Aprilia Mss 850

SERVICE STATION MANUAL
854245
NA 850 Mana ABS

SERVICE STATION
MANUAL
NA 850 Mana ABS
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 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 CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
BODYWORK BODYW
PRE-DELIVERY PRE DE
INDEX OF TOPICS
CHARACTERISTICS CHAR
Characteristics NA 850 Mana 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 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 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 POUR COOLANT ONTO HOT ENGINE OR EXHAUST SYSTEM COMPO-
NENTS; THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES. WHEN CARRYING
OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN
CHAR - 6
NA 850 Mana ABS Characteristics
THOUGH IT IS TOXIC, COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRAC-
TIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCES-
SIBLE TO ANIMALS AS THEY MAY DRINK IT.
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 PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE-

HICLE.
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
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 COM-
PONENTS 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 THE EYES, RINSE THEM IMMEDIATELY
WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
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. 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. IF THE FLUID GETS IN CONTACT WITH
YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE
SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY
FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADE-
QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
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.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
CHAR - 7
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 positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with 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 completely.
• 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 suc-
cessive 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).
ELECTRICAL CONNECTORS
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.
CHAR - 8
• 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
Running the engine in correctly is essential for ensuring engine longevity and functionality. Twisty roads
and gradients are ideal for running in the engine, brakes and suspension effectively. Vary your riding
speed during the running in period. This ensures that components operate in "loaded" conditions and
then "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 RUNNING IN PERIOD.
Follow these guidelines:
• 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.
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.
CHAR - 9
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 side of the headstock.
Chassis No. ....................
Dimensions and mass
DIMENSIONS
Specification Desc./Quantity
Max. length 2180 mm (85.83 in)
Max. width 800 mm (31.50 in)
Max. height 1130 mm (44.49 in)
CHAR - 10
Saddle height 810 mm (31.89 in)
Wheelbase 1470 mm (57.87 in)
Kerb weight (full fuel tank) 230 kg (507 lb)
Engine
ENGINE
Model M290 Duel
Type 90° longitudinal V-twin, 4-stroke, 4 valves per cylinder, single
overhead camshaft.
No. of cylinders 2
Overall cylinder capacity 839.3 cm³ (51.22 cu.in)
Bore / stroke 88 x 69 mm (3.46 x 2.72 in)
Valve clearance Inlet: 0.15 mm (0.0059 in)
Outlet: 0.15 mm (0.0059 in)
Compression ratio 10 - 10.6 : 1
Electric starter
Engine idle speed 1400 ± 100 rpm
TIMING SYSTEM 4 valves, single overhead camshaft, chain-driven.
MAX. torque 71 Nm at 4,500 rpm
Clutch Automatic
Lubrication system Dry sump system with separate oil tank
Lubrication pressure 3.5 ÷ 4 bar
Minimum lubrication pressure (100 °C - 212 °F) 0.8 bar
Air filter With dry cartridge filter
Cooling Forced-circulation coolant system.
GEARBOX
Type aprilia sport gear with electrically-controlled variator, double
mode: sequential and autodrive
OIL PUMP
Type Trochoidal
Rotor shim washers pressure pump: 12 mm (0.47 in)
scavenge pump: 22 mm (0.87 in)
Fitting clearances Lobe ends: 0.04 - 0.1 mm (0.0016 - 0.0039 in)
External rotor radial clearance 0.05 - 0.12 mm (0.0020 - 0.0047 in)
Flatness 0.015 mm (0.00059 in)
BY-PASS
Type with piston
Piston diameter 13.984 - 13.957 mm (0.5505 - 0.5495 in)
Unloaded spring length 52 mm (2.05 in)
Calibration pressure 4.5 bar (450 kPa) (65 PSI)
OIL FILTER
Type paper filter with pressure relief and anti-drain by-passes
OIL MINIMUM PRESSURE INDICATOR SWITCH

Calibration 0.3 ÷ 0.6 bar
CHAR - 11
HEAD LUBRICATION CONTROL JET

Diameter Ø 1 ± 0.05 mm *
* Tightening torque 5÷7 N·m
PISTON COOLING NOZZLE

Diameter Ø 0.95 - 1.05 mm (0.037 - 0.041 in)
CRANKCASE VENTILATION CHECK

Device metal reed valve and decantation chamber
Transmission
GEAR RATIO
Primary drive gear ratio Belt primary drive (2.079 - 0.831)
Secondary drive gear ratio Gear secondary drive (23/59)
Final drive gear ratio 18/40
Capacities
CAPACITY
Fuel (reserve included) 16 l (3.52 UKgal; 4.23 USgal)
Fuel reserve 3.3 l (0.73 UKgal; 0.87 USgal)
engine oil 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)
Coolant 2.5 l (0.55 UK gal; 0.66 USgal)
Seats 2
Vehicle max. load (rider + passenger + luggage) 210 kg (463 lb)
Drive chain
DRIVE CHAIN
Type Endless (without master link) and with sealed links. No. of links
100
Model 525 ZRPK
Electrical system
ELECTRICAL SYSTEM
Battery 12V - 12 Ah
Main fuses 30A - 40A
Secondary fuses 3A, 10A, 15A, 20A
ABS fuses 20 A
Alternator (permanent magnet type) 13.5 V - 450 W at 6000 rpm
Electric starter
CHAR - 12
Ignition Electronic, inductive, high-efficiency, integrated with the injec-
tion system, with variable advance separate HV coil.
Ignition advance Three-dimensional map managed by control unit
Pick-up air gap front: 0.1 - 3.17 mm (0.004 - 0.124 in)
rear: 0.1 - 2.0 mm (0.004 - 0.078 in)
SPARK PLUGS
Standard spark plugs NGK CR7EKB
Spark plug electrode gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Resistance 5 kOhm
BULBS
Low-beam light 12 V - 55 W H11
High-beam light 12 V - 55 W H11
Front daylight running light 12V - 5W
Turn indicator light 12V - 10W
License plate light 12V - 5W
Rear daylight running light / stop light LED
Rpm indicator lighting LED
Multifunction display lighting LED
WARNING LIGHTS
High beam light LED
Right turn indicator LED
Left turn indicator LED
General warning LED
Fuel reserve LED
RPM 1 LED
RPM 2 LED
RPM 3 LED
RPM 4 LED
Frame and suspensions
CHASSIS
Type High strength steel tubular perimeter frame.
Steering inclination angle 24°
Trail 103 mm (4.05 in)
CHASSIS HEIGHTS
A1 386.4 ± 0.5 mm (15.21 ± 0.02 in)
CHAR - 13
A2 702.6 ± 0.5 mm (27.66 ± 0.02 in)
B1 225.5 ± 0.6 mm (8.88 ± 0.02 in)
B2 187.2 ± 0.6 mm (7.37 ± 0.02 in)
SUSPENSIONS
Front Upside-down hydraulic action telescopic fork, Ø 43 mm (1.69
in) stems
Travel 120 mm (4.72 in)
Rear Oscillating swingarm and adjustable hydraulic single shock ab-
sorber
Wheel travel 120 mm (4.72 in)
Brakes
BRAKES
Front Double floating disc, Ø 320 mm (12.60 in), radially-mounted
callipers with four plungers- two of them Ø 27 mm (1.06 in), 2
diam. 32.03 mm (1.26 in) and 4 pads
Rear Ø 260 mm (10.24 in) disc brake, Ø 25 mm (0.98 in) twin-plunger
calliper
Wheels and tyres
WHEEL RIMS
Type Light alloy rims with extractable bolt
Front 3.50 x 17"
Rear 6.00 x 17"
TYRES
Tyre type (standard) DUNLOP SPORTMAX QUALIFIER - PIRELLI SCORPION
SYNC
Front 120/70 ZR17" (58W)
Inflation pressure 1 passenger: 2.3 bar (230 kPa) (33.36 PSI)
2 passengers: 2.5 bar (250 kPa) (36.26 PSI)
Rear 180/55 ZR17" (73W)
Inflation pressure 1 passenger: 2.5 bar (250 kPa) (36.26 PSI)
2 passengers: 2.8 bar (280 kPa) (40.61 PSI)
Supply
FUEL SYSTEM
Type Electronic injection (Multipoint)
Throttle diameter 38 mm (1.50 in)
Fuel Premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)
CHAR - 14
Tightening Torques
LUBRICATION
Name Torque in Nm
Engine oil drainage plug 21 - 29
Oil pump compartment cover bulkhead screws 3-4
Engine oil filter 12 - 16
Chain tensioner slider - oil pump 2-3
Oil pump screws 5-6
By-pass scavenge pipe fixing screws 11 - 13
Lubrication circuit upper bulkhead 3-4
Oil pump sprocket gear screw 10 - 14
Screws fixing oil pump to crankcase 5-6
Minimum oil pressure sensor 12 - 14
Water pump gear fixing screws 5-6
THERMAL GROUP AND TIMING SYSTEM

