiring diagram:Temperature sensors Location: on the vehicle: on the plastic protection under the instrument panel connector: under the instrument panel
Electrical characteristics: Resistance at 0C: 32.5 kOhm +/- 5% Resistance at 25C: 10.0 kOhm +/- 5%
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Pin-out: 1. Voltage 5V 2. Ground connection THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. Instrument panel ERROR DSB 06 Error cause An oil sensor failure is signalled when it is detected that the sensor circuit is open or shorted to positive. Troubleshooting Check the sensor connector and the instrument panel connector (PINS 10 and 30): If not OK, restore; if OK, check the continuity of the pink cable between the sensor connector and the instrument panel connector PIN 10: if not OK, restore the cable harness; if OK, check the correct sensor resistance: if it is not OK, replace the sensor; if it is OK, check the continuity of the brown/black cable between the sensor connector and PIN 30 of the instrument panel connector: If not OK, restore the cable harness; if OK, with key set to ON, check if there is voltage at the sensor connector PIN 1: if there is no voltage, replace the instrument panel; if there is approximately 12V, restore the cable harness (there is a short circuit in the battery). If there is 5V voltage, connect a 10 kOhm resistance to PIN 1 of the sensor connector and to the vehicle ground connection: if, with key set to KEY ON, the voltage measured upstream the resistance decreases, replace the instrument panel. If voltage continues to be approximately 5V, restore the pink cable (there is a short circuit at + 5V). Notes If a short circuit to ground is detected at PIN 10 of the instrument panel connector, the display will show a temperature full scale indication. Check the earth insulation of the sensor connector pink cable: if there is a connection, restore the cable harness; if it is earth insulated, check that sensor resistance is correct: if it is not OK, replace the sensor; if it is OK, replace the instrument panel.
Electric fan circuit

ELECTRIC FAN CIRCUIT ELE SYS - 111
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Function Radiator fan and coolant - Operation. Operation / Operating principle When the control unit detects a temperature above 100 C, it closes the fan control relay pickup circuit to ground until the temperature falls to 97 C. Level in wiring diagram:electric fan Location: Relay located under the helmet compartment, right side.
Electrical specifications: relay normally open; drive coil resistance 110 Ohm (+/- 10 %)
STATUSES Fan relay Example value:on / off. THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM ELECTRICAL ERRORS Fan relay P0481 - shorted to positive / open circuit, shorted to negative. Error cause If shorted to positive: excessive voltage has been detected at PIN 14 of connector B (BLUE). If the circuit is open, shorted to negative: voltage equal to zero has been detected If the circuit is open, shorted to negative: voltage equal to zero has been detected.
Troubleshooting If shorted to positive: check whether the relay electrical specifications are correct by disconnecting it from the cable harness. If they are not correct, replace the relay; if they are correct, restore the cable harness (blue/brown cable). If the circuit is open/shorted to negative: check whether the relay electrical specifications are correct by disconnecting it from the cable harness. If they are not correct, replace the relay; if they are correct, restore the cable harness (blue/brown cable).
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Electric lock
ELECTRIC LOCK Function To open the helmet compartment. Level in wiring diagram:Services. Location: on the vehicle: under key block, left side connector: on electric lock
Electrical characteristics: Pin-out: 1. Ground. 2. Supply. THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
150 Ohm +/- 20 %
RUN/STOP switch
Run / stop switch Function It tells the control unit if the driver wishes to enable engine start-up or to keep the engine running. Operation / Operating principle If the driver wants to shut off the engine or to disable engine start-up, the switch should be open, i.e. the Marelli control unit should not detect voltage at PIN 27 of connector B "BLUE". Level in wiring diagram:Start-up enabling switches. Location: on the vehicle: right light switch ELE SYS - 113
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connector: right side, under helmet compartment, along upper frame.
Electrical characteristics: STOP position: the circuit is open RUN position: closed circuit (continuity) Pin-out: 1. Green/orange cable: ground connection 2. Yellow/grey cable: voltage 12V THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: FUEL INJECTION SYSTEM STATUSES Run / stop switch Example value:Run/Stop Troubleshooting Indication on Axone always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity towards the switch of the two cables- yellow/grey and green/ orange: if there is not continuity, replace the sensor; if there is, check the connector. If it is not OK, restore the cable harness; if it is OK, with key set to KEY ON, check if there is voltage on the yellow/grey cable: if there is no voltage, restore the cable harness; if there is, check the yellow/grey cable earth insulation: if there is continuity to ground, restore the cable harness; if it is OK, take the key to KEY OFF and check the control unit connector and the continuity of the yellow/grey cable between the connector in question and PIN 27 of the control unit connector B "BLUE": if not OK, restore the cable harness; if OK, replace the Marelli control unit. Indication on Axone always RUN: disconnect the connector and, with the switch set to STOP, check if there is continuity between the two cables of the switch: if there is continuity, replace the switch; if there is not, it means that, with key set to KEY ON, the green/orange cable is shorted to positive: restore the cable harness.
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Transmission control unit
Function It controls the TRANSMISSION system. Operation / operating principle It receives information from the sensors connected to it and, via CAN line communication with the instrument panel and the injection control unit, it controls the predetermined operating strategies for the position of the driving pulley in order to obtain the gear ratio requested by the user (manual transmission) or expected according to the kind of calibration of the selected gear (automatic transmission). Level in wiring diagram: transmission management Position: on the vehicle: between the helmet compartment and the saddle connector (if available): on the control unit
Electrical specifications: Pin-out: see the CONNECTORS section

CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE / AUTOMATIC TRANSMISSION system ISO SCREEN PAGE Hardware number - Example value: 04 Hardware version number - Example value: 0004 Software number - Example value: 04 Software release number - Example value: 0033 NOTES - Control unit mapping PARAMETERS Automatic system Temperature inside the control unit Example value: C There is a sensor inside the control unit. Maximum value reached by the temperature inside the control unit ELE SYS - 115
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Example value: C There is a sensor inside the control unit. AXONE: STATUSES AXONE / AUTOMATIC TRANSMISSION system - ECU operation status Example value:automatic/manual/from manual to automatic/from automatic to manual/semiautomatic/ start-up/power latch/error General ECU operation status. Gearshift mode Example value:manual/automatic/semiautomatic/from automatic to manual/from manual to automatic Gearshift mode setting. Entered ratio Example value:gear not defined/first/second/third/fourth/fifth/sixth/seventh/invalid Performance limitations Example value: none/rpm limitation/start-up restriction with side stand down Rpm limitation: if there is a malfunction in the driving pulley control electrical motor with the engine running Start-up restriction with side stand down: if the stand is down, the start-up is blocked for safety reasons due to a system malfunction Gearbox fault Example value: absent/present If the status is "present", a malfunction has been detected in the gear system or in one of its components (mode control or gear control buttons excluded) Gear calibration Example value: absent/present If the status is "present", a malfunction has been detected in the gear system or in one of its components (mode control or gear control buttons excluded) Ignition Example value:enabled/disabled It indicates if the engine can be started through the transmission control unit. In the "conditioned" status, and depending on the case, ignition may be blocked or enabled but it affects the regular operation (variator position cannot be modified). ACTIVATIONS Error clearing The errors stored in the transmission ECU can be deleted. Errors ambient parameters reading The ambient conditions at the time of the last detection of the error can be read. Especially the Riding cycles parameter without detection of the error indicates how many times the key ON/OFF operation has been performed from the last reading of the error. ERRORS ELE SYS - 116
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EEPROM error - Code 9009 - transmission reset not carried out/ EEPROM access error Error cause If the transmission has not been reset: the potentiometer reset or belt reset procedures have not been successful or a new transmission ECU has been fitted without resetting the transmission. If there is an EEPROM access error: the control unit cannot read or update the data contained in the EEPROM. The transmission ECU should be replaced. Troubleshooting If the transmission has not been reset: the potentiometer reset or belt reset procedures have not been successful, it is therefore necessary to try those operations again by means of the diagnosis instrument, or a new transmission ECU has been fitted without resetting the transmission. In case there is a yellow or black label OBD module, without 2006 legend, it is consider normal that the error is displayed before the Potentiometer reset function, Phase 2, or the Belt replacement, Phase 2: it will no longer be displayed even after this second phase has been carried out correctly. If there is an EEPROM access error: replace the transmission ECU (see New control unit activation procedure) and the belt. Belt wear - Code 9011 - above maximum threshold Error cause Excessively worn belt: the second wear limit has also been exceeded. This implies the forced setting of the transmission in automatic mode, RAIN setting. Troubleshooting It is necessary to replace the worn belt and in the future, before starting the engine, select the Belt replacement or Belt replacement, Phase 1, and Belt replacement, Phase 2, function (next, see Adjustable parameters). ADJUSTABLE PARAMETERS
CAUTION
DURING THIS PROCEDURE, THE REAR WHEEL SHOULD NOT TOUCH THE GROUND. Potentiometer reset: Follow the procedure step by step as indicated in the various screen pages (OBD 2006 module). Belt replacement: Follow the procedure step by step as indicated in the various screen pages (OBD 2006 module). Potentiometer reset, Phase 1: Follow the procedure step by step as indicated in the various screen pages (yellow or black label OBD module without 2006 legend). Potentiometer reset, Phase 2: Follow the procedure step by step as indicated in the various screen pages (yellow or black label OBD module without 2006 legend). Belt replacement, Phase 1: Follow the procedure step by step as indicated in the various screen pages (yellow or black label OBD module without 2006 legend). ELE SYS - 117
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Belt replacement, Phase 2: Follow the procedure step by step as indicated in the various screen pages (yellow or black label OBD module without 2006 legend). Entering the gearshift stroke category: In case there is a new ECU, the gearshift stroke category can be entered (category is displayed in the parameters screen page, see also the Driving pulley position sensor section). Gearshift stroke default value setting: The default value for the gearshift stroke category can be entered if any component of the variator that affects the gearshift stroke is replaced. The components are: spacer slider support bearing support bushing bearing support fixed driving half-pulley movable driving half-pulley NEW CONTROL UNIT ACTIVATION PROCEDURE It is necessary to replace also the belt and before the start-up, it is necessary to carry out the Potentiometer reset procedure (driving pulley). It is also advisable to enter the Gearshift stroke category through the adjustable parameter named Entering the gearshift stroke category, read from the previous ECU (the value is present in the ECU and on the half-pulley only for vehicles manufactured after February 2008). If the category is not entered, the ECU uses the default value.
CAUTION
FAILURE TO REPLACE THE BELT CAN SERIOUSLY DAMAGE THE SYSTEM SINCE THE NEW CONTROL UNIT, TAKING FOR GRANTED THE BELT IS NEW, COULD MISJUDGE THE ACTUAL WEAR AND CAUSE THE BELT TO BREAK.
Driving pulley position sensor

SENSOR FITTING Reset procedure It is necessary to use Axone in case the variator unit is removed and the potentiometer is replaced or removed: Potentiometer reset
CAUTION
FOR VEHICLES INCLUDED IN THE FOLLOWING RANGE ZD4RC000_7S000002 - ZD4RC000_7S000737 IN ORDER TO FIT THE DRIVING PULLEY POSITION SENSOR CORRECTLY, SEE THE "Engine" CHAPTER, "Transmission Cover Fitting" SECTION.
See also
Refitting the transmission cover
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Function It tells the position of the driving half-pulley to the transmission ECU. Operation / Operating principle It is a double track potentiometer, with inversely proportional voltage variation. Level in wiring diagram:transmission management Location: on the vehicle: on the upper part of the transmission cover. connector: directly on the sensor.
Electrical characteristics: Track resistance (pin 1-5 or 2-3): 1.5 k. Signal resistance (pin 4-5 or 3-6): Min 1.0 k (released sensor) - Max. 2.5 k (rotated sensor) Pin-out: 1. Track 1 ground (Green/Grey - Digitek Pin A5) 2. Track 2 supply + 5 V (Yellow/Purple - Digitek Pin A4) 3. Track 2 ground (Pink/Purple - Digitek Pin C7) 4. Track 1 signal (Purple/Red - Digitek Pin A2) 5. Track 1 supply + 5 V (Grey/Purple - Digitek Pin C6) 6. Track 2 signal (Green/Pink - Digitek Pin C2)
CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
CAUTION
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BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: AUTOMATIC TRANSMISSION system PARAMETERS Driving pulley position potentiometer: track 1 Example value:2.02 mm Current gap, compared to the lower mechanical stop position, based on the potentiometer track 1: to make sure that the read value is correct, check the status of the driving pulley position Potentiometer: track 1. Driving pulley position potentiometer: track 1 Example value:3.5 V Current voltage for potentiometer, track 1. Driving pulley position potentiometer:track 2 Example value:2.09 mm Current gap, compared to the lower mechanical stop position, based on the potentiometer track 2: to make sure that the read value is correct, check the status of the driving pulley position Potentiometer: track 2. Driving pulley position potentiometer:track 2 Example value:1.6 V Current voltage for potentiometer, track 2. Driving pulley potentiometer supply voltage: track 1 Example value:4.98 V Voltage supplied by the transmission ECU. Driving pulley potentiometer supply voltage: track 2 Example value:4.97 V Voltage supplied by the transmission ECU. Driving pulley target position Example value:2.09 mm Target gap, compared to the lower mechanical stop position, supplied by the control unit based on conveyed commands. Driving pulley lower stop position Example value:0 mm It is the reference position for all the other positions indicated by the driving pulley position sensor. Driving pulley saved position in first gear Example value:2.06 mm It should be a value between 0.5 and 2.5 mm. Movement of the first gear in relation to the saved position (wear) Example value:0.03 mm ELE SYS - 120
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Even if the belt is worn, the first gear position is modified in relation to the initial position in order to keep the pre-set ratio Gearshift stroke It is the maximum complete stroke of the driving half-pulley useful in case of compensation for belt wear (used in seventh gear). Gearshift stroke category It is the category the gearshift stroke belongs to: from 1 to 8 or 64 (corresponding to the default value, a shorter stroke corresponds to a stroke lower than category 1) When the ECU is replaced, the gearshift stroke category can be entered in the ECU. AXONE: AUTOMATIC TRANSMISSION system STATUSES Driving pulley position potentiometer:track 1 Example value:Invalid data / Valid data If the "Invalid Data" message is displayed, it means that the parameter value in the Engineering parameters screen page is not correct. Driving pulley position potentiometer:track 2 Example value:Invalid data / Valid data If the "Invalid Data" message is displayed, it means that the parameter value in the Engineering parameters screen page is not correct. NOTE When troubleshooting, use the interface, code 020481Y, with the adaptor, code 020481Y004. The correspondence between the control unit PIN and the interface PIN is the following: control unit PIN A1.A8 and interface PIN interface 11.18, control unit PIN B1.B8 and interface PIN interface 21.28, control unit PIN C1.C8 and interface PIN interface 31.38 ERRORS Track 1 potentiometer - Code 9001 - above maximum threshold/ below minimum threshold/ signal not valid. Error cause If above the maximum threshold: excessive voltage has been detected at PIN A2. If below the minimum threshold: voltage equal to zero has been detected at PIN A2. If signal is not valid: excessive deviation of the potentiometer track value in relation to the other track. Troubleshooting If above the maximum threshold: with key set to KEY ON, disconnect the sensor and observe, with the diagnosis instrument, if the voltage value of the "Driving pulley position potentiometer: track 1" parameter drops to zero: if it drops to zero, replace the sensor; if it does not, restore the purple/red cable.
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If below the minimum threshold: check the transmission ECU connector and the sensor connector: if they are not OK, restore; if they are OK, check continuity on the purple/red cable: if it is not OK, restore the cable; if it is OK, replace the sensor.
If signal is not valid: check the transmission ECU connector and the sensor connector: if they are not OK, restore; if they are OK, replace the sensor.
Track 2 potentiometer - Code 9002 - above maximum threshold/ below minimum threshold/ signal not valid. Error cause If above the maximum threshold: excessive voltage has been detected at PIN C2. If below the minimum threshold: voltage equal to zero has been detected at PIN C2. If signal is not valid: excessive deviation of the potentiometer track value in relation to the other track. Troubleshooting If above the maximum threshold: with key set to KEY ON, disconnect the sensor and observe, with the diagnosis instrument, if the voltage value of the "Driving pulley position potentiometer: track 2" parameters drops to zero: if it drops to zero, replace the sensor; if it does not, restore the green/pink cable. If below the minimum threshold: check the transmission ECU connector and the sensor connector: if it they are not OK, restore; if they are OK, check continuity on green/pink cable: if it is not OK, restore the cable; if it is OK, replace the sensor. If signal is not valid: check the transmission ECU connector and the sensor connector: if they are not OK, restore; if they are OK, replace the sensor. Driving pulley potentiometer supply voltage: track 1 - Code 900B - signal not valid. Error cause Voltage value at PIN C6 is not within the expected limits.
Troubleshooting With key set to KEY ON, read the value of the "Driving pulley potentiometer supply voltage: track 1" parameter: if it is equal to the battery voltage, there is a short circuit on the battery and it is necessary to restore the cable harness; if it is equal to zero, disconnect the sensor: if voltage goes up to approximately 5 V, replace the sensor; if the voltage remains at zero, check the transmission ECU connector: if it is not OK, restore; if it is OK, check if there is continuity between PIN C6 and the ground connection: if there is continuity restore the cable harness; if there is not continuity, replace the transmission ECU. Driving pulley potentiometer supply voltage: track 2 - Code 900C - signal not valid. Error cause Voltage value at PIN A4 is not within the expected limits.
MSS Mana GT ABS
Electrical system
With key set to KEY ON, read the value of the "Driving pulley potentiometer supply voltage: track 2" parameter: if it is equal to the battery voltage, there is a short circuit on the battery and it is necessary to restore the cable harness; if it is equal to zero, disconnect the sensor: if voltage goes up to approximately 5 V, replace the sensor; if the voltage remains at zero, check the transmission ECU connector: if it is not OK, restore; if it is OK, check if there is continuity between PIN A4 and the ground connection: if there is continuity, restore the cable harness; if there is not continuity, replace the transmission ECU.
ADJUSTABLE PARAMETERS
CAUTION
DURING THIS PROCEDURE, THE REAR WHEEL SHOULD NOT TOUCH THE GROUND. Potentiometer reset Follow the procedure step by step as indicated in the various screen pages (black label module OBD, 2006). Potentiometer reset, Phase 1 Follow the procedure step by step as indicated in the various screen pages (yellow or black label OBD module without 2006 legend). Potentiometer reset, Phase 2 Follow the procedure step by step as indicated in the different screen pages (yellow or black label OBD module without 2006 legend). Entering the gearshift stroke category If the ECU is replaced, the gearshift stroke category can be entered in the new ECU (reading the category in the old ECU). The categories range from 1 to 8. Gearshift stroke default value setting: Setting to be used if a component of the variator that affects the gearshift stroke has been replaced.
See also
Refitting the driving pulley
Driven pulley speed sensor

Function To indicate the driven pulley speed by reading the speed of rotation of the fixed half-pulley that has four studs. Operation / Operating principle Inductive sensor: sinusoidal alternating current is generated (approximately 0.7 V at idle speed) for the transmission ECU reading.
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Level in wiring diagram:transmission management Location: on the vehicle: on the crankcase cover, driven pulley upper part. under fuel tank (inside the protection rubber housing). Electrical specifications: Coil resistance at Ambient temperature: 0.7 - 1.1 kOhm. Pin-out: 1. Signal (cable colour not defined) 2. Ground (cable colour not defined) 3. Shielding
CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE: AUTOMATIC TRANSMISSION system PARAMETERS Driven pulley rotation Example value: rpm To make sure that the read value is correct, check its status in the Device Status screen page. STATUSES Driven pulley rotation Example values: Invalid data / Valid data If the "Invalid Data" message is displayed, it means that the parameter value in the Engineering parameters screen page is not correct. ERRORS Driven pulley rotation sensor Code 9004 - no signal/ signal not valid/ below minimum threshold. Error cause
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If there is no signal: an electric circuit interruption has been detected at PINS B3 and B6. If signal is not valid: variable signal with excess speed or non variable if below minimum threshold: voltage equal to zero has been detected at PIN B3.
Troubleshooting If there is no signal: check the transmission ECU connector and the sensor connector: if it is not OK, restore; if it is OK, check the continuity of the PIN 1 cable between the transmission ECU connector and the sensor connector: if it is not OK, restore; if it is OK, check the continuity of the sensor circuit (PINS 1 and 2 of sensor connector): if it is not OK, replace the sensor; if it is OK, check the continuity between PIN 2 of the sensor connector and PIN B6 of the transmission ECU connector: if it is not OK, restore the cable harness; if it is OK, check with key set to key ON, that PIN B6 of the transmission ECU does not have continuity with the ground connection, and then replace the transmission ECU (in this case the Vehicle speed sensor error (Code 9003), no signal, should also be present). If signal is not valid: check the sensor resistance, from the transmission ECU connector, between PINS B6 and B6: if it is not OK, replace the sensor; if it is OK, with key set to key ON, check the voltage at PIN B3: if voltage is other than zero, see Phase 1; if voltage is equal to zero, check in the same way with running engine: if the non variable voltage is above zero, replace the sensor; if alternating voltage is excessively below approximately 0.7 V at idle speed, check the correct position of the sensor. Phase 1: check if upon disconnecting the sensor, the PIN B3 voltage reaches zero: if it reaches zero, replace the sensor; if it does not reach zero, restore the cable harness (PIN 1 cable shorted to battery or a cable at 5V). If below the minimum threshold: check if there is continuity between PIN B3 and the ground connection: if there is continuity, check if upon disconnecting the sensor, the continuity with the ground connection of PIN B3 is interrupted: if it is interrupted, replace the sensor; if the continuity with the ground connection remains, restore the cable harness (PIN 1 cable shorted to ground connection).
Transmission mode control

