2010-2011 Aprilia Mana GT ABS Service & Repair Manual

SERVICE STATION MANUAL 854171 NA 850 Mana

SERVICE STATION MANUAL NA 850 Mana THE VALUE OF SERVICE Thanks to continuous technical updates and specific training programs on 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 conditions. Checking the vehicle before riding, its regular maintenance and the use of Original aprilia Spare Parts only are essential factors! For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or search directly on the inset map in our Official Website: www.aprilia.com Only aprilia Original Spare Parts ensure products already studied and tested during the vehicle design stage. All aprilia Original Spare Parts undergo quality control procedures to guarantee full reliability and duration. The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this manual 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 shown in this publication are available in all countries. The availability of individual versions should be confirmed with the official aprilia sales network. © Copyright 2007- 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.

SERVICE STATION MANUAL NA 850 Mana 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 CHAR SPECIAL TOOLS S-TOOLS MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS BODYWORK BODYW PRE-DELIVERY PRE DE

INDEX OF TOPICS CHARACTERISTICS CHAR

Rules This section describes the vehicle maintenance operations and general safety regulations. Safety rules Carbon monoxide If you need to keep the engine running in order to carry out any procedure, please ensure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a smoke-extraction system. CAUTION EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH. Fuel CAUTION FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND CAN BECOME EXPLOSIVE UNDER SPECIFIC 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 AND NEAR FUEL VA- POURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE. DO NOT DISPERSE FUEL IN THE ENVIRONMENT. KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been shut off. Before handling these components, make sure that you are wearing 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 PAY ATTENTION NOT TO POUR COOLANT ON HOT ENGINE OR EXHAUST SYSTEM COMPO- NENTS; IT MAY CATCH FIRE PRODUCING INVISIBLE FLAMES. WHEN CARRYING OUT MAIN- TENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN IF IT IS TOXIC, Characteristics NA 850 Mana CHAR - 6

THE 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 UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil CAUTION IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE. ENGINE OR TRANSMISSION 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 THE BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SUR- FACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMME- DIATELY 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, IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IF THE ELEC- TROLYTIC FLUID COMES INTO CONTACT WITH THE SKIN, RINSE WELL WITH ABUNDANT FRESH WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS INTO CON- TACT WITH YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CON- SULT 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 EX- PLOSIVE 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 IT OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT- TERY TO BE ACTIVATED. NA 850 Mana Characteristics CHAR - 7

Maintenance rules GENERAL PRECAUTIONS AND INFORMATION When repairing, dismantling and reassembling the vehicle follow the recommendations reported 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 other tools other than the especially designed wrench. • Mark positions on all connection joints (pipes, cables, etc.) before separating them, and identify them with distinctive symbols. • Each component needs to be clearly marked in order to be identified during assembly. • Clean and wash the removed components carefully using a low-flammability detergent. • Keep coupled parts together since they have "adjusted" to each other due to normal wear and tear. • Some components must be used together or replaced altogether. • Keep away from heat sources. REASSEMBLING COMPONENTS CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH- ERWISE THEY NEED REPLACING. • Only use ORIGINAL APRILIA SPARE PARTS. • Comply with lubricant and consumables usage guidelines. • Lubricate parts (whenever possible) before reassembling them. • When tightening nuts and screws, start from the ones with the largest section or from the internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap- plying the tightening torque. • Always replace self-locking nuts, washers, sealing rings, circlips, O-rings, split pins and screws with new ones if their tread is damaged. • When fitting bearings, make sure to lubricate them well. • Check that each component is fitted correctly. • After a repair or routine maintenance procedure, carry out pre-ride checks and test the vehicle on private grounds or in an area with low traffic density. • Clean all junction surfaces, oil guard rims and washers before refitting them. Smear a light layer of lithium-based grease on the oil guard rims. Reassemble the oil guard and the bearings with the brand or lot number facing outward (visible side). ELECTRIC CONNECTORS Characteristics NA 850 Mana CHAR - 8

Electric connectors must be disconnected as described below as non-compliance with the procedure so described causes irreparable damage to both the connector and the cable harness: Press the relevant safety hooks, if any. • Grip the two connectors and disconnect them by pulling them in opposite directions. • If there are signs of dirt, rust, humidity, etc., clean the connector internal parts carefully using a pressurised air jet. • Make sure that the cables are correctly linked to the connector internal terminal ends. • Then insert the two connectors making sure that they couple correctly (if the relevant hooks are provided, you will hear them "click" into place). CAUTION TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES. NOTE THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT WAY ROUND. TIGHTENING TORQUE CAUTION DO NOT FORGET THAT THE TIGHTENING TORQUE OF ALL FASTENING ELEMENTS ON WHEELS, BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE TIGHTENING TORQUE OF FASTENING PARTS ON A REGULAR BASIS AND AL- WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COM- PLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO GET LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISE VEHICLE HANDLING. THIS CAN 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 driving speed during run-in. In this way, you allow for the work of components to be "loaded" and then "unloaded", thus cooling engine parts. CAUTION ONLY AFTER THE SERVICE AT THE END OF THE RUN-IN PERIOD CAN THE BEST PERFORM- ANCE OF YOUR VEHICLE BE OBTAINED. 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) operate the brakes with caution, avoid rough and long braking. That is to permit the adequate adjustment of the pad friction material to the brake discs. NA 850 Mana Characteristics CHAR - 9

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 of this booklet. The chassis number is handy when purchasing spare parts. CAUTION ALTERING IDENTIFICATION NUMBERS IS AN OFFENCE WHICH CAN RESULT IN SEVERE CRIMINAL AND ADMINISTRATIVE CHARGES. PARTICULARLY MODIFYING THE CHASSIS NUM- BER WILL IMMEDIATELY INVALIDATE THE WARRANTY. This number is composed by numbers and letters, as in the example shown below. ZD4RC0000YMXXXXXX KEY: ZD4: WMI (World manufacturer identifier) code; RC: model; 000: 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 left side engine crankcase. Engine No. .................... CHASSIS NUMBER The chassis number is stamped on the right side of the headstock. Chassis No. .................... Characteristics NA 850 Mana CHAR - 10

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2010-2011 Aprilia Mana GT ABS Service & Repair Manual

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