Name Torque in Nm
Spark plug 12 - 14
Head fixing stud bolts ***
Head fixing nuts 10 - 12
Exhaust/ intake head fixing nuts 10 - 12
Head lubrication control jet 5-7
Tensioner slider fixing screw 10 - 14
injector fixing screw 3-4
Inlet manifold fixing screws 11 - 13
Tappet cover fixing screws 7-9
Throttle body fixing screws 11 - 13
Camshaft retaining bracket fixing screws 4-6
Head fixing screws 10 - 12
Coolant temperature sensor 21 - 23
Rpm-timing sensor fixing screw 7.5 - 8.5
Timing system chain tensioner screw 11 - 13
Timing system crown screw on camshaft 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 Torque in Nm
Driving pulley screw 175 - 195
Driven pulley nut 153 - 187
Driving pulley ring nut 65 - 75
External driving pulley ring nut 80 - 90
External transmission cover screws 5-7
Internal transmission cover screws 11 - 13
Air deflector screws 3-4
Air outlet grid screws 3-4
FLYWHEEL COVER
Name Torque in Nm
Flywheel fixing nut 116 - 128
Stator clamps 8 - 10
Screws fixing freewheel to flywheel 13 - 15
Flywheel cover screws 11 - 13
CRANKCASE AND CRANKSHAFT