GEAR MODE CONTROL Function To tell the transmission ECU that the driver wishes to change the gear mode (automatic/manual) and the type of transmission calibration (touring/ sports/ rain). Operation / operating principle
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The circuit is made up of a switch that, when activated, modifies the circuit resistance and consequently the voltage detected. Level in wiring diagram: transmission management Position: gear mode control on vehicle: right light switch connector: right side, under helmet compartment, along upper frame Electrical characteristics Released switch 860 +/- 5% Ohm Pressed switch 180 +/- 5% Ohm Pin-out: 1. power supply + 5 V 2. ground connection THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE / AUTOMATIC TRANSMISSION system PARAMETERS Gear mode control Example value: 3.8 V Voltage detected at PIN B7: if the button is pressed, voltage drops from approximately 3-4 V to approximately 1 V. STATUSES Gear mode control Example value: Released/Pressed/Invalid data If the "Invalid Data" message is displayed, it means that a malfunction has been detected NOTE: When troubleshooting, use the interface, code 020481Y, with the adaptor, code 020481Y004. The correspondence between the control unit PIN and the interface PIN is the following: control unit PIN A1.A8 and interface PIN interface 11.18, control unit PIN B1.B8 and interface PIN interface 21.28, control unit PIN C1.C8 and interface PIN interface 31.38 ERRORS ELE SYS - 126
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Gear mode switch - Code 9005 - above maximum threshold/ below minimum threshold. Error cause If above the maximum threshold: excessive voltage has been detected at PIN B7. If below the minimum threshold: voltage equal to zero has been detected at PIN B7. Troubleshooting If above the maximum threshold: check circuit continuity between PIN B7 and C5: if it is not OK, see Phase 1; if it is OK, check the transmission ECU connector and the gear mode control connector and restore. Phase 1: check the continuity of the yellow/pink cable; if it is not OK, restore; if it is OK, check for the interruption in the circuit of the gear mode control and replace the component. If below the minimum threshold: check the gear mode control resistance on its connector: if the resistance is not within the expected limit values, replace the control; if it is within the expected values, check the continuity of the yellow/pink cable and the ground connection and then restore the cable harness.
Gearshift pedal
PEDAL GEARSHIFT CONTROL Function To tell the transmission ECU that the driver wishes to change the variator transmission ratio (gear shift in manual gear mode). Operation / operating principle Either control (+) or (-) is made up of a deviator with both outputs electrically connected to the transmission ECU. Level in wiring diagram: transmission management Position: pedal gearshift control on vehicle: pedal gearshift lever connector: under the fuel tank (inside the rubber protection housing) Electrical characteristics Gear upshift: 0 Ohm, between PIN C5 and PIN A7,
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infinite resistance between PIN C5 and PIN A3
Gear downshift: 0 Ohm between PIN C5 and PIN A6 infinite resistance between PIN C5 and PIN C4 Pin-out: Gear upshift: 1 - supply + 12 V (blue - black/purple) 2 - ground (brown - blue/black) 5 - supply + 12 V (red - blue/purple)
Gear downshift: 3 - ground (black - blue/black) 4 - supply + 12 V (green - black/yellow) 8 - supply + 12 V (yellow - blue/yellow)
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE / AUTOMATIC TRANSMISSION system STATUSES Pedal gear upshift control Example value: Released/Pressed/Invalid data If the "Invalid Data" message is displayed, it means that a malfunction has been detected Pedal gear downshift control Example value: Released/Pressed/Invalid data If the "Invalid Data" message is displayed, it means that a malfunction has been detected NOTE: When troubleshooting, use the interface, code 020481Y, with the adaptor, code 020481Y004. The correspondence between the control unit PIN and the interface PIN is the following: control unit PIN A1.A8 and interface PIN interface 11.18, control unit PIN B1.B8 and interface PIN interface 21.28, control unit PIN C1.C8 and interface PIN interface 31.38. ERRORS Pedal gear upshift control - Code 900D - signal not valid for logic reasons/ blocked control. Error cause ELE SYS - 128
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If the electric signal is not valid due to a logic reason: the control unit detects no voltage or the same voltage as the other at PIN A3 or PIN A7. If the control is blocked: the control has been in the pressed position for too long (some minutes).
Troubleshooting If the electric signal is not valid due to a logic reason: the transmission ECU waits to detect a voltage above approximately 1V in one of the two PINS and at the same time, a voltage below approximately 1 V in the other PIN; if this does not happen, the control unit signals this error. CASE 1) If voltage is below 1V on both, with control not activated, it means that a voltage below 1V, instead of battery, is detected at PIN A3; disconnect the gearshift control connector and read voltage at PIN A3: if voltage is below 1 V, it means that on the blue/ yellow cable there is a short circuit to ground; if voltage is above 1 V (approximately battery voltage), replace the gear upshift control sensor. CASE 2) if both voltages are below 1 V with control activated, it means that at that moment a voltage below 1 V, instead of battery, is detected at PIN A7; disconnect the gearshift control connector and read voltage at PIN A7: if voltage is below 1 V, it means that on the black/yellow cable there is a short circuit to ground; if the voltage is above 1 V (approximately battery voltage), replace the gear upshift control sensor CASE 3) if both voltages are the same as the battery voltage, with control not activated, it means that there is an interruption in the circuit from PIN A7 to PIN C5 or that PIN C5 does not have a ground connection: check the transmission ECU connector and the gearshift control connector: if they are not OK, restore; if they are OK, check continuity on the black/yellow cable: if it is not OK, restore; if it is OK, check continuity on the blue/ black cable from the gearshift control connector to PIN C5: if it is not OK, restore; if it is OK, check continuity of the gearshift control from the gearshift control connector (between green cable and black cable): if it is not OK, replace the control; if it is OK, check, with key set to KEY ON, that there is no ground connection in the blue/black cable and then replace the transmission ECU. CASE 4) if both voltages are above 1 V (approximately battery voltage), with control activated, it means that there is an interruption on the circuit from PIN A3 to PIN C5: check the transmission ECU connector and the gearshift control connector: if they are not OK, restore; if they are OK, check continuity on the blue/yellow cable: if it is not OK, restore; if it is OK, check, with control activated, that there is not continuity of the gearshift control from the gearshift control connector (between black cable and yellow cable) and then replace the control. If the control is blocked: check the control mechanically: if it is not OK, restore; if it is OK, it means that the "Pedal gear upshift control" statues on the diagnosis instrument indicates "Pressed": the gear upshift control must be replaced. Pedal gear downshift control - Code 900E - signal not valid for logic reasons/ blocked control. Error cause
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If the electric signal is not valid due to a logic reason: the control unit detects no voltage or the same voltage as the other at PIN C4 or PIN A6. If the control is blocked: the control has been in the pressed position for too long.
Troubleshooting If the electric signal is not valid due to a logic reason: CASE 1) if both voltages are below 1 V, with control not activated, it means that a voltage below 1 V, instead of battery, is detected at PIN C4; disconnect the gearshift control connector and read voltage at PIN C4: if voltage is equal to 1 V or below, it means that on the blue/purple cable there is a short circuit to ground; if voltage is above 1 V, replace the gear upshift control sensor. CASE 2) if both voltages are below 1 V with control activated, it means that at that moment a voltage below 1 V, instead of battery, is detected at PIN A6; disconnect the gearshift control connector and read voltage at PIN A6: if voltage is below 1 V, it means that on the black/purple cable there is a short circuit to ground; if the voltage is above 1 V (approximately battery voltage), replace the gear upshift control sensor. CASE 3) if both voltages are above 1 V (approximately battery voltage), with control not activated, it means that there is an interruption in the circuit from PIN A6 to PIN C5 or that PIN C5 does not have a ground connection: check the transmission ECU connector and the gearshift control connector: if they are not OK, restore; if they are OK, check continuity on the black/purple cable: if it is not OK, restore; if it is OK, check continuity on the blue/black cable from the gearshift control connector to PIN C5: if it is not OK, restore; if it is OK, check continuity of the gearshift control from the gearshift control connector (between red cable and blue cable): if it is not OK, replace the control; if it is OK, check, with key set to KEY ON, that there is no ground connection in the blue/black cable and then replace the transmission ECU. CASE 4) if both voltages are above 1 V (approximately battery voltage), with control activated, it means that there is an interruption on the circuit from PIN C4 to PIN C5: check the transmission ECU connector and the gearshift control connector: if they are not OK, restore; if they are OK, check continuity on the blue/purple cable: if it is not OK, restore; if it is OK, check, with control activated, that there is not continuity on the gearshift control from the gearshift control connector (between red cable and brown cable) and then replace the control. If the control is blocked: check the control mechanically: if it is not OK, restore; if it is OK, it means that on the diagnosis instrument the status of "Pedal gear downshift control" indicates "Pressed": the gear downshift control must be replaced.
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Electrical system
Gearshift lever on the handlebar

GEARSHIFT CONTROL ON HANDLEBAR Function To tell the transmission ECU that the driver wishes to change the variator transmission ratio (if transmission in manual mode). Operation / operating principle Either control (+) or (-) is made up of a deviator with both outputs electrically connected to the instrument panel: at the same time, the instrument panel sends the requested command to the transmission ECU, via CAN line. Level in wiring diagram: transmission management Position: handlebar gearshift control on vehicle: left light switch connector: behind front headlight, under the instrument panel Electrical specifications Gear upshift: 0 Ohm, between PIN 2 and PIN 1 infinite resistance between PIN 2 and PIN 5 Gear downshift: 0 Ohm between PIN 3 and PIN 8 infinite resistance between PIN 3 and PIN 4 Pin-out: Gear upshift: 1 - supply + 12 V (green - black/purple) 2 - ground (black - brown/black) 5 - supply + 12 V (yellow - blue/purple)
Gear downshift: 3 - ground (brown - brown/black) 4 - supply + 12 V (blue - black/yellow) ELE SYS - 131
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MSS Mana GT ABS
8 - supply + 12 V (red - blue/yellow)
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. AXONE / AUTOMATIC TRANSMISSION system STATUSES Handlebar gear upshift control Example value: Released/Pressed/Invalid data If the "Invalid Data" message is displayed, it means that a malfunction has been detected. Handlebar gear downshift control Example value: Released/Pressed/Invalid data If the "Invalid Data" message is displayed, it means that a malfunction has been detected. ERRORS Handlebar gear upshift control - Code 900F - signal not valid Error cause There is a malfunction in the handlebar gear upshift control.
Troubleshooting If, besides the error, the status of "Handlebar gear upshift control" indicates "Invalid data": the instrument panel waits to detect a voltage above approximately 1 V at one of either PINS and at the same time a voltage below approximately 1 V on the other PIN; if this does not happen, the instrument panel sends the information to the control unit which signals this error. CASE 1) if the voltage is below 1V on both, with control not activated, it means that a voltage below 1V, instead of battery, is detected at instrument panel PIN 5; disconnect the gearshift control connector and read voltage at PIN 5 of the instrument panel: if voltage is below 1 V, it means that on the blue/purple cable there is a short circuit to ground; if voltage is above 1 V (approximately battery voltage), replace the gear upshift control sensor. CASE 2) if both voltages are below 1 V with control activated, it means that at that moment a voltage below 1 V, instead of battery, is detected at PIN 13 of the instrument panel; disconnect the gearshift control connector and read voltage at PIN 13 of the instrument panel: if voltage is below 1 V, it means that on the black/purple cable there is a short circuit to ground; if the voltage is above 1 V (approximately battery voltage), replace the gear upshift control sensor. CASE 3) if both voltages are equal to battery voltage, with control not activated, it means that there is an interruption in the circuit from PIN 13 to PIN 30 of the instrument panel or that PIN 30 does not have a ground connection: check the instrument panel connector and ELE SYS - 132
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Electrical system
the gearshift control connector: if they are not OK, restore; if they are OK, check continuity on the black/purple cable: if it is not OK, restore; if it is OK, check continuity on the brown/ black cable from gearshift control connector to PIN 30 of the instrument panel: if it is not OK, restore; if it is OK, check continuity of the gearshift control from the gearshift control connector (between black cable and green cable): if it is not OK, replace the control; if it is OK, check, with key set to key ON, that there is no ground connection in the brown/black cable and then replace the instrument panel. CASE 4) if both voltages are above 1 V (approximately battery voltage), with control activated, it means that there is an interruption on the circuit from PIN 5 to PIN 30 of the instrument panel: check the instrument panel connector and the gearshift control connector: if they are not OK, restore; if they are OK, check continuity on the blue/purple cable: if it is not OK, restore; if it is OK, check, with control activated, that there is not continuity of the gearshift control from the gearshift control connector (between black cable and yellow cable) and then replace the control. If, besides the error, the status of "Handlebar gear upshift control" indicates "Pressed", check the control mechanically: If it is not OK, restore; if it is OK, the gear upshift control must be replaced. ERRORS Handlebar gear downshift control - Code 9010 - signal not valid Error cause There is a malfunction in the handlebar gear downshift control.
Troubleshooting If, besides the error, the status of "Handlebar gear upshift control" indicates "Invalid data": the instrument panel waits to detect a voltage above approximately 1 V at one of either PINS and at the same time a voltage below approximately 1 V on the other PIN; if this does not happen, the instrument panel sends the information to the control unit which signals this error CASE 1) if the voltage is below 1V on both, with control not activated, it means that a voltage below 1V, instead of battery, is detected at PIN 18 of the instrument panel; disconnect the gearshift control connector and read voltage at PIN 18 of the instrument panel: if voltage is below 1 V, it means that on the blue/yellow cable there is a short circuit to ground; if voltage is above 1 V (approximately battery voltage), replace the gear upshift control sensor. CASE 2) if both voltages are below 1 V with control activated, it means that at that moment a voltage below 1 V, instead of battery, is detected at PIN 19 of the instrument panel; disconnect the gearshift control connector and read voltage at PIN 19 of the instrument panel: if voltage is below 1 V, it means that on the black/yellow cable there is a short circuit to ground; if the voltage is above 1 V (approximately battery voltage), replace the gear upshift control sensor CASE 3) if both voltages are equal to battery voltage, with control not activated, it means that there is an interruption in the circuit from instrument panel PIN 19 to PIN 30 or that PIN 30 does not have a ground connection: check the instrument panel ELE SYS - 133
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connector and the gearshift control connector: if they are not OK, restore; if they are OK, check continuity on the black/yellow cable: if it is not OK, restore; if it is OK, check continuity on the brown/black cable from gearshift control connector to PIN 30 of the instrument panel: if it is not OK, restore; if it is OK, check continuity of the gearshift control from the gearshift control connector (between brown cable and blue cable): if it is not OK, replace the control; if it is OK, check, with key set to key ON, that there is no ground connection in the brown/ black cable and then replace the instrument panel. CASE 4) if both voltages are above 1 V (approximately battery voltage), with control activated, it means that there is an interruption on the circuit from PIN 18 to PIN 30 of the instrument panel: check the instrument panel connector and the gearshift control connector: if they are not OK, restore; if they are OK, check continuity on the blue/yellow cable: if it is not OK, restore; if it is OK, check, with control activated, that there is not continuity on the gearshift control from the gearshift control connector (between brown cable and red cable) and then replace the control. If, besides the error, the status of "Handlebar gear downshift control" indicates "Pressed", check the control mechanically: if it is not OK, restore; if it is OK, the gear downshift control must be replaced.
Driving pulley electric motor

DRIVING PULLEY CONTROL ELECTRICAL MOTOR Function By means of a transmission gear, it allows the rotation of the driving pulley control bushing which in turn moves the driving half-pulley axially. Operation / Operating principle DC motor with pulse activation (duty cycle). The rotation in both directions is controlled by the control unit by inverting the power supply polarity. Level in wiring diagram:Transmission management Location: on the vehicle: up and to the left of the transmission cover connector: Under helmet compartment
Electrical characteristics: Pin-out: 1. Red 2. Black AXONE / AUTOMATIC TRANSMISSION system ELE SYS - 134 Winding resistance < 1 Ohm Input: nominal 10A Maximum input: 22 A
MSS Mana GT ABS
Electrical system
PARAMETERS Driving pulley control electrical motor duty cycle Example value: % It is a speed indicator of the driving half-pulley movement in axial direction. NOTE: When troubleshooting, use the interface, code 020481Y, with the adaptor, code 020481Y004. The correspondence between the control unit PIN and the interface PIN is the following: control unit PIN A1.A8 and interface PIN interface 11.18, control unit PIN B1.B8 and interface PIN interface 21.28, control unit PIN C1.C8 and interface PIN interface 31.38. ERRORS Driving pulley electrical motor - Code 900A - excessive actuation time/ excessive current input/ signal not valid. Error cause If activation time is excessive: the position is not reached within a standard time although the driving pulley motion control is activated. If input current is excessive: the transmission ECU detects excessive ampere input for the driving pulley electric motor. If the signal is not valid: a short-circuit to ground has been detected at battery PIN A8 or PIN B8. Troubleshooting If activation time is excessive: check circuit continuity between PIN A8 and B8: if it is not OK, continue with Phase 1; if it is OK, check the gears which receive the movement from the electrical motor and set the position of the driving half-pulley. Phase 1: check continuity of the red cable and the black cable between the electrical motor connector and the control unit connector: if they are not OK, restore the cable harness; if they are OK, check that there is not continuity on the circuit of the electrical motor and replace it. If input current is excessive: check the driving half-pulley movement system mechanically (excessive friction material). If the signal is not valid: set the key to key ON and check the voltage value at PIN A8 and B8 which should be approximately 3 V at both PINS; if there is voltage similar to battery voltage or there is continuity with the ground in one of the two PINS, restore the cable harness; otherwise, replace the transmission ECU.
Connectors
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ECU
INJECTION ECU PIN OUT BROWN "A" CONNECTOR 1. 2. 3. Throttle position sensor input 4. 5. 6. 7. 8. 9. Idle motor D 10.Front coil control output 11.12.13.14.Air temperature sensor input 15.16.17.Idle motor A 18.Idle motor B 19.Idle motor C 20.Reference voltage output + 5 V temperature sensors 21.22.23.24.25.Revolution sensor input ( + ) 26.ELE SYS - 136
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Electrical system
27.28.Rear injector control output 29.Throttle position sensor ground connection 30.31.32.Throttle sensor voltage output 33.34.Revolution sensor shielding 35.Revolution sensor input (-) 36.37.Front injector control output 38.Rear coil control output
BLUE "B" CONNECTOR 1. Start-up control output 2. 3. 4. Control unit direct power supply 5. Water temperature sensor input 6. Auxiliary injection relay control output 7. 8. -
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9. 10.11.Lambda heater control output 12.13.14.Electric fan relay control output 15.16.Serial K line for diagnosis 17.Key switch 18.19.20.CAN H Line (high speed) 21.22.Lambda sensor input (+) 23."Stop switches" input 24.25.26.27.28."Start engine" switch input 29.CAN L Line (high speed) 30.31.32.Lambda sensor input (-) 33.34.35.Fall sensor input 36.37.38.Side stand input
ELE SYS - 138
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Electrical system
Transmission control unit
TRANSMISSION ECU PIN OUT A1 - / A2 - Track 1 driving pulley position sensor input A3 - Gear UP pedal sensor normally open input A4 - Track 2 driving pulley position sensor voltage output A5 - Track 1 driving pulley position sensor ground A6 - Gear DOWN pedal sensor normally closed input A7 - Gear UP pedal sensor normally closed input A8 - Engine ( + ) B1 - Key switch B2 - Series K line for diagnosis B3 - Pulley speed sensor input ELE SYS - 139
Electrical system
MSS Mana GT ABS
B4 - CAN L Line (high speed) B5 - CAN H Line (high speed) B6 - Speed sensors ground B7 - Gearshift mode sensor input B8 - Engine ( - ) C1 - Control unit direct power supply C2 - Track 2 driving pulley position sensor input C3 - Vehicle speed sensor input C4 - Gear DOWN pedal sensor normally open input C5 - Gearshift pedal sensors ground C6 - Track 1 driving pulley position sensor voltage output C7 - Track 2 driving pulley position sensor ground C8 - Ground
Dashboard
INSTRUMENT PANEL PIN OUT GREY CONNECTOR PIN 1 - + Key PIN 2 - Right indicator control PIN 3 - * PIN 4 - High-beam input PIN 5 - gear UP normally open input PIN 6 - Select 3 (Set) PIN 7 - Select 2 (Down) PIN 8 - Select 1 (Up) PIN 9 - Fuel reserve sensor PIN 10 - Ambient temperature sensor PIN 11 - + Battery PIN 12 - Left indicator control PIN 13 - gear UP normally closed input ELE SYS - 140
MSS Mana GT ABS
Electrical system
PIN 14 - heated handgrip warning light PIN 15 - * PIN 16 - Indicators reset PIN 17 - Oil sensor input PIN 18 - gear DOWN normally open input PIN 19 - gear DOWN normally closed input PIN 20 - K line BLACK CONNECTOR PIN 21 - + Battery PIN 22 - Front left turn indicator activation PIN 23 - Front right turn indicator activation PIN 24 - Aerial 2 PIN 25 - * PIN 26 - CAN H PIN 27 - CAN L PIN 28 - ABS Warning light input PIN 29 - * PIN 30 - Sensors ground PIN 31 - + Battery PIN 32 - Rear left turn indicator activation PIN 33 - Rear right turn indicator activation PIN 34 - Aerial 1 PIN 35 - Light relay activation PIN 36 - Heated handgrips A PIN 37 - Heated handgrips B PIN 38 - General ground PIN 39 - General ground PIN 40 - General ground
ABS Modulator
INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR Check the initial position of the lever that couples the connector.
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MSS Mana GT ABS
When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm (0.29 in).
If the initial position of the connector and the driving lever is not that shown in fig. 1, the connector will not be properly coupled and the distance measured will be greater (12 mm approx. (0.47 in)). In this case repeat the operation as described in the two previous points.
It is advisable to create a template to check the correct connector insertion.
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Electrical system
Insert the housing as shown in the figure.
Can line
CAN line Function It allows communication between the Marelli injection control unit, the transmission ECU and the instrument panel. Level in wiring diagram:CAN line Pin-out: see wiring diagram AXONE / AUTOMATIC TRANSMISSION system: ERRORS "Mute Node" CAN Line, U1601 - Mute Node. Error cause The transmission ECU cannot send CAN signals; it receives signals from the instrument panel and the injection control unit: the control unit may need replacing. Troubleshooting Replace transmission ECU.
CAN line to instrument panel Code 9007 - no signal Error cause No signal arrives to the instrument panel from either CAN line cables.
Troubleshooting Check the connector of the instrument panel: if it is not OK, restore; if it is OK, check the continuity of the two lines from the instrument panel connector to the transmission ECU connector: if not OK, restore the cable harness; if OK, replace the instrument panel. CAN line to injection ECU Code 9006 - no signal Error cause No signal arrives from the injection ECU from either CAN line cables.
Troubleshooting
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Check the transmission ECU connector and the Marelli control unit connector: if they are not OK, restore; if they are OK, check the continuity of the two lines from the transmission ECU connector and from the Marelli control unit connector: if it is not OK, restore the cable harness; if it is OK, replace the Marelli control unit.
AXONE / FUEL INJECTION system: ERRORS Mute Node CAN Line, U1601 - Mute Node Error cause The control unit cannot send CAN signals; it receives signals from the instrument panel and the transmission ECU: the control unit may need replacing. Troubleshooting Replace injection ECU.
CAN line, no signal, U1602- Bus Off Error cause No communication on CAN line (PIN B4 and/or PIN B5): problem on the whole network (for example, battery cut-off or short circuited or shorted to ground). Troubleshooting Check the Marelli control unit connector: if not OK, restore; if OK, check the earth insulation of the two CAN lines from PIN 20 and PIN 51 of the VEHICLE connector: If not OK, restore the cable harness; if OK, check continuity of the two CAN lines from the Marelli control unit VEHICLE connector to the filter casing large connector and to the instrument panel connector: if not OK, restore the cable harness; if OK, check that the two lines are not short circuited to positive testing each of the 3 connectors (Marelli control unit connector, filter casing large connector and instrument panel connector) with 1 connector disconnected at a time and by setting the key to ON: If not OK, restore; if OK, replace the Marelli control unit. CAN line to instrument panel, U1701 - No signal Error cause No signal arrives to the instrument panel from either CAN line cables.
Troubleshooting Check the connector of the instrument panel: if it is not OK, restore; if it is OK, check the continuity of the two lines from the instrument panel connector to the injection ECU connector: if not OK, restore the cable harness; if OK, replace the instrument panel. CAN line to transmission ECU, U1702 - No signal Error cause No signal arrives from the transmission ECU from either CAN line cables.
MSS Mana GT ABS
Electrical system
Check the transmission ECU connector and the Marelli control unit connector: if they are not OK, restore; if they are OK, check the continuity of the two lines from the transmission ECU connector and from the Marelli control unit connector: if it is not OK, restore the cable harness; if it is OK, replace the transmission ECU.
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INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
MSS Mana GT ABS
Engine from vehicle
Vehicle preparation
Rest the vehicle on its rear centre stand. Remove the helmet compartment. Remove the radiator. Remove the expansion tank. Disconnect the lambda probe connector. Remove the rear ABS sensor. Disconnect the rear stop switch connector.
Disconnect the fall sensor connector.
Disconnect the pickup connector.
ENG VE - 147
Engine from vehicle
MSS Mana GT ABS
Disconnect the two sensors.
Remove the clamp.
Undo and remove the four upper fixing screws.
ENG VE - 148
MSS Mana GT ABS
Engine from vehicle
Remove the upper cover of the transmission cooling housing.
Undo and remove the two lower fixing screws.
Undo and remove the internal fixing screw.
Undo and remove the screw fixing the gearshift lever. Remove the gearshift lever.
ENG VE - 149
Engine from vehicle
MSS Mana GT ABS
Undo and remove the lower screw.
Remove the left passenger footrest support. Remove the transmission cooling cover.
Undo and remove the starter motor supply cable fixing nut. Slide off the starter motor power supply cable.
Remove the five clamps placed on the cable harness.
ENG VE - 150
MSS Mana GT ABS
Engine from vehicle
Undo and remove the screw fixing the speed sensor. Remove the speed sensor.
Undo and remove the two screws fixing the stand sensor. Remove the stand sensor.
Undo and remove the gear sensor fixing screw. Remove the two gearshift pedal sensors.
Disconnect the potentiometer connector.
ENG VE - 151
Engine from vehicle
MSS Mana GT ABS
Remove the variator motor cover. Undo and remove the two fixing screws.
Remove the variator motor.
Disconnect the horn connectors.
ENG VE - 152
MSS Mana GT ABS
Engine from vehicle
Disconnect the yellow cable connector.
Remove the connector of the voltage regulator cable harness.
Remove the ground lead.
Disconnect the intake air sensor from the throttle body.
ENG VE - 153
Engine from vehicle
MSS Mana GT ABS
Disconnect the temperature sensor from the throttle body.
Remove the two retaining straps. Disconnect the timing sensor.
Working on the left side, slide off the spark plug tube.
Working on the right side, slide off the spark plug tubes.
ENG VE - 154
MSS Mana GT ABS
Engine from vehicle
Disconnect the front coil connector.
Release the coil ground lead.
Disconnect the rear coil connector.
Slide off the six relays from their seats.
ENG VE - 155
Engine from vehicle
MSS Mana GT ABS
Release the water bulb.
Undo and remove the fixing screw and collect the washer.
Release the two quick-release joints for fuel delivery and return.
Remove the injector connectors.
ENG VE - 156
MSS Mana GT ABS
Engine from vehicle
Disconnect the ignition connectors.
Remove the oil pressure sensor and release it from the seal clamp.
Remove the exhaust. Slide off the rubber protection. Undo and remove the cable holder sheath fixing nut.
Slide off the throttle grip cable. Repeat the same operations for the second throttle grip cable.
ENG VE - 157
Engine from vehicle
MSS Mana GT ABS
Removing the engine from the vehicle