Name Torque in Nm
Starting ring gear retaining plate 3-4
Crankcase-engine coupling screws (M6) 11 - 13
CHAR - 15
FRAME
Name Torque in Nm
hex headflanged screw fixing coil support - M6x20 (2) 10 Nm (7.38 lbf ft)
Lower self-locking M4 nut fixing coils (8) 3 Nm (2.21 lbf ft)
Self-locking M10 nut fixing shock absorber (1) 50 Nm (36.88 lbf ft)
DAX M14 nut fixing engine to chassis (2) 80 Nm (59 lbf ft)
TBEI screw fixing rubber rings with groove for saddle - M6x30 10 Nm (7.38 lbf ft)
(2)
TCEI screw fixing tank front rubber rings - M8x20 (2) 25 Nm (18.44 lbf ft)
Screw fixing ABS control unit (1) - M6x25 10 Nm (7.37 lbf ft) - Loctite 243
Nut fixing ABS control unit (2)- M6 10 Nm (7.37 lbf ft)
FOOTPEGS
Name Torque in Nm
Non-slip bolt on driver footrest (2) 25 Nm (18.44 lbf ft)
hex headflanged screw for footrest finish - M6x12 (8) 10 Nm (7.38 lbf ft)
TBEI flanged screw fixing heelrests - M5x16 (4) 6 Nm (4.42 lbf ft)
TCEI screw fixing footrest support to fork pin - M10x63 (2) 50 Nm (36.88 lbf ft)
Lower self-locking flanged M10 nut fixing footrest support to 30 Nm (22.13 lbf ft)
stand bolt (2)
Lower screw fixing rider footrest 25 Nm (18.44 lbf ft)
STAND
Name Torque in Nm
Bolt fixing screwed stand to fork (1) 10 Nm (7.38 lbf ft)
Stand bolt safety lock nut - M10x1.25 (1) 30 Nm (22.13 lbf ft)
Self-locking nut fixing centre stand front bolt (1) 50 Nm (22.13 lbf ft)
TCEI screw fixing switch - M5x25 (2) 6 Nm (4.42 lbf ft)
SWINGARM
Name Torque in Nm
Rear wheel bolt nut fixing fork pin (1) 90 Nm (66.38 lbf ft)
Chain tensioner pad set screw (2) manual
Serpress M8 nut fixing chain tensioner screws (2) manual
M5x15 TBEI screw with washer fixing chain crankcase (4) 6 Nm (4.42 lbf ft)
M5x12 TBEI screw fixing chain slider (2) 3 Nm (2.21 lbf ft) - Loctite 243
Rear brake calliper support lock pin (1) 50 Nm (36.88 lbf ft) - Loctite 243
FRONT SUSPENSION
Name Torque in Nm
Stainless steel TCC M8x30 screw fixing stanchions on upper 25 Nm (18.44 lbf ft)
plate (2)
Stainless steel TCC M8x30 screw fixing stanchions on lower 25 Nm (18.44 lbf ft)
plate (4)
Headstock ring nut - M25x1 (1) tighten to 20 Nm (14.75 lbf ft) - unscrew and tighten to 7 Nm
(5.16 lbf ft)
Headstock cap - M22x1 (1) 100 Nm (73.76 lbf ft)
Screw fixing fork feet on wheel pin - M8x40 (4) 25 Nm (18.44 lbf ft)
TCEI screw fixing handlebar U-bolts to upper plates - M10x60 50 Nm (36.88 lbf ft)
(2)
REAR SUSPENSION
Name Torque in Nm
Self-locking M10 nut fixing shock absorber to fork (1) 50 Nm (36.88 lbf ft)
ENGINE
Name Torque in Nm
TEF screw fixing gear control unit - M6x16 (4) 10 Nm (7.37 lbf ft)
TBEI screw with washer fixing micro-switch bracket - M5x9 (1) 6 Nm (4.42 lbf ft)
TCEI screw fixing pin lever to gearshift lever - M6x16 (1) 10 Nm (7.38 lbf ft)
TCEI screw fixing gearshift lever to engine pin - M6x16 (1) 10 Nm (7.38 lbf ft) - knurled washer
CHAR - 16
Name Torque in Nm
Self-tapping screw fixing air deflector cover on air deflector (4) 1 Nm (0.74 lbf ft)
Self-tapping screw fixing mesh filter on air deflector (2) 1 Nm (0.74 lbf ft)
Self-tapping screw fixing filter cover to air deflector (1) 1 Nm (0.74 lbf ft)
TCCIC screw with shank fixing air deflector to engine (4) 7 Nm (5.16 lbf ft)
hex headflanged screw fixing voltage regulator on bracket - 10 Nm (7.38 lbf ft)
M6x30 (2)
FILTER BOX
Name Torque in Nm
SWP screw assembling filter support to filter box - M5x19 (6) 2 Nm (1.47 lbf ft)
SWP screw fixing filter box cover - M5x19 (3) 2 Nm (1.47 lbf ft)
hex headflanged screw fixing filter box to chassis - M6x25 (2) 10 Nm (7.37 lbf ft)
EXHAUST SYSTEM
Name Torque in Nm
Self-locking flanged nut tightening exhaust manifolds to heads 25 Nm (18.44 lbf ft)
(4)
TBEI flanged screw fixing exhaust front protection (4) 8 Nm (5.9 lbf ft)
M8 flanged self-locking nut fixing silencer (1) 25 Nm (18.44 lbf ft)
M10 screw fixing compensator on footrest support (2) 30 Nm (22.13 lbf ft)
Manifolds fixing clamp (2) 18 Nm (13.28 lbf ft)
COOLING SYSTEM
Name Torque in Nm
Radiator TCEI fixing screw - M6x35 (2) 10 Nm (7.38 lbf ft)
Heat protection fixing screw - M5x10 (1) 6 Nm (4.42 lbf ft)
Heat protection fixing screw - M6x16 (3) 10 Nm (7.38 lbf ft)
Expansion tank TCEI fixing screw - M6x25 (1) 10 Nm (7.38 lbf ft)
Electric fan fixing screw (3) 0.3 Nm (0.22 lbf ft)
Radiator cover TBEI fixing screw - M5x12 (4) 6 Nm (4.42 lbf ft)
FRONT BRAKE
Name Torque in Nm
hex headflanged screw fixing calliper - M10x1.25x55 (4) 50 Nm (36.88 lbf ft)
Union with breather fixing pipe to callipers - M10x1 (2) 25 Nm (18.44 lbf ft)
Union fixing pipe to pump - M10x1 (1) 25 Nm (18.44 lbf ft)
TEF screw fixing braking system to lower plate - M6x16 (1) 10 Nm (7.38 lbf ft)
REAR BRAKE
Name Torque in Nm
Screw fixing pin on brake lever - M6x16 (1) 10 Nm (7.38 lbf ft)
Screw fixing lever on footrest support (1) 25 Nm (18.44 lbf ft) - Loctite 243
Brake pipe union on pump and calliper - M10x1 (1) 25 Nm (18.44 lbf ft)
Hydraulic stop switch (1) 25 Nm (18.44 lbf ft)
M6 Lock nut for fork (1) 10 Nm (7.38 lbf ft)
Parking brake calliper retainer - M8x21 (2) 25 Nm (18.44 lbf ft) - Loctite 243
Hydraulic calliper retainer - M8x29 (2) 25 Nm (18.44 lbf ft) - Loctite 243
hex headscrew fixing pump on footrest plate - M6x25 (2) 10 Nm (7.38 lbf ft) - Loctite 243
Oil tank hex head fixing screw - M6x15 (1) 10 Nm (7.38 lbf ft)
Upper TCEI screw fixing parking lever unit - M6x30 (2) 10 Nm (7.38 lbf ft)
Lower TCEI screw fixing parking lever unit - M6x20 (1) 10 Nm (7.38 lbf ft)
Brake pipe support bracket fixing screw (2) 25 Nm (18.44 lbf ft)
Parking brake cable guide fixing screw (1) 10 Nm (7.38 lbf ft)
FRONT BRAKE
Name Torque in Nm
hex headflanged screw fixing calliper - M10x1.25x55 (4) 50 Nm (36.88 lbf ft)
Union with breather fixing pipe to callipers - M10x1 (2) 25 Nm (18.44 lbf ft)
Union fixing pipe to pump - M10x1 (1) 25 Nm (18.44 lbf ft)
TEF screw fixing braking system to lower plate - M6x16 (1) 10 Nm (7.38 lbf ft)
Screw tightening ABS sensor (1) - M5 6 Nm (4.42 lbf ft)
Screw fixing ABS sensor plate (2) - M5x12 6 Nm (4.42 lbf ft)
CHAR - 17
REAR BRAKE
Name Torque in Nm
Screw fixing pin on brake lever - M6x16 (1) 10 Nm (7.38 lbf ft)
Screw fixing lever on footrest support (1) 25 Nm (18.44 lbf ft) - Loctite 243
Brake pipe union on pump and calliper - M10x1 (1) 25 Nm (18.44 lbf ft)
Hydraulic stop switch (1) 25 Nm (18.44 lbf ft)
M6 Lock nut for fork (1) 10 Nm (7.38 lbf ft)
Parking brake calliper retainer - M8x21 (2) 25 Nm (18.44 lbf ft) - Loctite 243
Hydraulic calliper retainer - M8x29 (2) 25 Nm (18.44 lbf ft) - Loctite 243
hex headscrew fixing pump on footrest plate - M6x25 (2) 10 Nm (7.38 lbf ft) - Loctite 243
Oil tank hex head fixing screw - M6x15 (1) 10 Nm (7.38 lbf ft)
Upper TCEI screw fixing parking lever unit - M6x30 (2) 10 Nm (7.38 lbf ft)
Lower TCEI screw fixing parking lever unit - M6x20 (1) 10 Nm (7.38 lbf ft)
Brake pipe support bracket fixing screw (2) 25 Nm (18.44 lbf ft)
Parking brake cable guide fixing screw (1) 10 Nm (7.38 lbf ft)
Screw tightening ABS sensor (1) - M5 6 Nm (4.42 lbf ft)
HANDLEBAR / CONTROLS / TRANSMISSION

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

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

Name Torque in Nm
hex headscrew fixing transmission cover on engine crankcase 12 Nm (8.85 lbf ft)
- M6x35 (13)
Central crankcases hex headfixing screw - M8x60 (11) 25 Nm (18.44 lbf ft)
hex headscrew fixing flywheel cover on engine crankcase - 12 Nm (8.85 lbf ft)
M6x35 (16)
Overhaul data
CHAR - 19
Assembly clearances
Cylinder - piston assy.

CAUTION
EACH CYLINDER TYPE, MADE OF ALUMINIUM OR CAST IRON, MUST BE COUPLED TO THE
SPECIFIC PISTON, AS SHOWN IN THE FOLLOWING TABLE.
- 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 BETWEEN THE PISTON AND THE ALUMINIUM CYLINDER

Name Initials Cylinder Piston Play on fitting
Cylinder - Piston A 87.990 - 87.997 87.954 - 87.961 0.029 ÷ 0.043
Cylinder - Piston B 87.997 - 88.004 87.961 ÷ 87.968 0.029 ÷ 0.043
Cylinder - Piston C 88.004 - 88.011 87.968 ÷ 87.975 0.029 ÷ 0.043
Cylinder - Piston D 88.011 - 88.018 87.975 ÷ 87.982 0.029 ÷ 0.043
- Pistons and cylinders are classified according to their diameter. The coupling is carried out in pairs
(M-M, N-N, O-O, P-P).
COUPLING CATEGORIES BETWEEN THE PISTON AND THE CAST IRON CYLINDER
Name Initials Cylinder Piston Play on fitting
Cylinder - Piston M 87.990 - 87.997 87.933 - 87.940 0.050 - 0.064
Cylinder - Piston N 87.997 - 88.004 87.940 - 87.947 0.050 - 0.064
Cylinder - Piston O 88.004 - 88.011 87.947 - 87.954 0.050 - 0.064
Cylinder - Piston P 88.011 - 88.018 87.954 - 87.961 0.050 - 0.064
NOTE
THE ROTATION DIRECTION OF THE ENGINE AND OPPOSITE TO RUNNING, CONSEQUENTLY
THE PISTONS ARE ORIENTED IN A DIFFERENT WAY WHEN INSTALLING:
THE FRONT CYLINDER PISTON (RUNNING FRONT) MUST BE FITTED WITH THE ARROW TO-
WARDS THE INTAKE.
THE REAR CYLINDER PISTON, UNLIKE THE FRONT ONE, MUST BE FITTED WITH THE ARROW
TURNED TOWARDS THE EXHAUST.
THE PISTON RINGS MUST BE FITTED WITH THE "TOP" REFERENCE OR THE TRADEMARK
FACING UP.
Rod small end - pin - piston
ROD SMALL END - PIN COUPLING CLEAR-

ANCE
- Calculate the rod small end - pin coupling clear-
ance.
Characteristic
Standard clearance:
0.015 - 0.029 mm
CHAR - 20
PIN - PISTON COUPLING CLEARANCE

- Calculate the pin - piston coupling clearance.
NOTE
THE PIN HOUSINGS HAVE TWO LUBRICATION CHAN-
NELS FOR THIS REASON MEASURE THE DIAMETER AC-
CORDING 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 opening in the rings as shown in this figure.
*** Value «A» of the sealing ring inside the cylinder.
CHAR - 21
FITTING CLEARANCE PISTON RINGS- SEALING RINGS

DENOMINATION CLEARANCE WHEN MAXIMUM CLEARANCE STANDARD COUPLING
FITTING (A) AFTER USE (A) CLEARANCE (B)
1st Compression ring (mm) 0.15 ÷ 0.35 0.50 0.01 ÷ 0.06
2nd Compression ring (mm) 0.25 ÷ 0.50 0.65 0.02 ÷ 0.07
Oil scraper rings (mm) 0.25 ÷ 0.50 0.65 0.01 ÷ 0.06
Maximum clearance after use: B = 0.10 mm
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.
CRANKSHAFT
Cat. 1 Standard diameter: 45.010 ÷ 45.016
Cat. 2 Standard diameter: 45.016 ÷ 45.022
CHAR - 22
CRANKSHAFT / CONNECTING ROD AXIAL CLEARANCE

Name Description Dimensions Initials Quantity
Half shaft, transmission 29.9 +0.05 A D = 0.20 ÷ 0.60
side
Half shaft, flywheel side 29.9 +0.05 B D = 0.20 ÷ 0.60
Connecting rod 22 -0.10 -0.15 C D = 0.20 ÷ 0.60
Complete crankshaft 104 +0.1 -0.05 E
Characteristic
Crankshaft-crankcase axial clearance (H)
0.1 ÷ 0.45 mm (when cold)
CHAR - 23
- Measure the inside diameter of the connecting

rod small end using a bore meter.
NOTE
IF THE CONNECTING ROD SMALL END DIAMETER EX-
CEEDS THE STANDARD DIAMETER, SHOWS SIGNS OF
WEAR OR OVERHEATING, REPLACE THE CRANKSHAFT
AS DESCRIBED IN THE «CRANKCASE AND CRANK-
SHAFT» 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.
KEY
X = Crankshaft category
Y = Crankcase half-shells category
A = Red
B = Blue
C = Yellow
Recommended products chart
RECOMMENDED PRODUCTS
Product Description Specifications
ENI i-RIDE Aprilia Racing 5W-40 Engine oil Use top-branded oils that meet or exceed
the requirements of JASO MA, MA2 - API
SL - ACEA A3 specifications
AGIP ARNICA SA 32 Fork oil (Marzocchi) SAE 0W - ISO-L-HV
AGIP FORK 5W Fork oil (Showa) SAE 5W
FUCHS TITAN SAF 1091 Fork oil (Sachs) -
CHAR - 24
Product Description Specifications

AGIP MP GREASE Black smooth textured lithium-calcium ISO L-X-BCHB 2 - DIN 51 825 KP2K-20
soap based grease containing EP (ex-
treme pressure) additives with optimal
water-repellent properties
AGIP CHAIN GREASE SPRAY Recommended CHAIN oil Grease
AGIP BRAKE 4 Brake fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO
4925 - CUNA NC 956 DOT 4 synthetic
fluid
AGIP PERMANENT SPECIAL Ethylene glycol-based antifreeze fluid ASTM D 3306 - ASTM D 4656 - ASTM D
with organic inhibition additives. Red, 4985 - CUNA NC 956-16
ready to use.
CHAR - 25
INDEX OF TOPICS
SPECIAL TOOLS S-TOOLS