Carry out the operations described under Vehicle preparation. Support the vehicle by means of belts and a hoist. Remove the saddle. Remove the passenger grab handle. Remove the helmet compartment. Remove the radiator. Remove the filter casing. Remove the transmission cooling cover. Remove the left footrest plate. Remove the exhaust. Position the vehicle adequately on the front service stand and on the undersump stand. Undo and remove the rear shock absorber fixing screw. Secure the shock absorber to the chassis. Release the parking brake cable. Undo and remove the plate fixing screw and remove the right footrest holder plate.
ENG VE - 158
MSS Mana GT ABS
Engine from vehicle
Unscrew and remove the lower nut.
Undo and remove both brake plate fixing screws.
Unscrew and remove the fixing nut. Collect the washer.
Working on the right side, hold the fork and with a rubber hammer, collect the fork pin.
Slide off the chain from the pinion.
ENG VE - 159
Engine from vehicle
MSS Mana GT ABS
From behind, slide off the fork unit together with gear and chain.
Working on the left side, unscrew and remove the fixing nuts of the engine bolts.
Working on the right side, slide off the engine bolts. Lower the engine.
ENG VE - 160
MSS Mana GT ABS
Engine from vehicle
ENG VE - 161
INDEX OF TOPICS
ENGINE
ENG
MSS Mana GT ABS
Engine
This section describes the operations to be carried out on the engine and the tools required.
Starter motor
The starter motor is sold as a complete part. Before deciding on its replacement, it is necessary to carry out the following checks: - Battery Check the voltage after a pause: Voltage > 12.5 V - Check the correct connection of the negative terminals (battery negative and starter motor negative) between them and to the chassis. - Recharge and if necessary, replace the battery. - Connect the diagnostic tester (see the injection chapter). Connect the induction clamp of an ammeter to the starter motor power supply positive cable. Remove the 7.5A fuse No. 10 (see the fuses chapter). Switch ON with the switch set in the RUN position and the side stand up. Select the PARAMETERS function. Command to start the engine (so that it cannot move) long enough to measure the rpm and starter motor input.
NOTE
THE DECLARED RPM VALUE IS THAT INDICATED BY THE DIAGNOSTIC TESTER, THE RPM READING IS NOT THE REAL ONE, BUT IT IS VALID FOR DIAGNOSIS PURPOSES.
Electric characteristic
Input at driving speed: 120 A Engine speed ~300 400 rpm The start-up system has a gear between the motor armature and the crankshaft equipped with a freewheel coaxial to the flywheel and the torque limiter on the intermediate shaft. The torque limiter is calibrated at 100 Nm (73.76 lbf ft); this component protects the structure of the engine and the start-up kinematic mechanism in the event of incorrect start-up procedure, resulting in inverse rotation. The freewheel is used for a sufficiently silent start-up. The start-up control (energised remote control) is slaved to enabling signals by the side stand and the emergency OFF/RUN switch, which does not allow starting given dangerous conditions. The start-up control circuit is not controlled by the immobiliser system; therefore, before insisting on the starter system in an abnormal way, check the immobiliser enabling switch. ENG - 163
Engine
MSS Mana GT ABS
To check the enabling switch circuit, see the "Electrical system" chapter; to check the crankshaft control transmission, follow what is described in the Flywheel and start-up system chapter.
Removing the starter motor

- Disconnect the electric terminals. - Unscrew the nuts fixing it to the crankcase.
Installing the starter motor

- Check that the O-ring is in good conditions and lubricate it. - Fit the starter motor. - Tighten the 2 fixing screws to the prescribed torque.

Starter motor retainers 11 Nm - 13 Nm (8.11 lbf ft 9.59 lbf ft
Removing the idle gear

- Check that the toothing is not worn. - Check the diameter of the two bearings.
Characteristic
Gear bearing diameter 12 (0; - 0.011) mm (0.47000 (0; -0.00043) in)
ENG - 164
MSS Mana GT ABS
Engine
Also check the diameter of the bearings on the flywheel cover and on the engine crankcase.
Characteristic
Diameter of bearing on the flywheel cover 12 (+0.034; - 0.016) mm (0.47000 (+0.0013; -0.0006) in)
Characteristic
Diameter of bearing on the engine crankcase 12 (+0.034; - 0.016) mm (0.47000 (+0.0013; -0.0006) in)
NOTE
THE TORQUE LIMITER IS EQUIPPED WITH 4 GEARS THAT FUNCTION AS CLUTCH DRIVING PLATES. Driven plates consist of 4 Belleville springs with grooved profiles; this assembly allows transmitting torques below 100 Nm (73.75 lbf ft). In case of incorrect start-up procedures, the torque limiter prevents any kicks, resulting in inversion of rotation direction of the crankshaft which would impair the engine structure.
The limiter assembly cannot be overhauled. In case of clearly visible irregularities on the toothed discs, replace the assembly.
ENG - 165
Engine
MSS Mana GT ABS
Fitting the idle gear

- Grease the gear housing on the engine crankcase.
- Fit the intermediate gear with torque limiter.
Removing the starter gear

- Check that there is no wear or abnormal marks on the rollers of the freewheel and on the surface of the starter ring gear hub. - Check the hub outside diameter.
Characteristic
Hub outside diameter 45.665 mm (+0.008; +0.005) mm (1.79 in (+0.0003; + 0.0002) in) - Check the inside diameter of the start-up gear bushing. - Check that the toothing is not worn.
Characteristic
Bushing inside diameter 27 mm (+0.020; +0.041) mm (1.0629 in (+0.0008; 0.0016) in)
NOTE
IF THE FAULTS FOUND AFFECT THE HUB, IT IS EXPEDIENT TO REPLACE THE STARTING RING GEAR AND THE FREEWHEEL. ENG - 166
MSS Mana GT ABS
Engine
IF ONLY THE BUSHING IS WORN, REPLACE ONLY THE COMPLETE STARTING RING GEAR. ALSO CHECK THE DIAMETER AND THE SURFACE OF THE BEARING ON THE CRANKSHAFT. IN CASE OF IRREGULARITIES, REPLACE THE CRANKSHAFT.
Installing the starter gear

- Lubricate the internal bushing and the starter ring gear hub surface.
- Fit the starting ring gear on the flywheel by turning it clockwise and inserting the gear at the same time.
ENG - 167
Engine
MSS Mana GT ABS
Generator side
Removing the flywheel cover

- Undo the sixteen screws fixing it to the crankcase.
- Remove the flywheel cover.

NOTE
THE COVER OFFERS RESISTANCE DUE TO THE FLYWHEEL MAGNETIC FIELD.
ENG - 168
MSS Mana GT ABS
Engine
Magneto flywheel removal

- Lock the flywheel and tighten the nut fixing it to the shaft with the specific tool.
Specific tooling
020713Y Flywheel extractor
- Fit the specific extractor, and unlock the flywheel operating the tool.
CAUTION THE THREAD IS ANTICLOCKWISE.
Specific tooling
020713Y Flywheel extractor
- Once it is unlocked, remove the flywheel with the freewheel.
- Undo the plate fixing screw.
ENG - 169
Engine
MSS Mana GT ABS
- Remove the starting ring gear.
- Undo the five fixing screws and remove the oil pump compartment closing bulkhead.
- Remove the intermediate gear.
Removing the stator

- Undo the 3 fixing screws and remove the stator with the cable harness.
ENG - 170
MSS Mana GT ABS
Engine
Inspecting the cover components

- Check the condition of the stator and of the relevant cable harness.
- Check the continuity between the 3 phases.

NOTE THE VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.
Electric characteristic
Resistance: 0.2 1
- Check the earth insulation of each phase. - If faults are found, check the cable thoroughly as it consists of two types of cables: rigid cables close to the stator and flexible cables close to the connector.
- Check that the winding is placed so as not to interfere with the heads of the fixing screws.
ENG - 171
Engine
MSS Mana GT ABS
Flywheel components check

- Check that the magnets are in good conditions. - Check that the magnet support cage is not deformed or broken.
Checking the starter clutch

- Make sure the freewheel faying surfaces are in good condition. - Thoroughly clean the freewheel to remove any LOCTITE left. - Degrease the threading of the freewheel holes and the fixing screws. - Apply the recommended product to the end of the screws.
Recommended products
Loctite 243 Medium strength threadlock - Fit the freewheel on the magneto flywheel, making sure that the ground side is in contact with the flywheel, that is the wheel seeger ring should be visible. - Tighten the 6 fixing screws in a criss-cross sequence to the prescribed torque.
- Lubricate the freewheel rollers.
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Stator installation
- Fit the stator together with the cable harness, fixing the 3 screws to the prescribed torque.
NOTE INSERT THE SEALING GASKET OF THE RUBBER WIRING INTO THE SPECIFIC SEAT ON THE CRANKCASE.

Stator clamps 8 - 10
Flywheel cover installation

- Follow the removal steps but in reverse order; be careful to tighten to the prescribed torque with the specific tool.
CAUTION
CLOSING THE COVER MAY POSE A RISK TO THE OPERATOR DUE TO THE STRONG MAGNETISM OF THE FLYWHEEL. BE SPECIALLY CAREFUL WITH YOUR HANDS.

Flywheel cover screws 11 - 13
Head and timing

Schema
ENG - 173
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Removing the intake manifold

- Remove the coolant pipes.
- Undo the six fixing screws.
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- Remove the inlet manifold.
Removing the head cover

- Undo the 6 special screws with stop and the relevant rubber gaskets. - Remove the tappet cover with the relevant gasket.
Removing the timing control

- As indicated in the photograph, align the references on the timing system gear of the rear cylinder with the reference on the valves cap.
NOTE PLACING THE ENGINE AS INDICATED, IT IS IN THE COMBUSTION PHASE AND ALL THE VALVES ARE CLOSED. THIS FACILITATES FITTING-REMOVAL OPERATIONS.
- Loosen the central screw of the tensioner. - Unscrew the two retainers indicated in the photograph and remove the tensioner with the relevant gasket.
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- Lock the timing system gear with the specific tool, undo the central fixing screw and collect the washer. - Release the chain from the sprocket and be careful that it does not fall inside the transmission housing. - Remove the timing system gear and the tone wheel from the camshaft.
CAUTION THE TONE WHEEL IS ONLY ON THE REAR CYLINDER. IN THE FRONT CYLINDER IT IS REPLACED BY A SPACER.
Specific tooling
AP8106702 Flywheel lock calliper spanner - Repeat the operations for the front cylinder timing system gear.
Removing the cylinder head

- The head removal operation is carried out in two separate stages, first on the rear cylinder, then on the front one. - If the heads are removed together with the valves and the camshaft, follow the recommendations.
NOTE
THE HEADS MUST BE CORRECTLY REMOVED WITH THE PISTONS AT TDC AND THE VALVES CLOSED. - Remove the engine revolution sensor and the water temperature sensor, fitted only on the rear cylinder head.
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- The operations are described only once, but they are valid for both heads. - Remove the spark plugs. - Unscrew the two fixing nuts and collect the washers.
- Undo the spark plug side screw.
- Undo the two screws inside the head, timing system side.
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- Loosen the 4 head-cylinder fixing nuts in two or three stages and in a criss-crossed sequence. - Remove the head, the two centring dowels, the gasket and the lower chain guide slider.
Cylinder head Removing the overhead camshaft

- Remove the 3 fixing screws and the camshaft retaining bracket.
NOTE REMOVING THE FIXING SCREWS MAY BE DIFFICULT. BE CAREFUL NOT TO DAMAGE THE INTERNAL HEXAGON. IF NECESSARY, DETACH THE THREADS IN ADVANCE.
- Remove the camshaft.

CAUTION THE TWO CAMSHAFTS ARE DIFFERENT ONE FROM THE OTHER. IT IS POSSIBLE TO IDENTIFY THEM BY LETTER "A" (FRONT) OR "P" (REAR) STAMPED ON THE EXTERNAL SHOULDER, CROWN GEAR SIDE.
- Remove the pins and the rocking levers acting from the transmission-side holes.
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Removing the valves

- Using the appropriate tool fitted with an adapter, remove the cotter pins, plates, springs and valves.
Specific tooling
AP0276474 Valve spring compressor adaptor AP8140179 Support for valve fitting/removal
CAUTION ARRANGE THE VALVES SO AS TO RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD (FLYWHEEL-SIDE AND TRANSMISSION-SIDE).
- Remove the oil seals with the specific tool.
Specific tooling
020431Y Valve oil seal extractor
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- Remove the spring supports.

NOTE BLOW THE SEATS WITH COMPRESSED AIR TO FACILITATE REMOVING THE SPRING SUPPORTS.
Checking the overhead camshaft

- Check the camshaft bearings for signs of abnormal wear or scores. - Using a micrometer, measure the camshaft bearings.
STANDARD DIAMETER
Specification Bearing A : Bearing B : Desc./Quantity 42- 0.060 -0.085 mm 20- 0.020 -0.041 mm
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MINIMUM DIAMETER ALLOWED

Specification Bearing A : Bearing B : Desc./Quantity 41.910 mm 19.940 mm
- Using a gauge, measure the height of the cams.
LIMITS ALLOWED
Specification Inlet: Outlet: Standard axial clearance: Maximum axial clearance allowed: Desc./Quantity 33.740 mm 33.170 mm 0 0.22 mm 0.3 mm
STANDARD HEIGHT
Specification Inlet: Outlet: Desc./Quantity 33.988 mm 33.417 mm
- Check there are no signs of wear on the contact pads with the cam and on the articulated plate of the set screws. - In case of wear, replace the component. - Check there are no signs of wear or scoring on the rocking lever pins.
Characteristic
Standard diameter: 13 - 0.010 -0.018 mm
See also
Assembly clearances
ENG - 181
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Checking the rocker arms

- Check the inside diameter of each rocking lever.
Characteristic
Standard diameter: 13 + 0.026 +0.015 mm
Valve check
- Remove any carbon deposits from the valve seats. - Check the width of the mark on the valve seat V with Prussian blue.
Characteristic
Standard value: 1 1.3 mm Limit allowed: 1.6 mm - If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45 milling cutter and then grind. - Replace the head in case of excessive wear or damage.
VALVE STANDARD LENGTH

Specification Inlet: Outlet: Desc./Quantity 95.0 0.3 mm 94.2 0.3 mm
- Measure the diameter of the valve stem at the three positions indicated in the diagram.
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STANDARD DIAMETER
Specification Inlet: Outlet: Desc./Quantity 4.987 4.972 mm 4.975 4.960 mm
MINIMUM DIAMETER ALLOWED

Specification Inlet: Outlet: Desc./Quantity 4.96 mm 4.945 mm
- Calculate the clearance between the valve and its guide.
- Check the deviation of the valve stem by resting it on a "V" shaped support and measuring the extent of the deformation using a dial gauge.
Characteristic
Limit value allowed: 0.1 mm
- Check the concentricity of the valve head by placing a dial gauge at a right angle with respect to the valve head and rotating it on the "V" shaped support.
Characteristic
Limit allowed: 0.03 mm
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- Check that there are no signs of wear on the faying surface with the set screw articulated end and that its surface is smooth and not concave. - If no anomalies are found during the above checks, the same valves can be reused. For better sealing results, it is advisable to grind the valves. Grind the valves gently with finegrained lapping compound. Upon grinding, keep the cylinder head with the valve axles in a horizontal position. This will prevent the lapping compound residues from penetrating into the stemvalve guide coupling.
CAUTION TO AVOID SCORING THE FAYING SURFACE, DO NOT ROTATE THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED. CAUTION DO NOT CHANGE THE VALVE FITTING POSITION (RH LH).
See also
Installing the cylinder head
Inspecting the valve sealings

- Fit the valves into the cylinder head. - Alternatively test the intake and outlet valves. - The test should be carried out by filling the manifold with fuel and checking that the head does not ooze through the valves when they are just pressed by the fingers.
See also
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Inspecting the springs and half-cones

- Check that the upper and lower supporting spring plates, the cotters and the oil seal show no sign of abnormal wear. Otherwise, replace the component.
- Measure the unloaded spring length.