NA 850 Mana ABS Special tools
SPECIFIC TOOLS
Stores code Description
020193Y Gauge for oil pressure check
020262Y Crankcase splitting strip
020306Y Punch for fitting the valve seal rings
020330Y Stroboscopic light for timing checking
020331Y Digital multimeter
S-TOOLS - 27
Special tools NA 850 Mana ABS

020335Y Dial gauge magnetic support
020357Y 32 x 35 mm adaptor
020358Y 37 x 40-mm adaptor
020362Y 12 mm guide for oil seal in kick start pedal
S-TOOLS - 28

020363Y 20 mm guide for oil seal
020364Y 25-mm Guide
020365Y 22 mm (0.87 in) guide
020375Y 28x30 mm punch
020376Y Adapter handle
020408Y 72x75-mm (2.83x2.95 in) adaptor
S-TOOLS - 29

020412Y 15-mm Oil seal guide
020414Y 28 mm punch
020424Y Punch for fitting driven pulley roller casing
020434Y Fitting for oil pressure check
020439Y 17-mm guide for oil seal
020431Y Valve oil seal extractor
S-TOOLS - 30

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
020477Y 37-mm Adaptor
020478Y Punch for roller casing
S-TOOLS - 31

020480Y Fuel pressure check set
020481Y Adaptor cable harness
020481Y004 Adaptor cable
020483Y 30 mm guide
020527Y Engine support base
020621Y HV cable extraction adaptor
S-TOOLS - 32

020629Y 8 mm (0.31 in) guide
020648Y Single battery charger
020654Y 35-mm Guide
020655Y 62x68 mm Adaptor
020658Y Engine plate
020659Y Tool to remove clutch and repl. belt
S-TOOLS - 33

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
020665Y Transmission side crankshaft fitting tip
020709Y Engine support
S-TOOLS - 34

020713Y Flywheel extractor
020714Y Dial gauge mounting
020716Y Connecting rod locking
AP0276474 Valve spring compressor adaptor
AP8140146 Weight
AP8140147 Spacer tool
AP8140148 Spacer-piston separating plate
S-TOOLS - 35

AP8140149 Protection for fitting operations
AP8140150 Perforated rod for piston air bleed
AP8140179 Support for valve fitting/removal
AP8140180 Extractor for bushings
AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in)

orifices
AP8140302 Piston fitting ring
S-TOOLS - 36

AP8140595 Axone + battery charger (230V 50Hz)
AP8140187 Engine support stand
AP8106702 Flywheel lock calliper spanner
AP8140199 Tool panel
8140426 Hooks for panel
S-TOOLS - 37

020881Y Panel graphics
S-TOOLS - 38
INDEX OF TOPICS
MAINTENANCE MAIN
Maintenance NA 850 Mana ABS
Maintenance chart
Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum
function and performance.
To this end, Aprilia offers a set of checks and maintenance services (at the owner's expense), that are
summarised in the table shown on the following page. Any minor faults must be reported without delay
to an Authorised Aprilia Dealer or Sub-Dealer without waiting until the next scheduled service to
solve it.
All scheduled services must be carried out at the specified intervals and mileage, as soon as the pre-
determined 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 VE-
HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK
USE.
NOTE
THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED
TO MANAGEMENT ACTIVITIES.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
(1) Replace every 2 years
(2) Replace every 4 years
(3) Check every 2,000 km (1250 mi)
ROUTINE MAINTENANCE TABLE

km x 1,000 1 10 20 30 40 50 60 70 80
Battery terminals tightening I I I I I I I I I
Pulley control bushing L L L L L
Spark plug R R R R
Drive chain L
Transmission cables I I I I I I I I I
Drive belt R R R R
Throttle boby (self-adjustable parameters reset) C C
Steering bearings and steering clearance I I I I I I I I I
Wheel bearings I I I I I I I I
Diagnosis for engine control unit and transmission ECU I I I I I I I I I
Brake discs I I I I I I I I I
Air filter C R C R C R C R
Transmission air filter C C C C C C C C
Engine oil filter R R R R
Vehicle general operation I I I I I I I I I
Driving pulley lock ring nut I I I I I
Tappet clearance A A A
Braking systems I I I I I I I I I
Light circuit I I I I I I I I I
Safety switches I I I I I I I I I
Brake fluid (1) I I I I I I I I I
Coolant (1) I I I I I I I I I
Fork oil (1)
MAIN - 40
NA 850 Mana ABS Maintenance
km x 1,000 1 10 20 30 40 50 60 70 80
Engine oil R R R R R R R R
Fork oil seals I I I I I I I I I
Brake pads (3) I I I I I I I I I
Variator sliders R R R R
Parking brake calliper I I I I I I I I I
Tyres I I I I I I I I I
Tyre pressure I I I I I I I I I
Wheels and transmission cush drive I I I I I I I I I
Transmission screws and bolts torque tightening I I I I I I I I
Tightening bolts, nuts and screws I I I I I I I I I
Suspension and setting I I I I I I I I I
Final drive unit (chain, crown and pinion) I I R I I R I I
Fuel lines (2) I I
Labour time (minutes) 100 120 140 290 140 120 270 120 200
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, un-
screw and remove the spark plugs (two
per cylinder).
• Check the gap between the electrodes

with a feeler gauge.
CAUTION
DO NOT ATTEMPT TO READJUST THE ELECTRODE GAP.
MAIN - 41
The gap between the electrodes should be be-

tween 0.7 - 0.8 mm (0.027 - 0.031 in). Otherwise,
replace the spark plug (2).
• Make sure the washer is in good con-

ditions.
Installation:
• Once the washer is fitted, screw the

spark plug (2) carefully to avoid dam-
aging 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 PAR-
TICULAR 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 SUR-
FACE.
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 TRAV-
ELLING 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 MINI-
MUM LEVEL USING THE DIPSTICK (1), AND THE ENGINE
OIL MAXIMUM LEVEL THROUGH THE CRANKCASE
SIGHT GLASS (2).
MAIN - 42
• 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 INEX-
PERIENCED.
CONTACT AN OFFICIAL APRILIA DEALER IF REQUIRED.
IF YOU WISH TO PERFORM THESE OPERATIONS YOURSELF, FOLLOW THESE INSTRUC-
TIONS.
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 - 43
• Use a cloth to wipe off any mud deposit

on the area next to the filler plug (1).
• Place a container with + 4000 cm³ (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 com-
pletely.
• 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 RE-
SULTS 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 - 44
Engine oil filter
ENGINE OIL FILTER REPLACEMENT
• Replace the engine oil filter (1) at the

intervals specified in the routine main-
tenance 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 fix-
ing 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 - 45
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
NA 850 Mana ABS Troubleshooting
Engine
The engine does not start

CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING 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) SECONDARY 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?
• 4 - SEE THE "ELECTRICAL SYSTEM/ CHECKS AND CONTROLS/ ENGINE REVOLU-

TION SENSOR" CHAPTER: SEE THE WARNING RELATED TO THE TROUBLESHOOT-
ING 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?
• 8 - IS THERE CONTINUITY BETWEEN THE BLUE/GREEN CABLE OF THE PUMP CON-

NECTOR AND THE GROUND CONNECTION?
TROUBL - 47
Troubleshooting NA 850 Mana ABS
• 9 - RESTORE THE CABLE HARNESS - END

• 10 - CHECK THE ELECTRICAL SPECIFICATIONS OF THE FUEL PUMP - 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?

• 15 - IF THE REAR BRAKE IS OPERATED, DOES THE STOP LIGHT TURN ON?

• 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?

• 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?

• 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?

• 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)?

• 22 - WHEN TRYING TO START UP THE ENGINE (BY PRESSING THE STARTER BUT-
TON AND OPERATING THE BRAKES), IS VOLTAGE PULSE DETECTED ON THE RED
CABLE TOWARDS THE STARTER MOTOR OF RELAY No. 64 (START-UP REMOTE
CONTROL)?
TROUBL - 48
• 23 - IS THE STARTER MOTOR CORRECTLY CONNECTED TO THE VEHICLE GROUND

CONNECTION?
• 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?
• 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?
• 33 - CHECK CONTINUITY AND GROUND INSULATION OF THE YELLOW/GREEN CA-

BLE 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?
• 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?
• 38 - CHECK CONTINUITY AND GROUND INSULATION OF THE YELLOW/GREEN CA-

BLE 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 - 49
• 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 START-

UP 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?
• 46 - CHECK CONTINUITY BETWEEN PIN 1 AND PIN 2 OF THE RELAY AND CONTINU-
ITY 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?
• 50 - CHECK THE RIGHT LIGHT SWITCH CONNECTOR, THE CABLES FROM THE CON-
NECTOR 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 CON-
TROL 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?
• 56 - IS THERE CONTINUITY WITH THE GROUND OF THE BLUE CABLE OF THE START-
UP REMOTE CONTROL?
• 57 - REPLACE THE RELAY - END

TROUBL - 50

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 ex-
ceeded 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
• 1 - KEY ON, THE INSTRUMENT PANEL DOES NOT TURN ON
• 2 - IS THE FUEL PUMP ACTIVATED?
• 3 - CHECK THE INSTRUMENT PANEL CONNECTOR AND CHECK IF THERE IS CON-

TINUITY IN THE GREEN CABLE FROM AUXILIARY FUSE TO PIN 1 OF THE INSTRU-
MENT PANEL CONNECTOR - END
• 4 - DETACH THE MAIN INJECTION RELAY: IS IT ON THE GREEN/BLACK CABLE?
• 5 - DETACH THE KEY SWITCH CONNECTOR: IS THERE VOLTAGE IN THE WHITE/RED

CABLE?
• 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 - 51
• 8 - IS THERE VOLTAGE IN THE WHITE/RED CABLE?
• 9 - SLIDE OFF THE AUXILIARY 15A FUSE: IS THERE VOLTAGE IN THE RED/BLACK
CABLE?
• 10 - CHECK THE INSTRUMENT PANEL CONNECTOR AND CHECK IS THERE IS CON-

TINUITY 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 INJEC-
TION RELAY CONNECTOR - END
Service
CAUTION
• 1 - "EFI" WARNING LIGHT IS ON AND THE WORD "SERVICE" IS SHOWN ON THE DIS-
PLAY
• 2 - CONNECT TO AXONE SELECTING "PETROL INJECTION": ARE THERE ANY CUR-
RENT ERRORS?
• 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?
• 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 CON-
TROLS/INSTRUMENT PANEL/DIAGNOSIS CHAPTER) AND RESTORE THE CORRECT
OPERATION.
TROUBL - 52
• 11 - HAS THE INSTRUMENT PANEL BEEN REPLACED?

• 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 "DIAG-
NOSIS" FUNCTION OF THE INSTRUMENT PANEL - END
Belt
CAUTION
• 1 - WORD "BELT" SHOWN ON THE DISPLAY
• 2 - IS THE "EFI" WARNING LIGHT ON AND THE GEARSHIFT IN "AUTOMATIC - RAIN"
MODE?
• 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) SECONDARY 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 ER-
ROR IS PRESENT: FOR FURTHER INFORMATION ABOUT THE ERROR AND ITS POSSIBLE
CAUSES, PUSH BUTTON "?". THE AMBIENT PARAMETERS RELATED TO THE ERROR CAN ALSO
TROUBL - 53
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?
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 "ELEC-
TRICAL SYSTEM/CHECKS AND CONTROLS/DRIVING PULLEY POSITION SENSOR/ADJUSTA-
BLE 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 ELEC-
TRICAL SYSTEM/CHECKS AND CONTROLS/DRIVING PULLEY POSITION SENSOR/ADJUSTA-
BLE PARAMETERS - END
H-F-M
CAUTION
• 1 - LETTERS "H"; "F" OR "M" ARE SHOWN ON THE DISPLAY
• 2 - "H" DISPLAYED?
• 3 - IN THE INSTRUMENT PANEL, GO TO "MENU/CONTROL (on handlebar) ENABLING:

ARE THEY ENABLED?
• 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 - 54
• 5 - FIND THE MALFUNCTION (SEE THE "ELECTRICAL SYSTEM/CHECKS AND CON-

TROLS" 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
• 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 COMMU-
NICATE WITH THE CONTROL UNIT?
• 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 CONNEC-
TOR AND AUXILIARY FUSE BOX.
OIL BULB
CAUTION
• 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 CON-
TROLS/INSTRUMENT PANEL/DIAGNOSIS" CHAPTER AND RESTORE THE CORRECT
OPERATION
• 4 - HAS THE INSTRUMENT PANEL BEEN REPLACED?
• 5 - STORE ALL THE KEYS THE FIRST TIME THE INSTRUMENT PANEL IS SWITCHED
ON - END
TROUBL - 55
• 6 - DELETE THE ERROR WITH THE "ERROR CLEARING" FUNCTION IN THE "DIAG-
NOSIS" FUNCTION OF THE INSTRUMENT PANEL - END
TROUBL - 56
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

Electrical system NA 850 Mana ABS
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

MAIN INJECTION RELAY

AUXILIARY INJECTION RELAY

FAN CONTROL RELAY

START-UP RELAY

• Location on the vehicle: under the saddle.
RETENTION RELAY

HIGH-BEAM LIGHT RELAY

• Location on the vehicle: under the helmet compartment, next to the left fork.
RESISTANCE MODULE

• 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 - 58
NA 850 Mana ABS Electrical system
Electrical system installation
Motorcycle division
The wiring timing 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 recon-
nected and clamps and retainers restored.
• For the following connectors, check the connection and the correct tightening of the Sec-
ondary 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.
ELE SYS - 59
• THE CONNECTORS LISTED ARE CONSIDERED CRITICAL IN COMPARISON WITH

ANY OTHER BECAUSE THE VEHICLE WILL STOP IF THEY ARE ACCIDENTALLY DIS-
CONNECTED.
• Undoubtedly the connection of the rest of connectors is also important and essential for the
correct operation of the vehicle.
Front side
TABLE A
4 flexible rubber clips
TABLE B
2. Clamps 98x2 (3.86x0.08)
3. Grey reference tape between both clamps
TABLE C
ELE SYS - 60
TABLE D - Left light switch cables laying.