NOTE
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAPTER. - Measure the unloaded spring length.
Characteristic
Standard length: 44.4 mm Limit allowed after use: 42.4 mm
See also
Checking the valve guides

Measure the valve guides.
Characteristic
Valve guide: 5+0.012 mm
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- After measuring the valve guide diameter and the valve stem diameter, check the clearance between guide and stem.
OUTLET
Specification Standard clearance: Limit allowed: Desc./Quantity 0.025 0.052 mm 0.09 mm
INLET
Specification Standard clearance: Limit allowed: Desc./Quantity 0.013 0.04 mm 0.08 mm
See also
Checking the cylinder head

Clean all the coupling surfaces thoroughly before servicing the head. Pay attention to the position of the springs and valves so as not to change the original position upon refitting them - Using a trued bar and a thickness gauge, check that the cylinder head surface is not worn or distorted.
Characteristic
Maximum run-out allowed: 0.1 mm
- In case of irregularities, replace the head. - Check the sealing surfaces for the inlet and exhaust manifold. - Check that the camshaft and the rocker pin bearings show no signs of wear. - Check that the head cover show no signs of wear. - Check that the coolant sealing buffer is not rusted.
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Measure the camshaft seat bearings and rocking lever support pins with a bore meter
HEAD BEARINGS
Specification Bearing "A" Bearing "B" Bearing "C"
Desc./Quantity 42 +0.025 19.5 -0.2 13 +0.018
Installing the valves

- Place the valve spring supporting plates on the head.
- Fit the four oil seals alternately with the specific tool.
Specific tooling
020306Y Punch for fitting the valve sealing rings
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- Lubricate the oil seals and the valve guides. - Fit the valves, the springs and the plates.
- With the specific tool fitted with the appropriate adaptor, compress the springs and fit the cotters in their seats.
Specific tooling
AP8140179 Support for valve fitting/removal AP0276474 Valve spring compressor adaptor
NOTE
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REFERENCE COLOUR ON THE COTTERS SIDE (TURNS WITH GREATER PITCH).
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Timing
Removing the chain tensioner

- Remove the central screw, collect the washer and the spring carefully.
Checking the chain tensioner

- Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring. - If signs of wear are found, replace the whole assembly.
Checking the chain

- Check the chain, camshaft control timing system gear and crankshaft pinion for wear. In case of excessive wear, replace the entire chain-crown-pinion unit.
CAUTION
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IF THE CHAIN HAS DAMAGED THE PINION, REPLACE THE CRANKSHAFT.
Checking the sliders

- Check that the guide slider and the tensioner pad are not excessively worn. - Replace the sliders if they are worn.
Cam timing
The ignition advance is determined electronically on the basis of parameters known by the control unit. For this reason it is not possible to state the reference values based on the engine revs. The ignition advance value can be measured at any time with the Axone. It is possible to check whether the ignition advance determined by the injection system does in fact correspond with the value actually activated on the engine, by means of the stroboscopic light.
Specific tooling
AP8140595 Axone + battery charger (230V 50Hz) AP8202311 Axone + battery charger (110V 60Hz) 020330Y Stroboscopic light for timing checking - Unscrew the TDC reference inspection cap. - Connect the stroboscopic light.
- Connect the Axone. - Start the engine. - Select the parameter function from the menu. - Select the stroboscopic light control in the traditional four-stroke engine position (1 spark, 2 revs). - Check that the real values of revs and ignition advance match those measured using the Axone. - Refit the inspection cap on the flywheel side.
Specific tooling
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AP8140595 Axone + battery charger (230V 50Hz) AP8202311 Axone + battery charger (110V 60Hz) If the values do not correspond, check: - distribution timing - rpm timing sensor - injection control unit
Timing
- With the TORX wrench, remove the timing check cap.
- With the references aligned, operate on the driving pulley to turn the crankshaft until on the flywheel the rear cylinder timing reference mark 1 is aligned to the crankcase reference, corresponding to the rear piston top dead centre.
- Fit the tone wheel and the timing system gear with the chain and align the reference marks.
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- Once the reference marks are aligned as indicated with the reference marks on the valve cam cap, tighten the screw with the washer to the prescribed torque.

Timing system crown screw on camshaft 12
14
- Place the tensioner slider at the rest position, keeping the retaining tab pressed.
- Insert the chain tensioner in the cylinder with the gasket and tighten the screws to the prescribed torque.

timing chain tensioner screws 11 13
- Check and if necessary, restore the correct clearance of the valves.
Characteristic
Valve clearance Inlet: 0.15 mm
Outlet: 0.15 mm
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- Turn the crankshaft in the normal operating direction until the reference mark "A" on the tone wheel is aligned with the rear head reference, so as to take the front piston to the top dead centre.
- Check that the front cylinder phase reference mark "2" is aligned with the crankcase reference mark.
Cylinder-piston assembly Removing the cylinder

- Remove the coolant inlet pipes. - The described operations refer to one cylinder but apply to both.
- Slide off the cylinder with the relevant gasket and the centring dowel.
NOTE THE SECOND CENTRING IS ENSURED BY A DOWEL SET INTO THE CYLINDER. CAUTION TO AVOID DAMAGING THE PISTON, KEEP IT FIRM WHILE REMOVING THE CYLINDER.
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Disassembling the piston

- Remove the head. - Remove the 2 piston pin snap rings operating through the specific slots. - Slide off the pin and remove the piston.
NOTE USE PAPER OR A CLOTH TO CLOSE THE CYLINDER HOUSING MOUTH ON THE CRANKCASE TO PREVENT ONE OF THE TWO PIN SNAP RINGS FROM FALLING INSIDE.
- Remove the piston sealing rings and the scraper ring.

CAUTION PAY ATTENTION TO THE FITTING POSITIONS OF THE RINGS TO PREVENT INVERTING THE POSITION IN CASE THEY ARE REUSED. NOTE BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL.
See also
Removing the cylinder head
Checking the cylinder

All seal surfaces must be clean and flat. Make sure all threads are in proper conditions. Check cylinder sliding surface for signs of friction and scratches. Also check the seal surfaces for damages.
CAUTION
IF THE GROOVES ON THE CYLINDER LINER ARE EVIDENT, REPLACE THE CYLINDER AND THE PISTON. Clean off lime scales on the cylinder cooling slots.
ENG - 194
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CYLINDER CHECK
Specification B Cylinder C Desc./Quantity 43 mm (1.69 in) 88 mm (+0.018; -0.01) mm (3.4645 in (+0.0007; -0.00039) in)
Characteristic
Maximum run-out allowed: 0.05 mm
Checking the piston

- Measure the piston diameter according to value A and check that the size measured is within the specified range.
ENG - 195
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PISTON CHECK
Specification A Piston P Desc./Quantity 10 mm (0.393 in) 87.968 mm (+/- 0.014 mm) (3.4632 in (+/- 0.0005)in)
Inspecting the wrist pin

NOTE
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAPTER.
See also
Piston rings
Inspecting the piston rings

NOTE
See also
Piston rings
Checking the connecting rod small end

NOTE
Fitting the piston

- Fit the piston and wrist pin onto the connecting rod, aligning the piston arrow towards the engine direction of rotation.
NOTE THE PISTON MUST BE FITTED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE FITTED WITH THE REFERENCE TOP OR THE STAMPED MARK FACING UP.
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- Fit the pin snap ring in the specific tool, with the opening in the position indicated on the tool. S = left D = right
- Set the snap ring into its position with the punch.
- Fit the pin snap ring with the pin as shown in the figure.
Specific tooling
020470Y Pin snap ring fitting tool
NOTE
THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY.
CAUTION
USING A HAMMER MAY DAMAGE THE RINGS HOUSINGS.
Refitting the piston rings

- Place the oil scraper ring spring on the piston. - Fit the oil scraper ring keeping the gap opposed to the spring union and the word "top" facing the piston crown. In any case, the chamfered side of the must be facing the piston crown. - Fit the middle piston ring with the identification letter or the word "top" facing the piston crown. In
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any case, the tapered side of the ring must be facing opposite the piston crown. - Fit the top compression ring in the direction forced by the housing. - It is advisable to use a fitter to help fitting the rings.
NOTE THE 2 PISTON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT SECTION. THIS IS TO OBTAIN A BETTER BEDDING.
- Offset the piston ring openings by 120 as shown in the figure. - Lubricate the components with engine oil. - The engine is fitted with a top ring with an L-shaped section.
Installing the cylinder

- Fit the cylinder base gasket of the chosen thickness. - With the fork support and the retaining clamp, fit the cylinder as shown in the figure.
NOTE BEFORE FITTING THE CYLINDER, CAREFULLY BLOW AIR INTO THE LUBRICATION DUCT AND LUBRICATE THE CYLINDER LINER. CHECK THAT THERE ARE TWO REFERENCE DOWELS.
Specific tooling
AP8140302 tool for sealing ring fitting 020716Y Connecting rod locking - Remove the specific tool.
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- Check that the centring dowel is correctly fitted and push the cylinder until it stops.
Selecting the base gasket

- First fit the piston into the cylinder, without any base gasket. - Fit a dial gauge on the specific tool with the short union, as shown in the figure.
Specific tooling
020714Y Dial gauge mounting - With a contrasting surface, reset the dial gauge with a preloading of a few millimetres. - Finally fix the dial gauge. - Check the perfect sliding of the feeler pin. - Fit the tool on the cylinder without changing the dial gauge position. - Lock the tool with the original head fixing nuts. - Rotate the crankshaft up to TDC (the reversal point of the dial gauge rotation). - Measure the deviation from the reset value.
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- By means of the chart, identify the thickness of the cylinder base gasket to be used upon refitting. By correctly identifying the cylinder base gasket thickness, an adequate compression ratio can be maintained - Remove the specific tool and the cylinder.
NOTE
IF DEVIATIONS (PROTRUSIONS OR RECESSES) CLOSE TO THE CHANGE OF CATEGORY ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSITE SIDE. TO DO SO, REPEAT THE TOOL FITTING OPERATION, INVERTING ITS POSITION.
MEASUREMENT A IS A PROTRUSION OR RECESS VALUE OF THE PISTON CROWN COMPARED WITH THE CYLINDER PLANE. MEASUREMENT A ALLOWS TO DETERMINE THE THICKNESS OF GASKET B THAT HAS TO BE FITTED INTO THE CYLINDER BASE IN ORDER TO RESTORE THE COMPRESSION RATIO. THE MORE THE PLANE FORMED BY THE PISTON CROWN PROTRUDES BEYOND THE PLANE FORMED BY THE CYLINDER UPPER END, THE THICKER THE GASKET TO BE USED AT THE CYLINDER BASE B SHOULD BE. ON THE OTHER HAND, THE MORE THE PISTON CROWN IS RECESSED INTO THE CYLINDER TOP PLANE, THE SMALLER THE GASKET THICKNESS.
Characteristic
Compression ratio 10.5 0.5 : 1
BASE GASKET THICKNESS

Name MEASURE TAKEN A MEASURE TAKEN A MEASURE TAKEN A NOTE Measure A - 0.185 - 0.10 - 0.10 + 0.10 + 0.10 + 0.185 Thickness 0.4 0.05 0.6 0.05 0.8 0.05
VALUES INDICATED WITH - REFER TO RECESSES OF THE PISTON CROWN FROM THE CYLINDER PLANE.
NOTE
SIZE A MUST BE MEASURED WITHOUT ANY GASKET FITTED AT B

- The head is fitted in two separate stages. - According to the indications described, fit the rear cylinder head and then the front cylinder head. ENG - 200
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- Fit the chain guide slider. - Fit the two centring dowels between head and cylinder.
NOTE
THE FIGURE SHOWS THE FITTING POSITION OF THE TWO CENTRING DOWELS BETWEEN HEAD AND CYLINDER. THE DIRECTION OF FITTING FOR THE GASKET IS FORCED BY THESE DOWELS. - Fit the head gasket - The head gasket is made of steel and has a standard thickness.
- Check that the head lubrication channel is perfectly clean. Clean with short blasts of compressed air, if required. - Fit the head. - Lubricate the screw studs and the 4 fixing stud bolts.
- Tighten the 4 fixing stud bolts in a criss-crossed sequence to the prescribed torque as shown in the figure.

Head fixing stud bolts ***
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*** First, apply a preliminary torque of 10 Nm in a criss-crossed sequence. - tighten to a torque of 13 Nm + 90 in a crisscrossed sequence. - tighten again at 90 in a criss-crossed sequence.
- Tighten the fixing nuts on the outlet side and the intake side to the prescribed torque.

Exhaust/ intake head fixing nuts 10 - 12
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- Tighten the two internal screws on the head, timing system side, to the prescribed torque.

Exhaust/ intake head fixing nuts 10 - 12
- Fit the coolant temperature sensor with the washer and tighten it to the prescribed torque.
CAUTION FAILURE TO OBSERVE THE LOCKING TORQUE CAN DAMAGE THE SENSOR.

Coolant temperature sensor 21 23
- Fit the spark plugs and tighten them to the prescribed torque.

Spark plug 12 14 Nm - Fit the rpm timing sensor and tighten to the prescribed timing.

Rpm timing sensor screw 7.5 8.5 Nm
- Fit the timing control chain on the crankshaft observing the initial direction of rotation. - Fit the tensioner pad with the relevant spacer, tightening the fixing screw to the prescribed torque, using the recommended product.
Loctite 243 Medium strength threadlock -

Tensioner pad fixing screw 10 - 14 ENG - 203
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- Fit the pins and the rocking levers operating on the transmission side. - Lubricate the 2 rocking levers through the holes at the top.
- Clean the camshaft by blowing short blasts of compressed air, especially the groove that holds the retaining plate. - Lubricate the 2 bearings. - Fit the camshaft in the cylinder head with the cams opposing the rocking levers.
- Remove any LOCTITE left on the screws fixing the camshaft retaining bracket using a brush. - Apply the recommended product to the fixing screws and tighten them to the prescribed torque.
Loctite 243 Medium strength threadlock - Insert the camshaft retaining bracket so that the countersinks are visible and tighten the 3 fixing screws to the prescribed torque, being careful not to damage the internal hexagon.

Camshaft retaining bracket screws 4 6
- Finish closing the flywheel side crankcase with the components following the instructions described in the specific sections. - Time following the instructions in the specific section.
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- Fitting the head and the components of the front cylinder timing system vary if the spacer is fitted instead of the tone wheel and id the reference "A" instead of "P" is in the timing system gear.
Installing the head cover

- Check that the gasket is in good condition.
- Tighten the two screws indicated in the figure with 1 and 2 to limit the reciprocal sliding of the cover surface with the head surface. - Tighten the remaining 4 screws in a criss-crossed sequence (3,4,5,6).
NOTE PAY ATTENTION TO THE CORRECT POSITION OF THE GASKET.

Tappet cover fixing screws 7 - 9
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Installing the intake manifold

- Fit the inlet manifold in the engine.
- Insert the six fixing screws and tighten them to the prescribed torque.

Inlet manifold fixing screws 11 - 13
Crankcase - crankshaft
- Remove the transmission cover, the driving and the driven pulleys, as described in the Automatic transmission chapter. ENG - 206
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- Remove the flywheel cover as described in the Flywheel cover removal chapter. - Remove the magneto flywheel with the start-up control as described in the Magneto flywheel removal chapter. - Remove the thermal parts (cylinders, heads, pistons) as described in the Thermal group and Timing system chapter. - Before opening the engine crankcase, it is advisable to check the axial clearance of the crankshaft.
Specific tooling
020262Y Crankcase splitting strip 020335Y Dial gauge magnetic support
Characteristic
Standard clearance: 0.10 0.50 mm Increased limit after use: 0.60 mm - Higher clearances are signs of wear on the supporting surfaces of the crankshaft on the crankcase. - To carry out an accurate measurement, measure the clearance in both directions between crankcase and crankshaft.
Splitting the crankcase halves

- Working from the transmission side, unscrew the six screws A and collect the washers.
- Turn the support so as to operate on the flywheel side. - Undo the three screws fixing it to the support, collect the washers and remove the three centring bushings. - Undo the seven screws B and collect the copper washers. - Undo the twelve screws C and collect the washers.
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- Fit the specific tool on the flywheel side crankshaft, paying special attention that the tool matches the shaft perfectly.
CAUTION FAILURE TO OBSERVE THIS RULE CAN DAMAGE THE MAIN BUSHINGS.
Specific tooling
020664Y Flywheel side crankshaft fitting tip
- Lubricate the external surface of the tip with petroleum jelly grease. - Detach the crankcase half keeping the crankshaft connected to crankcase half on the transmission side. - Remove the coupling gasket.
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- Remove the tip.
Specific tooling
Removing the crankshaft

- Fit the specific tool on the transmission side crankshaft, paying special attention that the tool matches the shaft perfectly.
CAUTION DUE TO THE TIP WEIGHT PAY ATTENTION TO THE CORRECT COUPLING AND FALLING RISKS OF THE TOOL, ALWAYS HOLD IT WITH YOUR HANDS.
CAUTION
FAILURE TO OBSERVE THIS RULE CAN DAMAGE THE MAIN BUSHINGS.
Specific tooling
020665Y Transmission side crankshaft fitting tip - Lubricate the external surface of the tip with petroleum jelly grease.
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- Hold the tip with one hand and the crankshaft with the other, pull the crankshaft upwards.
- Pull out the tip from the bushings, remove the crankshaft.
- Once the crankshaft has been removed it is possible to remove the timing chain on the transmission side.
Inspecting the crankcase halves

- Before checking the crankcase halves, thoroughly clean all the surfaces and oil pipes. - Clean the jets and contacts carefully.
NOTE
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES PISTON CROWN COOLING. CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAKAGE CAN CONSIDERABLY CAUSE A DROP IN LUBRICATION PRESSURE FOR THE MAIN BUSHINGS AND CONNECTING ROD.
NOTE
AS ALREADY DESCRIBED IN THE LUBRICATION CHAPTER, IT IS ESPECIALLY IMPORTANT THAT THE BY-PASS VALVE HOUSING SHOWS NO WEAR THAT MAY IMPAIR THE PROPER SEALING OF THE LUBRICATION PRESSURE ADJUSTMENT PISTON. THE HEAD LUBRICATION ENG - 211
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CHANNEL IS FITTED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION. THIS CHOICE HAS BEEN MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP. Jet clogging impairs head lubrication and the timing mechanisms. A jet failure causes a drop in lubrication pressure for the main bushings and connecting rod. - Check the coupling surfaces for scratches or deformation, paying special attention to the cylinder crankcase surfaces and the crankcase halves coupling surfaces. - Defects in the crankcase coupling gasket or the surfaces can cause a drop in the oil pressure and affect the lubricating pressure. - Check that the surfaces limiting the crankshaft axial clearance show no signs of wear. To measure and check sizes follow the procedure described previously for checking crankshaft axial clearance and dimensions
Inspecting the crankshaft components

Crankshaft alignment
Specific tooling
020335Y Dial gauge magnetic support
MAXIMUM OFF-LINE ALLOWED

Specification A= B= C= D= Desc./Quantity 0.15 mm 0.010 mm 0.010 mm 0.10 mm
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Engine
Inspecting the crankshaft plain bearings

- In order to obtain proper bushing lubrication, make sure there are both an outstanding lubrication pressure (4.5 bar) and a good oil flow rate. To that end, the bushings must be correctly positioned so as not to obstruct the oil supply channels. - The main bushings are comprised of 2 half-bearings, one with holes and channels for lubrication while the other is solid. - The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason, it is arranged opposed to the cylinder. - So as not to obstruct the oil supply channels, the coupling surface of the two half-bearings must be perpendicular to the cylinder axis as shown in the figure. - The oil supplying channel section is also influenced by the depth to which the bushings are driven compared with the crankshaft axial clearance of the limiting surface.
NOTE
TO KEEP THIS POSITION OF THE BUSHINGS ON THE CRANKCASE, FITTING IS FORCED ON CAST IRON RINGS INSERTED IN THE CASTING OF CRANKCASE HALVES. - Measure the bushings diameter at the 3 positions indicated in the figure. - Repeat the measurements for the other half of the bushing. See figure.
NOTE DO NOT TAKE THE MEASUREMENT ON THE TWO HALFSHELLS COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.
Before fitting, check that the clearance between the engine crankcase bushing and the crankshaft is within the predetermined limits.
Characteristic
Crankshaft-bushing maximum clearance allowed: 0.08 mm - The standard bushing diameter after driving varies according to a coupling selection. - The bushing seats in the crankcase are classified into 2 categories - Cat 1 and Cat 2 - just like those for the crankshaft - Bushings are subdivided into 3 categories according to their thickness. (See chart on the "Specifications" chapter) ENG - 213
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See also
Crankcase - crankshaft - connecting rod
Installing the crankshaft

- Fit the driven pulley shaft and the universal joint axle.
- Fit the specific tool on the transmission side crankshaft, paying special attention that the tool matches the shaft perfectly.
CAUTION FAILURE TO OBSERVE THIS RULE CAN DAMAGE THE MAIN BUSHINGS. CAUTION DUE TO THE TIP WEIGHT PAY ATTENTION TO THE CORRECT COUPLING AND FALLING RISKS OF THE TOOL, ALWAYS HOLD IT WITH YOUR HANDS.
Specific tooling
020665Y Transmission side crankshaft fitting tip
- Lubricate the external surface of the tip with petroleum jelly grease.
NOTE
LUBRICATE THE BUSHINGS WITH ENGINE OIL BEFORE FITTING THE CRANKSHAFT.
CAUTION
FIT THE TRANSMISSION SIDE TIMING CHAIN. FIT THE DRIVE CHAIN BEFORE THE CRANKSHAFT.
ENG - 214
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- Fit the crankshaft with the driving pulley axle inside the transmission side crankcase halves.
NOTE PLACE THE CONNECTING RODS CORRECTLY.
- At the same time, hold with one hand the crankshaft and with the other the tip until the crankshaft stops on the crankcase half. - Remove the tip.
Specific tooling
020665Y Transmission side crankshaft fitting tip
- Place the coupling gasket.
ENG - 215
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- Fit the specific tool on the flywheel side crankshaft, paying special attention that the tool matches the shaft perfectly.
CAUTION FAILURE TO OBSERVE THIS RULE CAN DAMAGE THE MAIN BUSHINGS.
Specific tooling
- Lubricate the external surface of the tip with petroleum jelly grease.
NOTE
LUBRICATE THE BUSHINGS WITH ENGINE OIL BEFORE FITTING THE CRANKSHAFT. - Pay attention and fit the flywheel side crankcase half until there is a complete coupling.
ENG - 216
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- Remove the tip.
Specific tooling
ENG - 217
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Refitting the crankcase halves

- Tighten the seven screws B with the copper washers as far as they will go. - Tighten the twelve screws C with the washers as far as they will go. - Tighten to the prescribed torque.

Crankcase-engine coupling screws (M8) 25 28
- Fit the centring bushings, the washers and screw the fixing nuts to the support. - Turn the support so as to operate on the transmission side. - Screw the six screws A with the washers and tighten to the prescribed torque.

Crankcase-engine coupling screws (M6) 11 13 - Fit a new oil seal in the transmission side crankcase half on the driving pulley axle. - Fit the oil seal manually being careful that the internal lips are correctly placed on the crankshaft.
- With a pipe of the indicated size, inside XX,X mm - outside XX,X mm, set the oil seal at the indicated distance, check with the gauge, according to the indications described in the figure.
Lubrication
ENG - 218
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Conceptual diagrams
LUBRICATION CIRCUIT
Specification 1 2 3 4 5 6 7 8 9 10 11 12 14 13 16 15 17 18 19 20 21 The RED arrows indicate the oil delivery circuit. The BLUE arrows indicate the oil recovery circuit.
Desc./Quantity FRONT HEAD CAMSHAFTS REAR HEAD CAMSHAFTS CONNECTING ROD BUSHINGS FRONT PISTON LUBRICATION JET REAR PISTON LUBRICATION JET STARTING RING GEAR BUSHING LUBRICATION CRANKSHAFT BUSHINGS WATER PUMP CONTROL TRANSMISSION GEAR SHAFT LUBRICATION WATER PUMP SHAFT LUBRICATION MINIMUM OIL PRESSURE SENSOR NON-RETURN VALVE OIL CARTRIDGE FILTER BY-PASS VALVE OIL DELIVERY PUMP RECOVERY OIL PUMP FILLER NECK OIL SUCTION ROSE OIL DRAINAGE PLUG OIL TANK OIL TANK FILTER OIL PASSAGE FROM THE HUB TO THE TANK
General characteristics
The lubrication system is divided into two sections: - high pressure ENG - 219
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- low pressure The high pressure section includes all components located on the engine crankcase; while the low pressure section only refers to the thermal group. The trochoidal pump is fitted into the sump and controlled through the chain. To guarantee the integrity of the pump, a pre-filter is fitted. Pump delivery is controlled by means of a piston by-pass calibrated to 4.5 bar. This piston is located upline the cartridge filter. The by-pass located upline the cartridge filter improves the operating conditions for the filter, particularly with cold oil. The filter is equipped with an anti-drain valve and a pressure relief valve; the latter intervenes when the filtering element causes a pressure drop exceeding 1 0.2 bar. These conditions naturally occur only with cold oil and at high running engine or if the filter is dirty. The filtered oil is used to lubricate the water pump shaft and the transmission shaft, to lubricate the main bearings, the connecting rod head and the piston cooling nozzle, located on the transmission side bearing. The main bearing on the transmission side is fitted with an oil seal and the respective drain line. The supply line for the timing system comes from the flywheel-side bearing; delivery to the head is controlled by the respective jet screwed in the engine crankcase, in the same way the supply line of the timing system to the rear cylinder comes from the transmission. The components of the timing system work with low-pressure oil. The camshaft bearings are marked directly on the aluminium of the head; the camshaft axial clearance is partially compensated by the oil supplied to the smaller diameter bearing. The camshaft supplies the lubricant to the rocking levers via the bores provided; these are installed in a position so as to ensure that the lubrication is maintained even after the vehicle has stopped. This is achieved when the camshaft reaches its most usual and likely position when the engine is switched off. The oil used to lubricate the head returns to the sump via the chain casing channel and therefore it also provides lubrication for the chain. In order to avoid that the gas collected from the crankcase carries oil, a one-way valve and a decantation chamber are used. The one-way valve is a metal reed valve; the decantation chamber has a drainage hole. A failure in these components implies oil getting into the line supplying air to the engine. Excessive oil vapours may result in the clogging of ducts on the throttle body. In order to signal low oil pressure in the system, a pressure switch is used, located immediately after the oil filter outlet. The lubrication circuit does not include the piston or the pin, also in this case the cooling nozzle is particularly important.
Diagnosis guide
1 - Minimum oil pressure warning light on with hot engine. ENG - 220
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CONTINUE - point 2 2 - Remove the electric connector of the minimum pressure switch. Check that the warning light turns off. YES - point 3 NO point 11 3 - Check the actual oil pressure. CONTINUE - point 4 4 - Remove the switch and fit the specific tool with the relevant gasket.
Specific tooling
020193Y Gauge for oil pressure check 020434Y Fitting for oil pressure check - Remove the dipstick with the oil filler plug and insert a plug with the temperature probe supplied with the specific tool. Insert the probe to feel contact with the crankcase bottom and pull back a few millimetres.
Specific tooling
020331Y Digital multimeter CONTINUE - point 5
5 - Measure pressure with cold and idling engine.
STANDARD VALUES
Specification 20C Temperature 1400 rpm ~ 4.5 bar Desc./Quantity
YES - point 6 NO point 12 6 - Let the engine warm up and repeat the check with hot oil.
STANDARD VALUES
Specification 80C Temperature 1400 rpm ~ 1.5 bar Desc./Quantity
YES - point 7 NO point 8 7 - Replace the minimum oil pressure. ENG - 221
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8 - If pressure lower than 1.3 1.5 bar is measured. CONTINUE - point 9 9 - Replace the oil filter and repeat the pressure check with oil at 80C. YES - point 10 NO point 13 10 - The failure is fixed. It is advisable to observe the suggested number of kilometres covered. 11 - Check and restore the electrical system. 12 - If pressure lower than 4 bar is measured. CONTINUE - point 9 13 - Open the engine crankcase and check the by-pass efficiency. YES - point 14 NO point 15 14 - Check whether there is an irregular clearance on the crankshaft: - axial clearance (see the "Crankcase and Crankshaft" chapter) - radial clearance, especially in the direction of the cylinder axis - clearance according to the direction of rotation with the connecting rod in quadrature YES - point 16 NO point 17 15 - Replace damaged components. 16 - Overhaul the engine. 17 - Open the engine crankcase and remove the oil pump, as described in the "Crankcase and Crankshaft" chapter. - Check the oil pump as described in the following pages. - Check that the cooling nozzle and the timing system supply jet are properly fitted. - Visually inspect the crankshaft couplings and their size Specifications Chapter.
NOTE
ANY FAILURES IN THE COUPLINGS AND IN THE TIMING COMPONENTS CANNOT BE DETECTED BY THE LUBRICATION PRESSURE CHECK. THE FAILURES MAY BECOME EVIDENT BY AN INCREASE OF NOISE.
NOTE
IN CASE OF IRREGULAR PRESSURE ON THE BASE, CARRY OUT A VISUAL AND DIMENSIONAL INSPECTION OF THE TIMING COMPONENTS (SEE THERMAL GROUP AND TIMING SYSTEM CHAPTER).
Oil pressure check

1 - In case of oil or oil filter leaks, check the lubrication pressure. CONTINUE point 2 2 - Fit the specific tool.
Specific tooling
020193Y Gauge for oil pressure check 020434Y Fitting for oil pressure check CONTINUE - go to point 3 ENG - 222
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3 - Check the system pressure with cold engine and medium - high speed. Standard pressure < 6 bar YES go to point 4 NO go to point 5 4 - Replace the damaged components. 5 - Check the adjustment by-pass efficiency and restore the proper sliding.
NOTE
STANDARD PRESSURES ARE OBTAINED USING OIL WITH THE PRESCRIBED VISCOSITY. A HIGHER VISCOSITY CAUSES AN INCREASE OF THE SYSTEM PRESSURE. 1 - If oil consumption is higher than 250 gr/1000 km on run-in engine, proceed as follows. CONTINUE go to point 2 2 - Check the presence of oil at the recovery duct on the filter housing. YES - go to point 3 NO go to point 4 3 - Check the efficiency of the one-way reed valve and the decantation chamber drainage hole. YES - go to point 5 NO go to point 4 4 - Check the thermal group seals (piston rings, valve guides and oil seals), see the "Thermal group and Timing system" chapter. 5 - Restore the valve or the drainage hole efficiency.
Oil pump
KEY: A. Delivery pump B. Recovery pump ENG - 223
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C. By-pass
Removing
- The lubrication system includes the pressure and scavenge pumps. - To operate the pressure pump, remove the bulkhead of the oil anti-backflow plate under the flywheel. - To operate on the scavenge pump, open the crankcase, and operate inside the crankcase half on the flywheel side. - Operating from the outside undo the chain tensioner slider fixing screws. - Remove the chain tensioner slider.
- Lock with the specific tool, undo the fixing screw and collect the washer. - Remove the oil pump control crown.
NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED
Specific tooling
AP8106702 Flywheel lock calliper spanner - Unscrew the two fixing screws and remove the crankcase protecting the oil pump.
ENG - 224
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- Remove the oil pressure pump with the gasket.
- Operating from inside: - Lock the oil scavenge pump axle, undo the fixing screw and collect the washer.
- Remove the water pump control gear, undo the two indicated screws and collect the washers.
- Remove the bulkhead of the oil anti-backflow plate
ENG - 225
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- Remove the oil pump and the relevant gasket.
- Undo the four indicated screws.
- Remove the by-pass recovery duct with the gasket.
Inspection
- The procedure is described only once but it is valid for both pumps.
ENG - 226
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- Undo the two screws and remove the oil pump cover.
ENG - 227
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- Slide off the shaft with the rotor driving pin. - Remove the two rotors and wash them thoroughly.
NOTE VISUALLY INSPECT THAT ALL THE COMPONENTS ARE IN GOOD CONDITIONS. THERE MUST BE NO SIGNS OF WEAR OR SLIPPAGE. IN CASE OF THERE ARE EVIDENT TRACES OF WEAR, REPLACE THE COMPONENTS.
- Once checked if the components are in good conditions, assemble the pump and check the size. - Assemble the two rotors, and align them following the reference marks.
ENG - 228
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- Fit the assembled rotors inside the pump body, with the reference marks facing the inside.
CAUTION ONCE THE ROTORS ARE FITTED INSIDE THE PUMP BODY, THE REFERENCE MARKS ON THEM MUST NOT BE VISIBLE.
- Measure distance between rotors with a thickness gauge at the indicated position.
Characteristic
Standard clearance: 0.04 - 0.1 mm
- Measure the distance between the outer rotor and the pump body (see figure).
Characteristic
Standard clearance: 0.05 - 0.12 mm
ENG - 229
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- Check the levelness of the two rotor surfaces and the pump body with a trued bar as an abutment plane as indicated in the figure.
CAUTION FAILURE TO OBSERVE THESE RULES CAN CAUSE SERIOUS DAMAGE TO THE ENGINE. IF THE VALUES ARE NOT WITHIN THE PRESCRIBED LIMITS, REPLACE THE COMPONENTS.
Characteristic
Limit value allowed: 0.1 mm - Check all the conditions indicated above, fit the plug and tighten the fixing screws to the prescribed torque.

Cover screws 0.7 0.9
Installing
- Operating from inside the flywheel side crankcase half: - Fit the by-pass recovery duct, with the gasket and tighten the four fixing screws to the prescribed torque.

By-pass scavenge pipe fixing screws 11 - 13
- Make sure the gasket is in the correct position.

NOTE THE TOOTH OF THE GASKET MUST BE IN ITS SEAT.
ENG - 230
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- Fit the oil scavenge pump and the bulkhead of the oil anti-backflow plate. - Tighten the two screws indicated to the prescribed torque.

Screws fixing oil pump to crankcase 5 6
- Fit the water pump control gear on the oil pump shaft. - Tighten the locking screw with the washer and tighten to the prescribed torque.

Water pump gear fixing screws 5 6
- Once the oil scavenge pump fitting is finished, operate from outside the flywheel side crankcase half. - Make sure the gasket is in the correct position.
NOTE THE TOOTH OF THE GASKET MUST BE IN ITS SEAT.
- Fit the timing chain and the timing chain tensioner slider. - Tighten the fixing screw to the prescribed torque.

Tensioner pad fixing screw 10 - 14
- Fit the oil pressure pump.
ENG - 231
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- Fit the crankcase protecting the oil pump and tighten the two screws to the prescribed torque.

Screws fixing oil pump to crankcase 5 6
- Fit the oil pump control crown and the driving chain. - Screw the fixing screw with the belleville washer, with the specific tool and tighten to the prescribed torque.
CAUTION PLACE THE BELLEVILLE WASHER WITH THE CONVEX PART FACING THE OIL PUMP CONTROL CROWN.
Specific tooling
AP8106702 Flywheel lock calliper spanner

Oil pump crown gear screw 10 14 - Fit the tensioner pad and tighten the two screws to the prescribed torque.

Chain tensioner slider - oil pump 2 3
ENG - 232
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Automatic transmission
Transmission cover
- Remove the variator motor, the driven pulley revolution sensor and the driving pulley position sensor.
CAUTION FOR VEHICLES INCLUDED IN THE FOLLOWING RANGE ZD4RC000_7S000002 - ZD4RC000_7S000737 IN ORDER TO FIT THE DRIVING PULLEY POSITION SENSOR CORRECTLY, SEE THE "Engine" CHAPTER, "Transmission Cover Fitting" SECTION.
- Loosen the nut fixing the driven pulley shaft using an offset wrench and prevent pulley shaft rotation using a hexagonal socket wrench
ENG - 233
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- Undo the thirteen screws fixing it to the engine crankcase. - Remove the nut and collect the washer.
- Remove the transmission cover.
CAUTION REPLACE THE TWO CONTROL BUSHING O-RINGS EACH TIME THE COVER IS REMOVED.
Removing the driven pulley shaft bearing

- Remove the transmission cover. - Remove the Seeger ring.
ENG - 234
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- Place the transmission cover on a wooden surface and use the special tool so that it is adequately supported. - Extract the bearing with the specific tool.
NOTE BELL MUST BE PLACED INTO THE TRANSMISSION COVER, CLOSE TO THE BEARING SEAT AND THE WOODEN SURFACE, SINCE WITHOUT BELL THE ENTIRE COVER STRUCTURE WOULD BEND; NOT ONLY IN THE AREA OF MAXIMUM STURDINESS.
Specific tooling
AP8140180 Extractor for bushings 020376Y Adapter handle 020357Y 32 x 35 mm adaptor 020363Y 20-mm Oil seal guide
Refitting the driven pulley shaft bearing

- Heat the transmission cover inside with a heat gun. - Fit the bearing onto the special tool with a little grease to prevent it from coming out. - Refit the new bearing with the specific tool.
Specific tooling
020376Y Adapter handle 020359Y 42 x 47-mm adaptor 020363Y 20-mm Oil seal guide - Refit the Seeger ring.
ENG - 235
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Removing the bearing of the driving pulley control bushing

- Undo and remove the three screws, the relevant washers and remove the bearing.
Removing the bearings supporting the electric motor driving shafts

- Remove the gear.
- Extract the two bearings with the specific tool.
Specific tooling
AP8140180 Extractor for bushings
Fitting the bearings supporting the electric motor driving shafts

- Heat the transmission cover inside with a heat gun.
ENG - 236
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- Fit the bearings on the specific tools and refit the new bearings.
Specific tooling
020376Y Adapter handle 020441Y Oil seal punch 020455Y 10-mm guide for oil seal on water pump shaft
Gearshift control shaft removal

- Undo the screw and collect the two washers, the plate, the O-ring, the two balls and the spring.
- Slide off the assembled gear control shaft, collect the washer and the O-Ring.
Removing the driven pulley

See also
ENG - 237
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MSS Mana GT ABS
Removing the driving pulley
Inspecting the clutch drum

- Make sure that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter.
NOTE CHECK THE ECCENTRICITY FOUND; IT SHOULD BE 0.2 MM MAX.
Characteristic
Max. value: 175.5 mm Standard value: 175+0+0.2 mm
Removing the clutch

Remove the clutch with the driven pulley using the specific tool.
CAUTION
WHILE PERFORMING THESE OPERATIONS, AVOID CONTACT WITH OIL OR GREASE WHICH COULD MAKE THE CONTACT SURFACES BETWEEN THE BELT AND THE HALF-PULLEYS SLIPPERY.
Specific tooling
020659Y Tool to remove clutch and repl. belt - Place the clutch assembly on the tool by inserting the pins in the ventilation holes. - Fit the centring bushing until it stops.
- Unscrew the ring nut with the adaptor.
ENG - 238
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- Screw until the clutch is completely disassembled.
Inspecting the clutch

- Check the thickness of the clutch mass friction material.
Characteristic
Minimum thickness allowed: 1 mm - The masses must not show traces of lubricants. If they do, check the driven pulley unit seals.
NOTE
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. DIFFERENT CONDITIONS MAY CAUSE CLUTCH TEARING. - To avoid variation in the return spring load, do not use any tool to open the masses.
Pin retaining collar

- Slide off the collar with the aid of 2 screwdrivers.
ENG - 239
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- Remove the 4 guide pins. - Slide off the movable driven half-pulley.
Removing the driven half-pulley bearing

- Check there are no signs of wear or damage on the bushing; otherwise, replace the fixed driven half-pulley. - Remove the snap ring with pliers.
- With the special tool inserted through the roller bearing, pull out the ball bearing.
NOTE PROPERLY SUPPORT THE PULLEY TO PREVENT DAMAGING THE THREADING.
Specific tooling
020376Y Adapter handle 020456Y 24 mm punch 020364Y 25-mm Guide
NOTE
TO SERVICE THE BEARINGS ON A FITTED DRIVEN PULLEY UNIT, SUPPORT THE UNIT BY THE BELL.
Specific tooling
ENG - 240
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- Remove the roller bearing with the specific tool, supporting the fixed half-pulley with the bell.
Specific tooling
020376Y Adapter handle 020375Y 28 x30 mm Punch 020183Y 30 mm guide AP8140180 Extractor for bushings
Inspecting the driven fixed half-pulley

- Check that the belt contact surface is free from wear. - Measure the outside diameter of the pulley bushing.
Characteristic
Minimum diameter allowed: 54.91 mm Standard diameter: 55.00-0.015 -0.035 mm
Inspecting the driven sliding half-pulley

- Check that the belt contact surface is free from wear. - Remove the 2 inner sealing rings and the 2 external O-rings. - Measure the inside diameter of the movable halfpulley bushing.
Characteristic
Maximum diameter allowed: 55.05 mm Standard diameter: 55.00 +0.035 0.00 mm
ENG - 241
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Refitting the driven half-pulley bearing

- Fit a new roller bearing with the specific tool.
NOTE PLACE THE BEARING WITH THE WORDS AND THE BUILTIN OIL SEAL FACING OUTWARDS.
- Properly support the half-pulley to prevent damaging the threading. If you are working on the driven pulley assembly fully fitted, use the specific tool.
Specific tooling
020478Y Punch for roller casing AP8140180 Extractor for bushings
- Fit a new ball bearing with the specific tool.
Specific tooling
020376Y Adapter handle 020477Y 37-mm Adaptor 020364Y 25-mm Guide
- Fit the Seeger ring.
Refitting the driven pulley

- Fit the new oil seals. - Fit the new O-rings.
NOTE
THE O-RINGS COME IN TWO DIFFERENT SIZES. THE LARGE ONE IS FITTED ON THE MACHINING END RADIUS; AT THE BASE OF THE HALF-PULLEY.
ENG - 242
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- Fit the half-pulley on the bushing being careful not to damage the top sealing ring. - Make sure the pins and collar are not worn and refit the pins and the collar.
- Using a curved-spout grease gun, lubricate the driven pulley assembly with approximately 10 grams of grease. Apply the grease through one of the holes in the bushing until grease comes out through the hole on the opposite side. This procedure is necessary to prevent the presence of grease beyond the O-rings.
AGIP MP GREASE Grease for bearings, joints, couplings and leverages As an alternative to the recommended product, use top branded grease for roller bearings with an operating temperature range of -30C...+140C (-22F...+284F), a drop point of 150C...230C (302 F...446F), high corrosion protection qualities and good water and rust resistance.
Inspecting the clutch spring

- Measure the length of the movable driven halfpulley spring, when unloaded.
Characteristic
Standard length: 190.2 mm Limit allowed after use: 182 mm
ENG - 243
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Refitting the clutch

- Prepare the specific tool for the removal phase. - Preassemble the driven pulley unit. - Fit the driven pulley unit, the spring with sheath and clutch into the tool.
CAUTION WHILE PERFORMING THESE OPERATIONS, AVOID CONTACT WITH OIL OR GREASE WHICH COULD MAKE THE CONTACT SURFACES BETWEEN THE BELT AND THE HALF-PULLEYS SLIPPERY.
Specific tooling
020659Y Tool to remove clutch and repl. belt - Compress the spring and fit the clutch on the driven pulley bushing.
NOTE BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END.
- Screw the locking ring nut and tighten to the prescribed torque.

Clutch ring nut 65 - 75
- With a specific tool, separate the two half-pulleys and fit the belt according to its direction of rotation.
CAUTION PLACE THE TWO HALF-RINGS CORRECTLY SO THAT THEY PERFECTLY ADHERE TO THE HALF-PULLEY.
ENG - 244
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- Screw the tool so as to separate the two halfpulleys.
- Position the belt.
- Unscrew until the tool frees from the half-pulley and remove it.
ENG - 245
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MSS Mana GT ABS
Refitting the driven pulley

- Fit the driving belt in driven pulley with the specific tool. - Fit the assembled unit on the shaft.
See also
Refitting the clutch
Drive-belt
- Make sure the driving belt is not damaged and does not show signs of abnormal wear. - Replace according to the scheduled maintenance table.
Removing the driving pulley

- Lock the driving pulley using the specific tool.
Specific tooling
020660Y Driving pulley check ring
- Undo, remove the fixing screw and collect the washer. - Extract the gear from the seat removing it from the control bushing (remove completely after extracting the pulley).
ENG - 246
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- Remove the movable pulley unit.
- Remove the driven pulley with the belt.
- Remove the clutch bell.
- Remove the driving half-pulley.
ENG - 247
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- Remove the spacer.

NOTE THE SPACER IS CONICAL, UPON REFITTING PAY ATTENTION TO INSERT IT WITH THE SMALLER DIAMETER FACING THE INSIDE.
- Undo the five fixing screws and remove the air switch.
- Unscrew the control bushing from the driving pulley.
- Remove the ring nut and the stop washer from the driving pulley with a wrench available in the market.
ENG - 248
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- Remove the complete advancement bushing.
- Undo the four fixing screws and remove the bearing support.
- Remove the slider support with the relevant sliders from the movable driving half-pulley.
ENG - 249
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MSS Mana GT ABS
Driving pulley components check

- Check that the internal bushings are not abnormally worn and measure their inside diameter.
CAUTION DO NOT LUBRICATE OR CLEAN BUSHINGS
Characteristic
Max. diameter admitted 40.050 mm Standard diameter 40.000 +0.034 -0.009 mm - Check that the internal bushing is not abnormally worn and measure its inside diameter.
CAUTION DO NOT LUBRICATE OR CLEAN BUSHINGS
Characteristic
Max. diameter admitted 35.050 mm Standard diameter 35.000 +0.034 -0.009 mm - Measure the outside diameter of the sliding bushing.
Characteristic
Minimum outside diameter admitted 34.055 mm Standard diameter 35.000 -0.015 -0.040 mm
- Measure the spacer outside diameter.
Characteristic
Minimum outside diameter admitted 39.055 mm Standard diameter 40.000 -0.015 -0.040 mm
ENG - 250
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- Check that the sliders are not worn.
- The total clearance between slider and stud bolt should be between 0.01 and 0.1 mm at the place indicated in the figure.
DO NOT EXCEED THE MAXIMUM CLEARANCE ALLOWED AS THIS CAN CAUSE NOISE PROBLEMS.
Characteristic
Maximum clearance allowed 0.4 mm - Measure the inside diameter of the two bushings.
Characteristic
Max. diameter admitted 10.040 mm Standard diameter 10.000 +0.005 -0.030 mm
Refitting the driving pulley

- Fit the plate with the pads on the movable driving half-pulley.
ENG - 251
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- Fit the bearing support being careful with the dowel pin and lock the four screws with Loctite 270.
- Fit the advancement bushing.
- Fit the stop washer and tighten the ring nut with the level surface facing upwards.
ENG - 252
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- Screw the control bushing to the complete movable driving half-pulley. Push the bushing and check that the bushing sliding axis and the slider support engage by means of the two teeth. - Once the gear checking is finished, unscrew the driving pulley 1/2 of a turn.
CAUTION MAKE SURE THE TOOTHED BUSHING AND THE PAD SUPPORT ENGAGE CORRECTLY.
- Preassemble the belt on the rear pulley with a special tool.
Specific tooling
020659Y Tool to remove clutch and repl. belt - Fit the unit following the removal steps but in reverse order, using the specific tool and being careful to tighten to the prescribed torques.
CAUTION
WHEN REPLACING ONE OR MORE OF THE FOLLOWING COMPONENTS: SPACER (DIAM.: 40 MM; LENGTH: 50.5 MM) PADS SUPPORT BEARING SUPPORT (SLIDING) BUSHING BEARING SUPPORT FIXED DRIVING HALF-PULLEY MOVABLE DRIVING HALF-PULLEY TO AVOID THE RISK OF LOCKING THE VARIATOR IN THE SEVENTH GEAR, SET THE "DEFAULT" VALUE FOR THE GEARSHIFT STROKE IN THE ECU AS INDICATED IN THE CHAPTER NAMED "ELECTRICAL SYSTEM/CHECKS AND CONTROLS/DRIVING PULLEY POSITION SENSOR/ADJUSTABLE PARAMETERS"
ENG - 253
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Refitting the transmission cover

- Follow the removal steps but in reverse order, using the specific tool and being careful to tighten to the prescribed torques.