The thinnest cable must be placed inside.
TABLE E
4. Flexible rubber clips
TABLE F - Front ABS sensor fitting
• 3 Black nylon clamps

• White cable guide
TABLE F1
Cable laying
ELE SYS - 61
TABLE F2
The ABS front sensor cable must go through be-
hind the headlight
Fasten it with a black nylon clamp
TABLE G
6. ABS grommet
Pay attention to the front ABS hose guides pas-
sage so as not to flatten them.
TABLE H
7. Rear ABS system oil pipes
8. Front ABS system oil pipes
Be very careful when placing the rear pump-con-
trol unit pipes, insert the two pipes in the respective
lower clamps.
9. Modulator
ELE SYS - 62
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
Central part
TABLE A - COILS
1. Part for fitting ground terminals, on coil assembly.
2. Cable guide
ELE SYS - 63
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 - 64
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 - 65
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 - 66
TABLE O
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 - 67
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
ELE SYS - 68
TABLE R
19. The light switch connections must be placed
on the chassis pipe
20. The flywheel cable passes under the main ca-
ble 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 - 69
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 - 70
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 connec-
tor
Note - fasten the cable harness with a 178x4
(7.008x0.157) black clamp
TABLE ZF
25. Rear ABS sensor connector
26. Black nylon clamp
ELE SYS - 71
TABLE ZG
The lambda probe and rear stop switch ca-
bles must pass BEHIND the braking system pipes
Back side
TABLE A
1. Clamp to chassis
Perform cable taping where indicated by the ar-

row.
TABLE B - Rear headlight cable harness

2. Rear headlight connector
3. 2 Clamps code
TABLE C - Rear ABS sensor fitting

4. Black cable guide
5. Black nylon clamp
ELE SYS - 72
Note - The sensor cable must pass ABOVE the brake pipe.
TABLE D
2 black nylon clamps
ELE SYS - 73
General wiring diagram
KEY
1. MULTIPLE CONNECTORS
2. PULLEY POSITION SENSOR
3. START-UP CONTROL RELAY
4. PULLEY SPEED SENSOR
ELE SYS - 74
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 - 75
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 - 76
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, DIFFER-
ENT 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 correct
position on the component or on the coupling con-
nector, making sure that the locking catch is re-
leased.
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 termi-
nals are not loose, open/bent, etc.). For connec-
tors 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.
ELE SYS - 77
3. Pulling the cables slightly from the back of the connector in order to check the correct position of
terminals on the connector and of the cable on the terminal.
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 IRRELE-
VANT.
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 CIR-
CUIT.
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 ac-

cording 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.
ELE SYS - 78
Given this, and for some kinds of problems, the

engine can be started only if the side stand is up.
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 in-
strument 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 disconnec-
tion icon is displayed on the instrument panel and
the red general warning light turns on to signal this
condition.
ELE SYS - 79
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 "han-
dlebar" (handlebar control) and M is for
"mode" (gear mode selection).
In case of alarms related to the transmission con-
trol 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.
ELE SYS - 80
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 auto-

matically 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.
ELE SYS - 81
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 TO REFER TO THE ERROR
INDICATIONS GIVEN BY NAVIGATOR 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 connec-
ted 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 fault: key code read but not recognised.
ELE SYS - 82
DSB 02 - Immobilizer fault: key code not read (key not present or transponder not working)
DSB 03 - Immobilizer fault: aerial not working (open or short-circuited)
DSB 04 - Internal controller fault
DSB 05 - -
DSB 06 - Ambient air temperature sensor
Error cause
• An oil sensor fault 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 fault 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 fault 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 Navigator 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 INSTRU-

MENT.
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:
ELE SYS - 83
• 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
• ESPAÑOL
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 - 84
• 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 de-
tected 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 SHORT TO GROUND / OPEN CIRCUIT NO ERROR WILL APPEAR: SEE THE TROU-
BLESHOOTING CHAPTER, THE ENGINE DOES NOT START.
Checking the idle speed adj.system

IDLE REGULATION SYSTEM CHECK
Function
It checks the air flow in the inlet manifolds bypass-
ing the throttle valve.
The opening position is set by the injection control
unit and is performed by means of a Stepper elec-
trical 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
ELE SYS - 85
CAUTION
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 - 86
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 sup-
ply, 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, Lamb-
da 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 com-
partment.
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)
ELE SYS - 87
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
CAUTION
NAVIGATOR: 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 im-
mobilizer: 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 - 88
P0606 Microprocessor - circuit not operational.

Error cause
• Possible internal control unit error. Also check the control unit supply and ground connec-
tions.
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 fix-

ing 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 auto-
detection function using the diagnosis instrument
ELE SYS - 89
Speed sensor
VEHICLE FRONT SPEED SENSOR

FUNCTION:To indicate the vehicle speed by read-
ing the front wheel turning speed.
OPERATION / OPERATING PRINCIPLE:Magne-
toresistive sensor: a square-wave pulse is gener-
ated 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)
NAVIGATOR
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 interference.
ELE SYS - 90
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; pos-
sible 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 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, replace the speed sensor.
5D94 no acceleration after pressure reduction: Faulty sensor or missing sensor/tone wheel or ex-
cessive distance between the sensor and the tone wheel.
5D95 excessive speed measured: Faulty sensor or tone wheel, or tone wheel with wrong number of
teeth or wrong tyre size.
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 read-
ing the rear wheel turning speed.
OPERATION / OPERATING PRINCIPLE:Magne-
toresistive sensor: a square-wave pulse is gener-
ated with voltage approx. between 11.55 V and
11.25 V
WIRING DIAGRAM Level in wiring diagram: ABS.
ELE SYS - 91
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)
NAVIGATOR
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 interference.
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; pos-
sible 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.
ELE SYS - 92
5DA4 missing acceleration after pressure reduction: Faulty sensor or missing sensor/tone wheel
or excessive distance between the sensor and the tone wheel.
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
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.
Inductive sensor: sinusoidal-type generated volt-
age; 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 - 93
Pin-out:
1. Negative signal
2. Positive signal
CAUTION
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/RE-
PLACE 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.
ELE SYS - 94
Engine temperature sensor

ENGINE TEMPERATURE SENSOR
Function
it tells the engine temperature to the control unit so
as to optimise its operation.
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
• Resistance at 25°: 2.05 kOhm +/- 100