Driven pulley nut 153 187 Internal transmission cover screws 11 13 External transmission cover screws 5 7
- For vehicles with chassis included in the following range ZD4RC000_7S000002 - ZD4RC000_8S000737, after fitting the cover, fit the driving pulley position sensor until it stops, on a 1-mm (0.039 in) thickness gauge placed between the lever and cover, making sure that the first gear is engaged (corresponding to the sensor lever placed facing out). - Once the sensor is installed, make sure that the distance of the lever to the cover is between (0.7 - 1) mm (0.027 - 0.039 in). For vehicles with chassis included in the range indicated above, just fit the sensor by tightening the two screws.
EACH TIME THE ROTATING POSITION SENSOR OR ANY COMPONENT OF THE TRANSMISSION IS REMOVED OR REPLACED, CARRY OUT THE "POTENTIOMETER RESET" OPERATION AS INDICATED IN THE WORKSHOP MANUAL, "ELECTRICAL SYSTEM/DRIVING PULLEY POSITION SENSOR" CHAPTER. UPON RESETTING, MAKE SURE THAT THE POSITION SENSOR LEVER ROTATES FREELY AND DOES NOT TOUCH THE COVER. THIS RESETTING OPERATION IS CARRIED OUT BEFORE THE FIRST START-UP.
End gear
PINION UNIT AXLE BEARING FITTING - The toothed wheel (pinion unit axle), rotates on two bearings located on the two crankcase halves, for fitting follow these instructions. - Transmission side crankcase half: - Heat up the crankcase using the thermal gun.
- Fit the pinion unit axle bearing until it abuts against the bottom of the seat with the specific tool.
Specific tooling
020376Y Adapter handle ENG - 254
MSS Mana GT ABS
Engine
020363Y 20-mm Oil seal guide 020359Y 42 x 47-mm adaptor - Flywheel side crankcase half: - Heat up the crankcase using the thermal gun.
- Fit the oil seal until it abuts against the bottom of the seat using the specific tool.
Specific tooling
020376Y Adapter handle 020655Y 62x68 mm Adaptor 020662Y 50 mm guide - Insert the driven pulley shaft bearing up to the stop against the bottom of the seat with the specific tool.
Specific tooling
020376Y Adapter handle 020655Y 62x68 mm Adaptor 020662Y 50 mm guide
ENG - 255
Engine
MSS Mana GT ABS
PINION UNIT AXLE BEARING REMOVAL - The toothed wheel (pinion unit axle), rotates on two bearings located on the two crankcase halves, to replace follow these instructions. - Transmission side crankcase half: - Remove the driven pulley shaft axle and the toothed wheel.
ENG - 256
MSS Mana GT ABS
Engine
- Operating on the specific tool extract the bearing.
Specific tooling
- Flywheel side crankcase half: - Remove the oil seal and the bearing with the specific tool.
Specific tooling
020376Y Adapter handle 020662Y Guide 50 mm 020360Y 52x55 mm Adaptor
Removing the driven pulley shaft bearing

- Slide off the toothed wheel (pinion unit axle).
- Slide of the driven pulley shaft from one side and remove the oil seal from the other side with a screwdriver.
ENG - 257
Engine
MSS Mana GT ABS
- Remove the Seeger ring.
- With the specific tool, remove the bearing.
Specific tooling
020376Y Adapter handle 020483Y 30 mm guide 020358Y 37 x 40-mm adaptor
Inspecting the hub shaft

- Check the two shafts for wear or distortions on the toothed surfaces, on the bearing housings and the oil seal positions. - If faults are found, replace the damaged parts.
Characteristic
Bearing diameter for shaft driven pulley: A= 30 -0.01 -0.02 mm
B= 20 -0.01 -0.02 mm
Diameter for pinion unit shaft: C= 20 -0.01 -0.02 mm

D= 30 -0.013 -0.026 mm
ENG - 258
MSS Mana GT ABS
Engine
Refitting the driven pulley shaft bearing

- Heat up the crankcase using the thermal gun.
- Insert the driven pulley shaft bearing up to the stop against the bottom of the seat with the specific tool.
Specific tooling
020376Y Adapter handle 020483Y 30 mm guide 020655Y 62x68 mm Adaptor - Fit the Seeger ring.
ENG - 259
Engine
MSS Mana GT ABS
- From outside the transmission side crankcase half, fit the oil seal.
Refitting the hub bearings

- Place the two shafts as shown in the figure.
ENG - 260
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
MSS Mana GT ABS
Front Removing the front wheel
Key: 1. Front wheel 3.5"x17" 2. Tubeless valve 3. Internal spacer 4. Bearing 5. Sealing ring 30x47x7 6. Seeger ring 7. Front wheel right external spacer 8. Front brake disc 9. Washer 25.2x36x1 10.Wheel pin nut 11.TE flanged screw M8x20 12.Front wheel pin 13.Front cover 120/70 ZR 17" Hold the vehicle front part.
SUSP - 262
MSS Mana GT ABS
Suspensions
Unscrew the screws fixing the front mudguard and remove it.
Unscrew the screws fixing the front pliers and slide them off the disc.
Remove the wheel axle fixing nut. Retrieve the sealing washer.
Loosen the screws on the wheel axle clamps.
SUSP - 263
Suspensions
MSS Mana GT ABS
Tap the wheel axle slightly with a rubber mallet so that the hole on the opposite side is exposed.
Remove the wheel axle by inserting a screwdriver in the holes on the pin.
During extraction, support the wheel and then remove it. Collect the spacer from the front wheel left side.
Checking the front wheel

FRONT WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel.
CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOLLOWS. ROTATION CHECK Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless. If one or both bearings do not fall within the control parameters: Replace both wheel bearings.
RADIAL AND AXIAL CLEARANCE CHECK Check the radial and axial clearance.
Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: Replace both wheel bearings.
SUSP - 264
MSS Mana GT ABS
Suspensions
ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE. GASKETS Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive wear.
ALWAYS REPLACE BOTH GASKETS. ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE. wheel spindle Use a dial gauge to check the wheel spindle eccentricity. Replace the wheel spindle if the eccentricity exceeds the limit value.
Characteristic
Maximum eccentricity: 0.25 mm (0.0098 in) Using a dial gauge, check that the radial (A) and the axial (B) eccentricities of the rim do not exceed the limit value. An excessive eccentricity is usually caused by worn or damaged bearings. Replace the rim if, after replacing the bearings, the value is not within the specified limit.
Characteristic
Maximum radial and axial eccentricity: 2 mm (0.0079 in)
SUSP - 265
Suspensions
MSS Mana GT ABS
Handlebar
Key: 1. Handlebar 2. Anti-vibration weight fix. end 3. Anti-vibration weight v. 4. Screw M6x40 5. Handlebar upper U-bolt 6. TCC screw M8x25 7. Right light switch 8. Left light switch 9. Right hand grip with throttle control 10.Gear left hand grip 11.Mirror support 12.Gear control device 13.Screw M4x10 14.Throttle opening cable 15.Throttle closing cable 16.Right mirror 17.Left mirror
SUSP - 266
MSS Mana GT ABS
Suspensions
Front fork Diagram
Key: 1. Fork right stem 2. Fork left stem 3. Sleeve 4. Spring 5. Preloading pipe 6. Right pumping member assembly 7. Left pumping member assembly 8. Sleeve cap assembly 9. O-ring 10.Rubber ring 11.Nut 12.Snap ring 13.Stem+ right wheel holder assembly 14.Stem+ left wheel holder assembly 15.Dust guard 16.Seeger ring 17.Oil seal
SUSP - 267
Suspensions
MSS Mana GT ABS
18.Ring 19.Guide bushing 20.Sliding bushing 21.Special washer 22.Screw M10x1.5 23.TE flanged screw M8x40 24.Spring Centring
Removing the fork legs

Remove the ABS sensor. Remove the front wheel. Support the fork stem and loosen the screws on the upper and then the lower plate. Remove the fork stem.
Draining oil
NOTE
THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS.

NOTE
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS GET A CONTAINER WITH SUITABLE CAPACITY TO COLLECT THE OIL. Remove the fork.
SUSP - 268
MSS Mana GT ABS
Suspensions
Be careful not to damage the fork stem when placing it in vertical position in a vice and using the appropriate protection.
Specific tooling
AP8140149 Protection for fitting operations
Unscrew the sleeve cap.
Drain the oil into a container of suitable capacity to collect fluids.
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. DISPOSE OF ENGINE OIL STORED IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL RECLAMATION FIRM.
See also
Removing the fork legs
Disassembling the fork

NOTE
THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS. Drain the fork oil. Place the fork stem on a work table in upright position.
SUSP - 269
Suspensions
MSS Mana GT ABS
Fit the special tool.
Specific tooling
AP8140147 Spacer tool
With the help of a second operator: Hold the sleeve cap firmly. Push the special tool down. Take out the Seeger ring.
With the help of a second operator: Insert the special tool between the nut and the preloading pipe.
Specific tooling
AP8140148 Spacer-pumping element separating plate
Loosen the nut.
SUSP - 270
MSS Mana GT ABS
Suspensions
Remove the sleeve cap.
Slide off the preloading pipe together with the spring centring.
Be careful not to damage the fork stem when placing it in horizontal position in a vice and using the appropriate protections.
Specific tooling
Unscrew and remove the bottom screw and collect the special washer.
SUSP - 271
Suspensions
MSS Mana GT ABS
Slide off the pumping member together with the spring.
Remove the dust guard using a screwdriver as a lever.
Remove the Seeger ring from inside the sleeve with the aid of a screwdriver.
CAUTION DO NOT DAMAGE THE STEM DURING THE OPERATION.
Slide off the stem forcefully.
SUSP - 272
MSS Mana GT ABS
Suspensions
If necessary, remove the sliding bushing, guide bushing, ring, oil seal, Seeger ring and dust guard from the stem.
See also
Draining oil
Checking the components

Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value. If over the value, replace the stem.
CAUTION
A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.
Characteristic
Bending limit: 0.2 mm (0.00787 in) Sleeve Check that there are no damages and/or cracks; otherwise, replace it. Spring Check that the spring is in good conditions. Check that the spring length is within the limit value. Replace the spring if its length does not fall within the limit values. SPRING MINIMUM LENGTH WHEN UNLOADED: 300.8 mm (11.84 in) Check that the following components are in good conditions: sliding bushing; guide bushing;
SUSP - 273
Suspensions
MSS Mana GT ABS
pumping member pin.
If there are signs of excessive wear or damage, replace the affected component.
CAUTION
REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SURFACE. Replace the following components with new ones: dust guard oil seal
Reassembling the fork

NOTE
THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS. Fit the dust guard (1), Seeger ring (2), oil seal (3), ring (4), guide bushing (5) and sliding bushing (6) on the stem.
CAUTION FIT THE GUIDE BUSHING AND THE SLIDING BUSHING WITH CAUTION. GUIDE BUSHING (5) IS THICKER THAN SLIDING BUSHING (6).
Fit the stem into the sleeve and place the special fitting tool for fitting the D. 43 oil seal between the Seeger ring and the oil seal.
Specific tooling
AP8140189 Oil seal fitting tool for 43 mm (1.69 in) orifices
Push the oil seal fitting special tool hard, applied towards the sleeve with the aid of the specific weight.
Specific tooling
AP8140146 Weight
SUSP - 274
MSS Mana GT ABS
Suspensions
Fit the Seeger ring on the sleeve seat.
Fit the dust guard.
Screw the specific perforated rod on the pumping member threaded rod.
Specific tooling
AP8140150 Perforated rod for pumping member air bleed
Fit the centring plate. Fit the pumping member together with the centring plate in the sleeve. Insert the special washer in the screw. Tighten the screw to the prescribed torque.
UPON REFITTING, REPLACE THE SAFETY WASHER WITH A NEW ONE

Screw fixing the stem in wheel holder - M10x1.5 (2) 20 Nm (14.75 lbf ft)
SUSP - 275
Suspensions
MSS Mana GT ABS
Filling oil
NOTE
THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS. Place the fork stem on a work table in upright position. Fill the sleeve with the adequate quality and type of oil indicated on the recommended products table.
WARNING MOVE THE PUMPING ELEMENT SEVERAL TIMES UNTIL AIR BUBBLES ARE SEEN ON THE OIL SURFACE.
THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS.
Characteristic
Fork oil quantity (for each stem): 535 cm (32.65 cu.in) Oil level (from sleeve rim, without the spring and with pumping member fully down) 122 mm (4.80 in).
Fit the preloading pipe together with the spring centring.
SUSP - 276
MSS Mana GT ABS
Suspensions
Fit the special tool.
Specific tooling
AP8140147 Spacer tool
With the aid of a second operator, hold the pumping member rod firmly, lower the spacer retention tool, insert the stop ring and the plate separating the spacer-pumping member between the ring and the nut.
Specific tooling
AP8140148 Spacer-pumping element separating plate Insert the sleeve cap and screw the nut.
Be careful not to damage the fork stem when placing it in vertical position in a vice and using the appropriate protection.
Specific tooling
SUSP - 277
Suspensions
MSS Mana GT ABS
Tighten the sleeve cap.
Steering bearing
Key: 1. Folk lower plate 2. Screw M8x30 3. Washer 4. Roller bearing 5. Sealing ring 6. Ring nut 7. Headstock cap washer 8. Headstock cap 9. TCEI screw M10x60 10.Cap
SUSP - 278
MSS Mana GT ABS
Suspensions
11.Rubber ring 12.Lower U-bolt 13.Fork upper plate 14.Screw M8x30 15.Spacer 10.1x14.1x38
Adjusting play
Place the vehicle so that the front wheel is off the ground. Shake the fork in the riding direction. Adjust if clearance is detected. Unscrew and remove the U-bolt four fixing screws. Remove the U-bolt. Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out.
Unscrew and remove the top bolt on the headstock and retrieve the washer.
Operating from both sides, loosen the screws fixing the fork stems to the upper plate.
SUSP - 279
Suspensions
MSS Mana GT ABS
Undo and remove the two screws fixing the instrument panel support to the fork upper plate.
Slide off the fork upper plate by moving it towards the instrument panel.
Adjust the steering bearings preloading by tightening the ring nut with the specific tool.
When refitting the U-bolt, position the two references facing the front part of the vehicle.
Rear
SUSP - 280
MSS Mana GT ABS
Suspensions
Removing the rear wheel
Key: 1. Rear wheel 6"x17" 2. Internal spacer 3. Bearing 4. Seeger ring 5. Sealing ring 30x52x7 6. Tubeless valve 7. Anti-vibration buffer holder 8. 10x20 Pin 9. TCEI screw M10x30 10.Anti-vibration buffer rubber ring 11.Anti-vibration buffer pin 12.Crown z=40 13.Sprocket carrier assembly 14.Anti-vibration buffer spacer 15.Bearing 30x55x13 16.Seeger ring for d55 hole 17.Sealing ring 38x52x7 18.Self-locking nut M10 19.Rear wheel spacer
SUSP - 281
Suspensions
MSS Mana GT ABS
20.Complete chain 21.Rear cover Rest the vehicle on its centre stand.
Undo and remove the two fixing screws. Remove the rear brake calliper.
Undo and remove the two fixing screws. Remove the parking brake calliper.
SUSP - 282
MSS Mana GT ABS
Suspensions
Working from the vehicle right side, unscrew and remove the rear wheel pin fixing nut and collect the washer.
Loosen the right chain set screw.
SUSP - 283
Suspensions
MSS Mana GT ABS
Remove the spacer.
Slide off the chain. Slide off the pin with the aid of a plastic hammer, supporting the rear wheel. Remove the rear tyre.
Checking the rear wheel
CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOLLOWS. REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel. ROTATION CHECK Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless. If one or both bearings do not fall within the control parameters: Replace both wheel bearings.
SUSP - 284
MSS Mana GT ABS
Suspensions
ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE. Check the radial and axial clearance.
Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: Replace both wheel bearings.
REAR WHEEL GASKETS Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive wear.
ALWAYS REPLACE BOTH GASKETS. ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE. REAR wheel spindle Use a dial gauge to check the wheel spindle eccentricity (1). Replace the wheel spindle if the eccentricity exceeds the limit value (1).
Characteristic
Maximum eccentricity: 0.25 mm (0.0098 in) REAR WHEEL RIM Using a dial gauge, check that the radial (A) and the axial eccentricity (B) of the rim (2) do not exceed the limit value. An excessive eccentricity is usually caused by worn or damaged bearings. Replace the rim (2) if after replacing the bearings, the value is not within the specified limit.
Characteristic
Maximum radial and axial eccentricity: 2 mm (0.0079 in)
Shock absorbers
SUSP - 285
Suspensions
MSS Mana GT ABS
Removing
Place the vehicle on the service stand under the oil sump carefully. Undo and remove the front shock absorber fixing screw and collect the collar.
Undo and remove the rear fixing screw and collect the collar. Remove the rear shock absorber.
SUSP - 286
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
MSS Mana GT ABS
Swinging arm
Key: 1. Swing arm 2. Swing arm pin 3. Nut M20x1.5 4. Rear wheel pin 5. Right chain tensioner 6. Left chain tensioner 7. Rear wheel nut 8. Engine bushing 9. Sealing ring 10.Roller casing 30x37x26 11.Fork right internal spacer 12.Fork left internal spacer 13.Sealing ring 14.Ball bearing 20x37x9 15.Safety ring for holes 16.Nut 17.Chain tensioner set screw 18.Brake calliper support locking pin
CHAS - 288
MSS Mana GT ABS
Chassis
19.Chain lower crankcase 20.Chain guard 21.Chain slider 22.Slider cap 23.TBEI screw 5x12 24.Stand rear bushing 25.TSPEI screw M6x55 26.Washer 20x29x1 27.Rear brake hose guide 28.M5x15 TBEI screw with washer 29.T-shaped bushing
Exhaust
Key: 1. Silencer 2. Front manifold 3. Rear manifold 4. Flange 5. Sealant 6. Lambda probe 7. Bushing
CHAS - 289
Chassis
MSS Mana GT ABS
8. Clamp 9. TCEI screw M8x40 10.Silencer fixing bushing 11.Washer 12.Rubber ring 13.Spacer 14.Flanged self-locking nut M8 15.Exhaust protection 16.Silencer protection 17.T-shaped bushing 18.Graphite bushing 19.Rubber washer 20.Flanged TBEI screw 21.Rubber ring 22.M10 Compensator fixing screw 23.Washer for shafts D8 24.Flanged metalbloc self-locking nut
Removing the tail pipe

Loosen both sealing clamps.
Remove the front exhaust manifold.
CHAS - 290
MSS Mana GT ABS
Chassis
Operating from both sides, undo and remove the screw on the plate.
Undo and remove the muffler tip fixing screw. Remove the muffler tip.
Removing the exhaust manifold

FRONT CYLINDER MANIFOLD Loosen the nut tightening the clamp. Remove the clamp.
CHAS - 291
Chassis
MSS Mana GT ABS
Remove the exhaust manifold of the front cylinder.
CAUTION UPON REFITTING, TIGHTEN THE CLAMP LOCKING NUT TO THE PRESCRIBED TORQUE.

Manifolds fixing clamp (2) 18 Nm (13.28 lbf ft)
REAR CYLINDER MANIFOLD Loosen the nut tightening the flange. Move the flange.
Remove the exhaust manifold of the rear cylinder.
CAUTION UPON REFITTING, TIGHTEN THE CLAMP LOCKING NUT TO THE PRESCRIBED TORQUE.

Manifolds fixing clamp (2) 18 Nm (13.28 lbf ft)
CHAS - 292
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Braking system
MSS Mana GT ABS
ABS
Key: 1. ABS ECU control unit 2. FRONT ABS SENSOR 3. REAR ABS SENSOR 4. Battery 5. Main relay 6. ECU 7. Instrument panel 8. K line (diagnosis) 9. Key 10.CVT ECU control unit 11.fuses ABS ECU control unit pin configuration PIN 1 - GND - Ground connection PIN 2 - PCC1 - Vehicle identification ground connection PIN 4 - IGN - Key PIN 8 - WL - Alarm warning light PIN 11 - R_SIGN - Rear ABS sensor signal PIN 12 - R_GND - Rear ABS sensor ground connection
BRAK SYS - 294
MSS Mana GT ABS
Braking system
PIN 13 - F_GND - Front ABS sensor ground connection PIN 14 - F_SIG - Front ABS sensor signal PIN 15 - PCC2 - Vehicle identification ground connection PIN 16 - ISO_K - K line (diagnosis) PIN 18 - KL30 - Power supply
Foreword
Key: 1. Rear brake calliper 2. Modulator 3. Front bleed valve 4. Front brake reservoir 5. Front brake callipers 6. Rear brake pump 7. Rear brake reservoir
BRAK SYS - 295
Braking system
MSS Mana GT ABS
Operating diagram
ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever control 4. Rear system circuit
BRAK SYS - 296
MSS Mana GT ABS
Braking system
5. Rear brake pump 6. Rear brake pedal control 7. ABS CONTROL UNIT 8. Rear brake calliper 9. Front calliper (2 callipers) 10.Front brake circuit intake solenoid valve (normally open) 11.Humidifier 12.Rear brake circuit intake solenoid valve (normally open) 13.Rear brake exhaust circuit solenoid valve (normally closed) 14.Rear/front brake circuit low pressure accumulator 15.Front brake exhaust circuit solenoid valve (normally closed) 16.DC electric motor 17.Double circuit hydraulic pump (ABS) 18.Rear brake reservoir 19.Front brake reservoir ABS OPERATION General specifications: The front circuit is similar to the rear circuit. The ABS inlet valve (10 - 12) is normally open and it is closed only when the system intervenes to avoid wheel locking. The outlet valve (13 - 15) is normally closed and it is opened only when the system intervenes to avoid wheel locking. When the system is standby, the ABS processor never stops monitoring the speed of the wheels in order to assess potential wheel slippage. When in standby, the system does not intervene at all when the rider brakes; the braking system is the same as the one without ABS. Stages in ABS cycle (the following operations refer to the front circuit but are also applicable to the rear one): A - Brake activation: the rider starts braking as he would usually do. B - Pressure reduction: it coincides with danger recognition (wheel slippage above threshold): the system closes the inlet valve (10-12) and opens the outlet valve (13-15) temporarily. At this stage the rider cannot increase the pressure on the callipers (8-9) and the system reduces the pressure on the callipers partially. The excess fluid temporarily fills the front reservoir (18-19) until the ABS pump (17) self-activates and delivers the fluid back to the brake pump (2-5). C - Pressure maintained: the pressure in the callipers (8-9) remains low until total recovery of speed / wheel grip. The system restores the fluid taken from the calliper (8-9) in the section of the system between the brake pump (2-5) and the ABS inlet valve (10-12). BRAK SYS - 297
Braking system
MSS Mana GT ABS
D - Pressure restored: by opening the inlet valve (10-12) momentarily, the pressure of the callipers (8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the braking back to the rider. E - If the wheel does not reach complete grip, the system continues operating as before until complete grip is obtained or until the vehicle stops. An error can be detected if the duration of the pressure reduction phase exceeds the pre-set time limit.
ABS SYSTEM DESCRIPTION The ABS system is a device to avoid wheels locking in case of emergency braking, increasing vehicle braking stability when compared to a traditional braking system. Sometimes when the brake is operated, the tyre locks with a consequent loss of grip, which makes it difficult to control the vehicle. A position sensor (3) on the tone wheel (2), forming an integral unit with the vehicle wheel, "reads" the status of the vehicle wheel spotting any possible lock. A control unit (1) signals this out and adjusts the pressure in the braking circuit accordingly.
NOTE
WHEN THE ABS STARTS WORKING, A PULSING IS FELT ON THE BRAKE LEVER.
THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND. AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED, HANDLE BAR TURNED, ON UNEVEN OR SLIPPERY ROADS, OR WITH POOR GRIP CREATES LACK OF STABILITY DIFFICULT TO HANDLE. THEREFORE, RIDE CAREFULLY AND SENSIBLY AND ALWAYS BRAKE GRADUALLY. BRAKING WHILE TURNING A CORNER IS SUBJECT TO LAWS OF PHYSICS WHICH NOT EVEN ABS CAN ELIMINATE.
When the sensors (3) detect a significant speed difference between the rear and the front wheels (for example, when rearing up on the back wheel), the ABS system could take this as a dangerous situation. In this case, two things may occur: The ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the same speed of the other wheel. It is not possible to brake for an instant. if the speed difference lasts long, the system may detect an error and deactivate the ABS system. As a consequence, the system works like any regular braking system.
BRAK SYS - 298
MSS Mana GT ABS
Braking system
Riding with an active ABS system At engine start-up, the "general warning" warning light (4) and the ABS icon (5) turn on and remain on provided that the vehicle does not exceed 5 km/h (3.1 mph).
The "general warning" warning (4) light remains off and the ABS icon (5) is not shown on the display. If a failure is detected, the "general warning" warning light (4) and the ABS icon (5) turn on permanently to indicate the malfunction. The ABS device is automatically deactivated. 20 A fuse (ABS Main fuse) (6) Protects: ABS control unit. 15 A fuse (ABS Auxiliary fuse) (7) Protects: ABS, tail lights, stop lights, license place light, horn, electric lock, instrument panel power supply, transmission ECU power supply, resistance module.
Guide to diagnosis
PREMISE Each time the key is ON, at least one current or stored* error of the ABS system is often detected: the EFI warning light turns on permanently and the word ABS is shown on the display (NA 850 Mana ABS). the ABS warning light turns on permanently (SL 750 SHIVER ABS / DORSODURO 750 ABS). If on the vehicle NA 850 Mana ABS, temporary errors of other control units are detected, the word ABS shown on the display is displayed instead of the word relative to the other control units where errors have been detected (e.g. GEAR or SERVICE). The ABS system is deactivated! The system operates perfectly just as any other braking system without ABS * The diagnosis requires exceeding the 5 km/h. Each time the key is ON, if at least one current or stored* error of the ABS system is not detected: the EFI warning light flashes and the word ABS is shown on the display (NA 850 Mana ABS).
BRAK SYS - 299
Braking system
MSS Mana GT ABS
the ABS warning light flashes (SL 750 Shiver ABS / Dorsoduro 750 ABS)
When the 5 km/h (3.11 mph) are exceeded: - if errors are not detected the EFI warning light turns off and the word ABS on the display disappears (NA 850 Mana ABS). the ABS warning light turns off (SL 750 Shiver ABS / Dorsoduro 750 ABS)
- if at least one malfunction is detected the EFI warning light turns on permanently and the word ABS appears on the display (NA 850 Mana ABS) the ABS warning light turns on permanently (SL 750 Shiver ABS / Dorsoduro 750 ABS)
The ABS system is deactivated! The system operates perfectly just as any other braking system without ABS. The detection of malfunctions may require more or less time according to the type of failure. Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist within a given time. If during this given time one of the conditions is missing but then it comes back, the timer is reset and the system is no longer able to diagnose the error. The ABS system is still inactive. Example: - error code 5D93 requires some minutes before it is diagnosed during the given time: A - The EFI warning light keeps flashing with the word ABS on the display (NA 850 Mana ABS) B - The ABS warning light keeps flashing (SL 750 Shiver ABS / Dorsoduro 750 ABS)
ABS FAULTS - GUIDE TO THE DIAGNOSIS 1a. NA 850 Mana - WARNING LIGHT+ ABS ICON 1b. Dorsoduro 750 - SL 750 Shiver - ABS WARNING LIGHT TURNED ON 2. CONNECT AXONE DOES AXONE COMMUNICATE? (NO, go to 3; YES, go to 4) 3. PERFORM THESE CHECKS: A. PIN 1 Ground connection B. +12V at PIN 18 C. +12V at PIN 4 with key ON 4. ARE THERE ANY ERRORS? (YES, go to 5; NO, go to 6) 5. CONSULT THE ERRORS DISPLAY TABLE 6. ABS WARNING LIGHT ACTIVATION ACTIVE?(YES, go to 7; NO, go to 8) BRAK SYS - 300
MSS Mana GT ABS
Braking system
7. CONTACT TECHNICAL SERVICE 8. PERFORM THESE CHECKS: A. Cable continuity between PIN 8 of the ABS control unit connector and PIN 28 of the instrument panel. B. Check connectors - refer to the operations described in the chapter
If the previous checks are OK, the causes might be: C. ABS Control unit malfunction D. Instrument panel malfunction
NOTE: to check the wheel speed sensor through AXONE, refer to the operations described in chapter "ELECTRIC SYSTEM/CHECKS AND CONTROLS/SPEED SENSOR".
Using axone for the abs Abs screen pages ISO screen page
ISO This screen page shows general data regarding the control unit, for example software type, mapping, control unit programming date
ISO SCREEN PAGE

Characteristic Value/example Unit of measure ment Notes
Vehicle manufacturing date Chassis number Software version Vehicle code Vehicle identification according to the status of Pin 2 and 15 of the ABS control unit connector
Mana/Shiver/Dorsoduro/Scarabeo Mana/Shiver/Dorsoduro/Scarabeo
The vehicle code stored in the control unit is read. The vehicle type (Mana/Shiver/Dorsoduro) is defined according to the connection found for PIN 2 and PIN 15 of the ABS control unit connector. see table on workshop booklet
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Braking system
MSS Mana GT ABS
NOTE: the "X" in the table identifies the connector pin is grounded.
Parameter reading screen page

ENGINE PARAMETER READING This screen page shows the parameters measured by the several sensors (engine revs, engine temperature, etc.) or values set by the control unit (injection time, ignition advance, etc.)
ENGINE PARAMETER READING

Characteristic Value/example Unit of measure ment km/h km/h V Notes
Front wheel speed Rear wheel speed Battery voltage
0 0 11.9
With stopped wheel, 0 Km/h is displayed With stopped wheel, 0 Km/h is displayed
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Braking system
Devices activation screen page

DEVICES ACTIVATION This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit.
DEVICES ACTIVATION
Front brake bleeding procedure
Rear brake bleeding procedure
ABS warning light
Ambient parameter error reading (1)
Ambient parameter error reading (2) Ambient parameter error reading (3)
Error clearing (1) Error clearing (2)
Useful in case of lever sponginess although the bleeding has been done as in a regular braking system Useful in case of lever sponginess although the bleeding has been done as in a regular braking system For Shiver and Dorsoduro models, the ABS warning light is caused to flash. For the Mana model, both the EFI warning light and the ABS word flash on the display. The ambient parameters are 4: Number of error detections, Operation cycles from the last detection, Battery voltage, Speed. Number of error detections: number of times the error has been detected by the control unit; for example, if it indicates 2, it means that the error has been detected (ATT), then it has not been detected for a while (sent to the MEM) and then it has been detected again. Operation cycles from the last reading: a cycle is counted if the following occurs: key ON and speed over 20 km/h. If for example 5 is shown, it means that the last time the error has been measured was 5 cycles ago. Press "enter" to transfer errors from the memory (MEM) to the historical record (STO). In the next connection between Axone and the control unit, the historical errors (STO) are no longer shown.
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MSS Mana GT ABS
Errors display screen page

ERRORS DISPLAY This screen page shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO).
ERRORS DISPLAY
Front speed sensor: 5D90 electric malfunction Front speed sensor: 5D91 the signal works irregularly Front speed sensor: 5D92 the signal decreases periodically
Electrical fault in sensor or cable harness Faulty sensor or signal interferences Possible tone wheel fault due to deformations or dirt; possible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel vibrations Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone wheel Faulty sensor/tone wheel, or tone wheel with wrong number of teeth or wrong tyre size Electrical fault in sensor or cable harness Faulty sensor or signal interferences Possible tone wheel fault due to deformations or dirt; possible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel vibrations Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone wheel Faulty sensor or tone wheel with wrong number of teeth or wrong tyre size Possible control unit fault Possible control unit fault Possible control unit fault Possible control unit fault Possible control unit fault Voltage too low measured for 30 seconds at PIN 18 of the ABS control unit: Possible control unit fault Excessive voltage measured at PIN 18 of the ABS control unit Inconsistency detected between memory coding (ISO/Vehicle code) and what is measured at cable harness identification PIN (ISO screen page, Ve-
Front speed sensor: no signal or speed measured too low in relation to the rear wheel 5D93 Front speed sensor: 5D94 no acceleration after pressure reduction Front speed sensor: 5D95 excessive measured speed Rear speed sensor: 5DA0 electric malfunction Rear speed sensor: 5DA1 the signal works irregularly Rear speed sensor: 5DA2 the signal decreases periodically
Rear speed sensor: 5DA3 no signal or speed measured too low in relation to the front wheel Rear speed sensor: 5DA4 no acceleration after pressure reduction Rear speed sensor: 5DA5 excessive measured speed Control unit: 5DD2 missing valve calibration Control unit 5DD3 Recirculation pump 5DF0 Recirculation pump 5DF1 Control unit 5DF2 Low electric voltage - long period measurement 5DF3 Control unit 5DF5 High electric voltage 5DF7 Vehicle code 5E59
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Braking system
Characteristic
Value/example
Unit of measure ment
Notes
Control unit F000 CAUTION
hicle identification line - Pins 2-15 of ABS control unit) Possible control unit fault
IN CASE OF SPORADIC FLASHING OF THE ABS WARNING LIGHT (Dorsoduro 750 ABS, SL 750 Shiver ABS) OR WARNING LIGHT+ABS ICON (NA 850 Mana ABS) (ALSO FLICKERING) AND STORED OR CURRENT ERROR MISSING INDICATIONS, ALL THIS MEANS THAT THERE IS A BAD CONTACT BETWEEN THE BATTERY POSITIVE LEAD AND PIN 18 OF THE ABS CONTROL UNIT. CHECK THE TERMINALS, THAT THE 20A FUSE PINS ARE NOT RUSTED AND THE CONTINUITY OF THE RED-ORANGE/RED CABLE BETWEEN PIN 18 OF THE ABS CONTROL UNIT CONNECTOR AND THE BATTERY POSITIVE POLE.
Adjustable parameters screen page

ADJUSTABLE PARAMETERS
Coding (1) Coding (2)
Coding (3)
Used for re-coding the control unit or coding a new one. Vehicle identification is done according to the connection of PINS 2 and 15 of the ABS control unit connector and is stored in the control unit memory. The identification can be read in the ISO diagram in the line: Vehicle code.
NOTE: the "X" in the table identifies the connector pin is grounded.
CAUTION A PASSWORD IS REQUIRED. TO OBTAIN ONE, CONTACT THE TECHNICAL SERVICE.
BRAK SYS - 305
Braking system
MSS Mana GT ABS
Modulator
Remove the rear system pipes from their hooks (5) and the front system pipes from the hose guide (6).
MODULATOR REMOVAL Remove the helmet compartment. By undoing the nuts, remove and cover the brake oil pipes following this sequence: (4) - (3) - (1) - (2). ABS GROUND LEAD Pay attention to correctly connect the ABS system ground leads.
BRAK SYS - 306
MSS Mana GT ABS
Braking system
Undo and remove the radiator lower screw.
Undo and remove the two screws and collect the washers. Pay attention when refitting the screws because they have different sizes. Move the radiator forward and towards the left, sliding it off from pin (7).
Undo and remove the screw.
Undo and remove the expansion tank fixing screw.
Remove the bracket by undoing the two nuts (8) and the screw (9). Remove the bracket.
BRAK SYS - 307
Braking system
MSS Mana GT ABS
Remove the modulator upwards and backwards by disconnecting the connector.
Component maintenance
ABS control unit The ABS system is fitted with hydraulic system separated from the front and rear brake systems and consists mainly of: 1. Electronic card (ECU) 2. Hydraulic locking system (HCU) 3. Electric engine Note: none of the internal components can be overhauled, therefore, the whole ABS unit has to be replaced in case of malfunction. Modulator pipes A - From the front brake pump B - To the front calliper C - To the rear calliper D - From the rear brake pump
Rear brake calliper
Key: BRAK SYS - 308
MSS Mana GT ABS
Braking system
1. Rear brake pump 2. Rear brake calliper 3. Rear brake pipe 4. Hydraulic stop switch 5. Copper washer 6. Oil pipe screw 7. Rear brake lever 8. Brake lever pin 9. Brake lever rubber ring 10.TCEI screw M6x20 11.Lever pin 12.O-RING 13.Spring 14.Washer 15.O-RING 16.Nut 17.Fork M6 18.Fork clip 19.Rear brake pipe support 20.Rear calliper support bracket 21.Parking calliper 22.Parking brake lever unit 23.Parking brake lever 24.Parking brake control complete transmission 25.Complete rear brake oil tank 26.Rear brake disc D.260 27.TE flanged screw M8x20 28.Rear brake pad torque 29.Rear brake calliper pin and springs 30.Bleeding Kit 31.TCEI screw M6x20 32.TCEI screw M6x30 33.Notched washer 6.4x11xh.0.7 34.Ring 35.Clip M5 36.Screw M8x29 37.Screw M8x21 38.Cable guide BRAK SYS - 309
Braking system
MSS Mana GT ABS
39.TE flanged screw M6x16 40.Cable guide 41.Cap 42.Brake pump fixing screws
Removal
REAR BRAKE CALLIPER Undo and remove both rear brake calliper fixing screws. Remove the rear brake calliper.
PARKING BRAKE CALLIPER Release the control cable. Undo and remove both parking brake calliper fixing screws. Remove the calliper.
BRAK SYS - 310
MSS Mana GT ABS
Braking system
Front brake calliper
Key: 1. Front left brake calliper 2. Front brake calliper oro 3. Front brake pads - pair 4. Pin + calliper spring 5. Bleeding Kit 6. TE flanged screw M10x1.25x55 7. Copper washer
Removal
Turn the pins and remove both split pins.
BRAK SYS - 311
Braking system
MSS Mana GT ABS
Remove both pins.

CAUTION
Collect the anti-vibration springs. Extract one pad at a time.
AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
Bleeding the braking system

VEHICLE PREPARATION It is important to check that there is always enough brake fluid in the reservoir. Using a bleed device facilitates these operations while, in the meantime, the "Brake fluid replacement" operations are performed. In this case, the bleed process must be accompanied by further pedal strokes and with the bleed device connected (about 5 for each wheel circuit). BLEED SYSTEM AFTER BRAKE PUMP REPLACEMENT PRELIMINARY OPERATIONS Install the new brake pump. Connect the reservoir to the brake pump. Connect the brake pipe to the pump line coupling. Fill the reservoir with new DOT4 brake fluid. REGULAR BLEEDING SYSTEM Connect the bleed bottle to the bleed screw of the front brake calliper. Operate the brake lever. Open the bleed screw until all the pressure has been release and then close it. Release the brake lever. After releasing the lever, wait two seconds so that the brake fluid flows into the cylinder.
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Braking system
Repeat this procedure until the brake fluid is clear and has no air bubbles. (about 10 to 20 times).
NOTE: CHECK BRAKE FLUID LEVEL IN THE RESERVOIR AND, IF NECESSARY, TOP UP (CHECKING BRAKE PAD WEAR). Bleed as previously described, also on the bleed valve installed on the front brake pump. Then perform the same procedure for the rear brake calliper, acting only on the valve installed on that calliper. Fill the reservoir until it reaches the reference "MAX" and refit the cap (check pad wear). Detach the bleed hoses and close the bleed screws again to the correct tightening torque. Check the stroke and the sensitivity of both the lever and the brake pedal.
NOTE: IF AFTER BLEEDING, THE STROKE OF THE PEDAL OR THE LEVER IS TOO LONG, CHECK THAT THERE ARE NO LEAKS IN THE BRAKING SYSTEM AND IF EVERYTHING IS OK, CONTINUE BLEEDING OPERATIONS USING AXONE.
BRAKE BLEEDING AFTER ABS CONTROL UNIT REPLACEMENT VEHICLE PREPARATION Connect the bleed bottle to the bleed screws of the front and rear callipers and open it. Fully press down the lever and the brake pedal and fix them into position with the respective locking devices. Close the bleed screws of the front and rear callipers and remove the bleed bottle. Remove the damaged ABS control unit. Note: First of all, detach the brake pipes that go from the ABS control unit to the brake pump (1-4) and immediately seal the opened unions of the ABS control unit with protective caps. Afterwards, remove pipes (2-3) that go from the ABS control unit to the brakes and also seal these unions with protective caps. Install the new ABS control unit, previously filled up. BRAK SYS - 313
Braking system
MSS Mana GT ABS
So that the brake fluid remains in the ABS control unit, first remove the protective caps of the braking circuit unions and connect the respective pipes.
Once all the braking circuits have been connected, remove the protective caps from the braking pump unions and connect the braking pump pipes to the ABS control unit. Unlock the lever and the brake pedal. Remove the cap of the reservoir and fill it with the new DOT 4 brake fluid up to the reference "MAX".
CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEED, AS DESCRIBED AT THE BEGINNING OF THE CHAPTER.
Always fill the reservoir up to the reference "MAX" and refit the cap. Check the stroke and the sensitivity of both the lever and the brake pedal. If after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in the braking system and if everything is ok, continue bleeding operations using Axone as described.
Detach the bleed hoses and close the bleed screws again to the correct tightening torque.
BRAKE BLEEDING AFTER CALLIPER REPLACEMENT VEHICLE PREPARATION - The operations are described for the front system, but they are also valid for both braking systems. Connect the bleed bottles to the bleed screw of the front calliper and open it. Fully press down the brake lever and fasten it into position with a locking device so as to avoid fluid flowing out from the open system. Close the bleed screws of the front calliper and remove the bleed bottle. Replace the damaged calliper with a new one. Unlock the brake lever.
BRAK SYS - 314
MSS Mana GT ABS
Braking system
Remove the cap of the reservoir and fill it with the new DOT 4 brake fluid up to the reference "MAX".
BRAKING SYSTEM BLEEDING (only the new calliper)

CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEED, AS DESCRIBED AT THE BEGINNING OF THE CHAPTER.
Always fill the reservoir up to the reference "MAX" and refit the cap. Check the stroke and the sensitivity of both the lever and the brake pedal. If after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in the braking system and if everything is ok, continue bleeding operations using Axone as described.
Detach the bleed hoses and close the bleed screws again to the correct tightening torque.
BLEEDING USING AXONE This type of bleeding has to be carried out if after all the checks the brake lever and the pedal are still spongy. The operations described here are valid for both systems even though the description refers to the front system. FRONT With Axone properly connected, select the function "FRONT BRAKE BLEEDING PROCEDURE". The pump starts rotating. While the pump is performing a rotation cycle, operate and release the front brake lever until the message Axone cycle completion is received. This procedure allows the air to turn and to accumulate. Once the procedure with Axone is finished, perform the REGULAR BLEEDING to remove the air from the system completely.
CAUTION
PERFORM THE REGULAR BRAKING SYSTEM BLEED, AS DESCRIBED AT THE BEGINNING OF THE CHAPTER.
BRAK SYS - 315
Braking system
MSS Mana GT ABS
Changing the brake fluid

BRAKE FLUID REPLACEMENT VEHICLE PREPARATION Connect the bleeding unit to the reservoir of the braking system. Max. filling pressure to be applied to the system= 3 bar (300 kPa - 43.51 PSI). PURGING PROCESS TO CHANGE THE BRAKING SYSTEM FLUID Connect the bleed bottle to the bleed screw of the front calliper and open it. Operate the bleeding unit and while the system is being purged, top up the reservoir with the new DOT 4 brake fluid; keep doing this until clean oil begins to flow out through the bleed tube. Leave the screw open until the fluid in the tube is clear and free of air bubbles. Close the bleed screw. Repeat this procedure on the remaining bleed valves of the system and close them all to the prescribed tightening torque. Remove the bleeding unit. Always fill the reservoir up to the reference "MAX" and refit the cap. Check the stroke and the sensitivity of both the lever and the brake pedal. If after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in the braking system and if everything is ok, continue bleeding operations using Axone as described. Detach the bleed hoses and close the bleed screws again to the correct tightening torque.
PARKING BRAKE
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Braking system
Removal
Place the vehicle on its side stand. Loosen the cable adjusting nuts.
Slide off the parking brake cable.
Undo the two screws.
Remove the calliper.
CAUTION
Slide off the two pins and remove the two brake pads.
AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
BRAK SYS - 317
Braking system
MSS Mana GT ABS
Installation and adjustment

Release the cable by the lever section.
Fit the calliper and fix it with the two screws.
Fit the two brake pads and fix them with two pins. Hook the cable on the calliper leverage.
Hook the cable by the lever section again. Fasten the hook in the leverage set screw.
BRAK SYS - 318
MSS Mana GT ABS
Braking system
Adjust the cable. Once the adjustment is finished, check that the rear wheel turns freely with the lever pulled up to 1/3 of the stroke.
BRAK SYS - 319
INDEX OF TOPICS
COOLING SYSTEM
COOL SYS
MSS Mana GT ABS
Cooling system
Circuit diagram
Key: 1. Water radiator 2. Complete expansion tank 3. Expansion tank cap 4. Radiator right cover - silver crowd v. 5. Radiator left cover - silver crowd v. 6. TBEI screw - M5x12 7. Radiator heat protection 8. 75C thermostat valve unit 9. H20 pipe union tee 10.Electric fan 11.Fan pin 12.Electric fan spacer 13.Pin fixing screw 14.Washer 15.T-shaped bushing 16.Anti-vibration rubber ring 17.TCEI screw - M6x35 18.TCEI screw - M6x25
COOL SYS - 321
Cooling system
MSS Mana GT ABS
19.T-shaped bushing 20.Anti-vibration rubber ring 21.Clip M6 22.T-shaped bushing 23.Screw M6x16 24.Screw M5x10 25.Rear head Y 26.Front head - joint pipe 27.Radiator pipe - joint 28.Joint - thermostatic valve pipe 29.By-pass pipe 30.Radiator - valve pipe 31.Pump pipe 32.Bleed pipe 33.Radiator - expansion tank pipe 34.Clamp clic D35-33 35.Clamp clic D31 white 36.Clamp clic D29x8.9 37.Clamp clic D13.5 white 38.Clamp clic D17.5 white 39.Clamp clic D24.5x8.6
Electric fan
Remove the radiator. Undo and remove the three electric fan fixing screws. Remove the electric fan.
COOL SYS - 322
MSS Mana GT ABS
Cooling system
Coolant replacement
Remove the expansion tank cap. Place an appropriate container near the water pump.
Remove the clamp and slide off the manifold. Drain off the system.
TOPPING UP Place the sleeve and tighten the seal clamp. For topping up, follow the system bleeding procedure.
See also
System bleed
System bleed
Place a container under the rear bleed valve. Unscrew the expansion tank closing cap. Loosen the rear bleed valve screw and start the engine. Keep the screw open until coolant flows constant, so as to make sure that air bubbles have been eliminated. Screw the bleed screw again. Stop the engine. Top up the expansion tank fluid level and close the expansion tank closing cap. Start the engine and leave it running to warm up until the electric fan triggering temperature is reached. Shut off the engine. Wait until the engine cools down. COOL SYS - 323
Cooling system
MSS Mana GT ABS
Restore the expansion tank fluid level.
Water pump
NOTE
OVERALL SEAL REPLACEMENT CAN BE CARRIED OUT WITH ENGINE ASSEMBLED ON THE VEHICLE.
Specific tooling
020661Y Water pump overall seal replacement kit - With a screw remove the six screws and the water pump cover and the gasket.
COOL SYS - 324
MSS Mana GT ABS
Cooling system
- With a 10-mm wrench, unscrew the water pump rotor.

CAUTION THE ROTOR THREAD IS ANTICLOCKWISE. THE PUMP SHAFT FACILITATES REMOVING THE ROTOR AS THE GEARED CONTROL CANNOT ROTATE IN REVERSE SENSE.
- Use two flat blade screwdrivers, and place them as shown in the figure so as to lever on the marked crankcase edge and disassemble the overall seal, pressure-fitted on the rotor shaft.
CAUTION
USE TEFLON AS SHOWN IN THE FIGURE SO AS NOT TO DAMAGE THE WATER PUMP COVER SEALING SURFACE. Small scratches on the seat edge do not present functional problems.
Change the position of the screwdriver if necessary.
During seal disassembly, the ceramic may split.
COOL SYS - 325
Cooling system
MSS Mana GT ABS
- Before removal, clean thoroughly all the parts.
- Place the extractor complete with pin on the static part of the ceramic seal.
- Without modifying the extractor position, make three holes on the static part of the seal using the pin supplied and a hammer.
NOTE MAKE THE HOLES WITH A STRONG HIT. MULTIPLE BLOWS COULD DEFORM THE PART WITHOUT PASSING THROUGH.
- Fasten the extractor to the static part of the sealing, using the screws supplied with the tool.
CAUTION FASTEN IT CORRECTLY WITHOUT "TEARING" THE PLATE
COOL SYS - 326
MSS Mana GT ABS
Cooling system
- Complete the tool by fitting the bracket, screw and the nut.
- Hold the screw in one position and operate the nut until the static part of the sealing is completely removed.
- Remove the extractor with the static part of the entire sealing.
- In order to work on the water pump shaft and the corresponding oil seal, it is necessary to open the engine crankcase, and work from inside the transmission-side crankcase half. - Slide off the idle gear.
COOL SYS - 327
Cooling system
MSS Mana GT ABS
- Slide off the water pump control gear together with the shaft.
- Undo the two indicated screws and remove the gear protection plate.
- Introduce a punch on the water pump shaft seat and remove the oil seal.
See also
Splitting the crankcase halves - Fit the oil seal from the outside being careful not to grease the contact surfaces. - Operate on the specific tool until it stops.
Specific tooling
020663Y Water pump shaft oil seal punch
COOL SYS - 328
MSS Mana GT ABS
Cooling system
- Fit the plate in its position and lock it by tightening the two screws to the prescribed torque.

Water pump gear protection plate tightening screws 3 4 Nm (2.21 2.95 lbf ft)
- Fit the water pump shaft together with the control gear.
- Fit the idle gear.
Entire sealing fitting

CAUTION
CLEAN ALL THE COMPONENTS CAREFULLY.

CAUTION
LUBRICATE THE ROTOR SHAFT WITH OIL. - Place the entire sealing on the shaft.
COOL SYS - 329
Cooling system
MSS Mana GT ABS
- Fit the tie rod screwing it in the rotor shaft.

CAUTION THE SHAFT THREAD IS ANTICLOCKWISE, SCREW IT MANUALLY UNTIL IT STOPS.
- Place the calibrated punch (with preloading values).
- Apply the nut to the tie rod.
Lock the tie rod and screw the nut until the end of stroke. The tool the will fit the static seat on the crankcase and the movable seat on the shaft, producing the correct ceramic seal preloading.
COOL SYS - 330
MSS Mana GT ABS
Cooling system
- Screw the rotor. (anticlockwise thread).

Water pump rotor 4 5 Nm (2.95 3.69 lbf ft)
- Fit the pump cover with a new gasket, previously lubricated with petroleum jelly grease. - Screw the six cover screws and tighten to the prescribed torque.
NOTE DO NOT LUBRICATE THE O-RING WITH PETROLEUM GREASE TO AVOID DEFORMATION.

Water pump rotor cover 3 4 Nm (2.2 2.95 lbf ft)
Removing the radiator

Remove the right side fairing. Undo and remove the two protection fixing screws. Remove the protection.
Remove the expansion tank cap. Place an appropriate container near the water pump.
COOL SYS - 331
Cooling system
MSS Mana GT ABS
Remove the clamp and slide off the manifold. Drain off the system.
Remove the clamp. Release the sleeve.
Undo and remove the fixing screw.
Disconnect the electric fan connector.
COOL SYS - 332
MSS Mana GT ABS
Cooling system
Undo and remove the radiator lower fixing screw.
Release the sealing clamp of the radiator lower pipe.
Release the sealing clamp of the expansion tank upper pipe and release the pipe.
Release the sealing clamp of the expansion tank lower pipe and release the pipe.
See also
Side fairings Side fairings
COOL SYS - 333
Cooling system
MSS Mana GT ABS
Removing the expansion tank

Right bottom side removal. Drain off the system. Undo and remove the fixing screw.
Release the clamps and slide off the two sleeves.
COOL SYS - 334
INDEX OF TOPICS
BODYWORK
BODYW
Bodywork
MSS Mana GT ABS
Seat
Rest the vehicle on its stand. Turn the key anticlockwise. Lift the passenger saddle.
Undo and remove the two collar fixing screws.
Undo and remove the two side fixing screws.
Remove the saddle.
BODYW - 336
MSS Mana GT ABS
Bodywork
Instrument panel
Remove the internal screws of the instrument panel.
Remove the top fairing fixing screws and extract it.
Partially extract the internal instrument panel support Disconnect the instrument panel connector and remove it all.
Headlight assy.
Remove the instrument panel. Remove the side fairings. Cut the clamp (1).
Disconnect the connectors.
BODYW - 337
Bodywork
MSS Mana GT ABS
Remove the front fairing fixing screws (2) and remove the fairing.
Remove the clamp (3).
Remove the front headlight assembly.
See also
Instrument panel Side fairings Side fairings
BODYW - 338
MSS Mana GT ABS
Bodywork
Disassembling the lock

Remove the saddle. Remove the license plate support. Slide off the cable.
Taillight assy.
Remove the license plate support. Undo and remove the two fixing screws.
Undo and remove the two fixing screws.
BODYW - 339
Bodywork
MSS Mana GT ABS
Slide off the light cover.
Slide off the light.
BODYW - 340
MSS Mana GT ABS
Bodywork
Rider footrest plate

The following operations also apply to both footrest holder plates. Undo and remove the lower fixing screw and collect the washer.
CAUTION UPON REFITTING, THE LOWER M10 FIXING SCREW SHOULD BE TIGHTENED TO THE SPECIFIED LOCKING TORQUE.

Lower screw fixing rider footrest 25 Nm (18.44 lbf
ft)
Undo and remove the central fixing screw and collect the washer.
The following operations are only applicable to remove the left footrest holder plate. Unscrew and remove the rear fixing nut and collect the washer.
Remove the passenger footrest support.
BODYW - 341
Bodywork
MSS Mana GT ABS
Side body panels

Remove the side fairing. Remove the saddle. Open the helmet compartment. Working on both sides, unscrew and remove the two top fixing screws.
Working on both sides, release the two bottom fixing snap-in rivets.
Remove the cover.
Remove the side fairing fastening screws. Remove the side fairing.
See also
Seat Side fairings BODYW - 342
MSS Mana GT ABS
Bodywork
Side fairings
Side fairings
Open the helmet compartment. Undo and remove the two fixing screws for the upper central small fairing (1) and collect the two washers.
Lower the helmet compartment. Remove the central small fairing (2).
Remove the screws (6).
Remove the rear screw (7).
BODYW - 343
Bodywork
MSS Mana GT ABS
Remove the internal air deflector. Disconnect the turn indicator connector. Remove the side fairing.
License plate holder

Remove the saddle. Undo and remove the two fixing screws.
Undo and remove the two screws fixing the passenger grab handle. Remove the passenger grab handle.
Remove the two spacers.
BODYW - 344
MSS Mana GT ABS
Bodywork
Operating from both sides, undo and remove the side screw.
Undo and remove the two lower fixing screws.
Partially slide off with great care the license plate support.
Remove the locking clamp.
BODYW - 345
Bodywork
MSS Mana GT ABS
Disconnect the rear light connector. Disconnect the rear turn indicator connector.
Hold the license plate support assembly. Undo and remove the two screws fixing the key lock. Remove the key lock.
Loosen the three screws and remove the hose guides.
BODYW - 346
MSS Mana GT ABS
Bodywork
Remove the clamp. Slide off the entire license plate support.
Air box
Remove the mat and rubber cover from the helmet compartment.
Unscrew and remove the two screws and remove the battery cover.
Remove the two screws from the helmet compartment.
BODYW - 347
Bodywork
MSS Mana GT ABS
Remove the steering lock protection.
Remove the side fairings. Undo and remove the two fixing screws. Remove the plastic radiator protection.
Disconnect the two horn connectors.
Undo the screw on the sleeve clamp through the hole in the helmet compartment.
BODYW - 348
MSS Mana GT ABS
Bodywork
Remove the filter box fixing screw inside the glove-box.
Remove the filter box fixing screw which is on the left of the chassis.
Release the blow by tube from the engine crankcase, working on the right of the vehicle.
Take the filter box away from the vehicle and release the blow by tube from the filter box.
Remove the filter box.
See also
Side fairings Side fairings
BODYW - 349
Bodywork
MSS Mana GT ABS
Helmet bay
Remove the saddle. Open the helmet compartment. Working on both sides, unscrew and remove the two top fixing screws.
Working on both sides, release the two bottom fixing snap-in rivets.
Remove the cover.
Undo and remove the two key cover fixing screws.
BODYW - 350
MSS Mana GT ABS
Bodywork
Close the helmet compartment. Slide off the cover. Reopen the helmet compartment.
Remove the side fairings. Working from both sides, undo and remove the protection front fixing screw.
Working from both sides, undo and remove the protection upper fixing screw.
Working from both sides, undo and remove the protection rear fixing screw.
BODYW - 351
Bodywork
MSS Mana GT ABS
Working from both sides, undo and remove the protection rear upper fixing screw.
Remove the lower screw fixing the fairing to the chassis.
Disconnect the control unit connectors.
Undo and remove the ground lead fixing screw. Remove the ground lead.
BODYW - 352
MSS Mana GT ABS
Bodywork
Working from both sides, undo and remove the compartment plastic part fairing upper fixing screws.
Working from both sides, undo and remove the compartment plastic part fairing lower fixing screws.
Move the compartment plastic part fairing.
Disconnect the faston connectors of the helmet compartment light control switch.
Remove the battery.
BODYW - 353
Bodywork
MSS Mana GT ABS
Disconnect the gear control ECU connector.
Disconnect the 12V socket connector.
Remove the clamp and disconnect the helmet compartment light connector.
Release the start-up remote control switch from the two tongues.
CAUTION UPON RELEASING THE REMOTE CONTROL SWITCH, TAKE CARE NOT TO DAMAGE THE TONGUES.
Slide off and backwards the fuses and the battery cables.
BODYW - 354
MSS Mana GT ABS
Bodywork
From both sides undo and remove the three helmet compartment external fixing screws.
Undo and remove the helmet compartment internal fixing screw.
BODYW - 355
Bodywork
MSS Mana GT ABS
Slide off the fuse box.
Lift the helmet compartment and disconnect the helmet compartment opening actuator connector.
Remove the helmet compartment.
Fuel tank
Remove the saddle. Remove the license plate support. Remove the fuel cap by rotating it anticlockwise. Close the tank with a cloth to prevent petrol splashes or dirt coming into the tank.
Undo and remove the two fixing screws and collect the washers.
BODYW - 356
MSS Mana GT ABS
Bodywork
Working from both sides, unscrew and remove the luggage fixing pin.
Remove the collar and slide off the breather pipe.
Lift sideways and remove the underseat cover.
CAUTION CHECK THAT THE FOUR MUSHROOM-HEAD RUBBER RINGS DO NOT PROTRUDE FROM THEIR POSITIONS.
BODYW - 357
Bodywork
MSS Mana GT ABS
Release the helmet compartment opening cable from its fitting.
Pull up the lever to open the helmet compartment manually and at the same time, lead the cable below; slide off the cable end from the fitting on the opening lever.
Slide off the cable.
Disconnect the quick couplers.
BODYW - 358
MSS Mana GT ABS
Bodywork
To disconnect the quick couplers, push the crown and at the same time pull the coupler up at 90 and slightly rotate it.
Disconnect the fuel pump connector.
Slide off the tank. Remove the cloth from the tank and screw the cap again.
BODYW - 359
Bodywork
MSS Mana GT ABS
Front mudguard
Operating from both sides, undo and remove the two screws.
Remove the front mudguard, by sliding it forwards and slightly pressing it so it passes through the forks.
Windscreen
Remove the top fairing fixing screws and extract it.
BODYW - 360
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Pre-delivery
MSS Mana GT ABS
Carry out the listed checks before delivering the vehicle.

WARNING
BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL.
Aesthetic inspection
- Paintwork - Fitting of Plastic Parts - Scratches - Dirt
Tightening torques inspection

- Safety locks: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers steering assembly - Plastic parts fixing screws
Electrical system
- Main switch - Headlamps: high-beam lights, low-beam lights, tail lights (front and rear) and their warning lights - Headlight adjustment according to regulations in force - Front and rear stop light switches and their bulbs - Turn indicators and their warning lights - Instrument panel lights - Instrument panel: fuel and temperature indicator (if present) - Instrument panel warning lights - Horn - Electric start-up - Engine stop via emergency stop switch and side stand - Helmet compartment electrical opening switch (if present)
PRE DE - 362
MSS Mana GT ABS
Pre-delivery
- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE.
CAUTION
UPON INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR APPROX. 15 MIN. AND SEEK MEDICAL ATTENTION IMMEDIATELY. IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK MEDICAL ATTENTION IMMEDIATELY. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
Levels check
- Hydraulic braking system fluid level - Clutch system fluid level (if present) - Gearbox oil level (if present) - Transmission oil level (if present) - Engine coolant level (if present) - Engine oil level - Mixer oil level (if present)
Road test
- Cold start - Instrument panel operation PRE DE - 363
Pre-delivery
MSS Mana GT ABS
- Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise
Static test
Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering - Possible leaks - Radiator electric fan operation (if present)
Functional inspection
- Hydraulic braking system - Stroke of brake and clutch levers (if present) - Clutch - Check for correct operation - Engine - Check for correct general operation and absence of abnormal noise - Other - Documentation check: - Chassis and engine numbers check - Supplied tools check - License plate fitting - Locks checking - Tyre pressure check - Installation of mirrors and any possible accessories
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST.

CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
PRE DE - 364
MSS Mana GT ABS
Pre-delivery
Specific operations for the vehicle
Fit the rubber elements with groove in the slots on the windshield. Insert the high T bushes from the inside of the windshield. Insert the low T bushes in their holes on the bodywork. Fit the windshield between the bodywork and the front glass cover. Tighten the screws.
Insert the cheese head screws from inside the fairing. Fix the turn indicators with the check nuts.
PRE DE - 365
A
ABS: 141, 294, 301 Air filter: 44
B
Brake: 308, 311, 316 Brake fluid: 316 Bulbs:
C
Chain: 12, 189 Clutch: 172, 238, 239, 243, 244, 246 Coolant: 323
D
Display: 50, 304
E
Engine oil: 41, 106
F
Fork: 267269, 274 Fuel: 101, 356 Fuses: 86
H
Headlight: 337
I
Identification: 10 Instrument panel: 50, 110, 337, 338
M
Maintenance: 8, 39, 308
O
Oil filter: 44
R
Recommended products: 25
S
Saddle: Shock absorbers: 285 Spark plug: 40
Spark plugs: Stand: 108 Start-up: 83
T
Tank: 334, 356 Transmission: 12, 115, 118, 125, 139, 233, 254 Tyres: 14
W
Warning lights:

Aprilia Mana 850 GT ABS-Shop Manual

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Aprilia Mana 850 GT ABS-Shop Manual

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SERVICE STATION MANUAL

MSS Mana GT ABS

SERVICE STATION MANUAL

MSS Mana GT ABS

SERVICE STATION MANUAL

MSS Mana GT ABS

MSS Mana GT ABS

MSS Mana GT ABS

MSS Mana GT ABS

DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.

MSS Mana GT ABS

MSS Mana GT ABS

Dimensions and mass

MSS Mana GT ABS

OIL MINIMUM PRESSURE INDICATOR SWITCH

HEAD LUBRICATION CONTROL JET

PISTON COOLING NOZZLE

CRANKCASE VENTILATION CHECK

MSS Mana GT ABS

Frame and suspensions

MSS Mana GT ABS

Wheels and tyres

MSS Mana GT ABS

THERMAL GROUP AND TIMING SYSTEM

CRANKCASE AND CRANKSHAFT

MSS Mana GT ABS

FRONT WHEEL UNIT

MSS Mana GT ABS

REAR WHEEL UNIT

MSS Mana GT ABS

Name Screw fixing ABS sensor plate (2) - M5x12

Torque in Nm 6 Nm (4.42 lbf ft)

HANDLEBAR / CONTROLS / TRANSMISSION

LIGHTS / INSTRUMENT PANEL

MSS Mana GT ABS

MSS Mana GT ABS

ENGINE MAIN RETAINERS

Overhaul data Assembly clearances Cylinder - piston assy.

Rod small end - pin - piston

MSS Mana GT ABS

MSS Mana GT ABS

Crankcase - crankshaft - connecting rod

MSS Mana GT ABS

CRANKSHAFT / CONNECTING ROD AXIAL CLEARANCE

MSS Mana GT ABS

Name Connecting rod Complete crankshaft

Dimensions 22 -0.10 - 0.15 91.8 +0.05

Quantity D = 0.20 0.55 D = 0.20 0.55

MSS Mana GT ABS

KEY X = Crankshaft category Y = Crankcase half-shells category A = Red B = Blue C = Yellow

Recommended products chart

AGIP FORK 5W AGIP MP GREASE

Fork oil Grease for bearings, joints, couplings and linkages

Recommended CHAIN oil Recommended BRAKE FLUID Recommended ENGINE COOLANT

MSS Mana GT ABS

Gauge for oil pressure check

Crankcase splitting strip

Punch for fitting the valve sealing rings

Stroboscopic light for timing checking

MSS Mana GT ABS

Stores code 020331Y

Description Digital multimeter

Dial gauge magnetic support