Ohm
• Resistance at 60°: 575 Ohm +/- 15
Ohm
• Resistance at 90°: 230 Ohm +/- 5 Ohm
Pin-out:
• Orange: 0-5 V signal: PIN B1

• Grey: Ground connection: PIN B2
CAUTION
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 - 95
• 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 sen-
sor; 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 Navigator if the temperature indicated is the
same as the engine temperature. Check also that the sensor electrical characteristics are ob-
served: 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 opti-
mise the petrol quantity necessary for correct com-
bustion.
Location:
ELE SYS - 96
• on the vehicle: on throttle body

• on connector sensor: on throttle body
• Resistance at 0°: 5.9 kΩ ± 5%

Pin-out:
1. 0-5 V signal: PIN 1

2. Ground connection: PIN 2
CAUTION
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
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 har-
ness 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 - 97
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 Navigator if the temperature indicated is
plausible in relation to the ambient temperature. Check also that the sensor electrical charac-
teristics 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.
The Marelli injection control unit reads and inter-
prets a voltage generated by the difference in oxy-
gen 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 up-
per metal bracket.
• Heater circuit: 7-9Ω at Ambient temp.
Pin-out:
1. Sensor signal + (grey wire)

2. Sensor signal - (black wire)
ELE SYS - 98
3. Heater ground connection (white)

4. Heater power supply (white)
CAUTION
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
ELE SYS - 99
• 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 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 resist-
ance: 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 nec-
essary to restore the cable harness.
Injector
INJECTOR
Function
To supply the correct amount of petrol at the right
timing.
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
ELE SYS - 100

CAUTION
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
Rear injector P0201 - shorted to positive / shorted to negative / open circuit.

Error cause

(BROWN).
• If the circuit is open: an interruption has been detected.
Troubleshooting
ELE SYS - 101

• 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
Fuel pump
• 0.7 +/-0.2 Ohm.
CAUTION
ACTIVATION
Fuel pump:
Operation for 30 seconds.
ELECTRICAL ERRORS
Fuel pump relay P0230 - shorted to positive / shorted to negative / open circuit.
Error cause
• If the circuit is open: an interruption has been detected.
ELE SYS - 102

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 gen-
erate the fuel ignition spark.
With inductive discharge: 2 coils with double sec-
ondary circuit (Twin spark)
Level in wiring diagram:Coils and injectors
Location:
• Under helmet compartment: Right coil

(rear cylinder) and Left coil (front cylin-
der)
• Primary circuit resistance: approx.

0.57 Ω at 20°C between PIN 1 and 2
• Secondary circuit resistance: approxi-
mately 7.3 Ohm at 20°C
Pin-out:
1. Supply + batt V
2. Activation from control unit
ELE SYS - 103

CAUTION
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 dis-
played in case of lack of activation.
ELECTRICAL ERRORS
Right coil (rear cylinder) P0351 - shorted to positive / open circuit, shorted to negative.
Error cause
(BROWN).
• If the circuit is open, short circuit to negative: voltage equal to zero has been detected
Troubleshooting
ELE SYS - 104

• 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 be-
tween 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, dis-
connect 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

(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 be-
tween 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, dis-
connect 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.
ELE SYS - 105

Throttle body
THROTTLE BODY
• Function
To tell the position of the throttle to the throttle

control unit.
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
• PINS A-C: throttle closed approximate-

ly 2.5 kOhm; throttle open approxi-
mately 1.5 kOhm.
• PINS A-B: approximately 1.1 kOhm.
Pin-out:
• A - Ground connection
• B - Supply voltage + 5V
• C - Potentiometer signal
CAUTION
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 - 106

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
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 - 107

Connector location: on the sensor

Pin-out:
1. Voltage 5V
CAUTION
Instrument panel
Error DSB 07
Error cause
• An oil sensor fault 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. There is an error when
the general warning light turns on.
Troubleshooting
• Check the sensor connector and the instrument panel connector (PIN 17): if they are not
OK, restore. If OK, check 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 fault 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
• Check if oil pressure is low with the specific gauge.
ELE SYS - 108

Side stand sensor
SIDE STAND SENSOR

Function
It tells the side stand position to the control unit.
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)
• Side Stand Up: closed circuit (continu-

ity)
• Side Stand Down: open circuit (infinite
resistance)
Pin-out:
2. Voltage 12V
CAUTION
STATUSES
Side stand
Example value:up/down
Troubleshooting
ELE SYS - 109

• Indication on Axone always down: check the connector: if not OK, restore; if it is OK, dis-
connect 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.
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
• Sensor in vertical position: open circuit

(resistance: 62 kOhm)
• Sensor inverted: closed circuit (con-
tinuity)
Pin-out:
2. Voltage 5V
CAUTION
ELE SYS - 110

PARAMETERS
Fall sensor
Example value: Normal / Tip over
Troubleshooting
• Indication on Axone always Normal, even when the sensor is inverted: disconnect the con-
nector 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 con-
nector B "BLUE")
• Indication on Axone always Tip over: disconnect the connector and check if there is con-
tinuity 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 instru-
ment panel.
Location:
• on the vehicle: on the plastic protection

under the instrument panel
• connector: under the instrument panel
• Resistance at 0°C: 32.5 kOhm +/- 5%

• Resistance at 25°C: 10.0 kOhm +/- 5%
ELE SYS - 111

Pin-out:
1. Voltage 5V
CAUTION
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 con-
tinuity 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 con-
nector 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 con-
tinues 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 - 112

Function
Radiator fan and coolant - Operation.
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.
• relay normally open;

• drive coil resistance 110 Ohm (+/- 10 %)
STATUSES
Fan relay
Example value:on / off.
CAUTION
ELECTRICAL ERRORS
Fan relay P0481 - shorted to positive / open circuit, shorted to negative.
Error cause
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 dis-
connecting 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).
ELE SYS - 113

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
• 150 Ohm +/- 20 %
Pin-out:
1. Ground.
2. Supply.
CAUTION
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.
If the driver wants to shut off the engine or to dis-
able engine start-up, the switch should be open,
i.e. the Marelli control unit should not detect volt-
age at PIN 27 of connector B "BLUE".
Level in wiring diagram:Start-up enabling
switches.
Location:
• on the vehicle: right light switch
ELE SYS - 114


compartment, along upper frame.
• STOP position: the circuit is open

• RUN position: closed circuit (continui-
ty)
Pin-out:
1. Green/orange cable: ground connection

2. Yellow/grey cable: voltage 12V
CAUTION
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 har-
ness; 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.
ELE SYS - 115

Transmission control unit
Function
It controls the TRANSMISSION system.
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
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 - 116

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).
ACTIVATION
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 - 117

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 trans-
mission. 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).
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 - 118

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: Allows you to enter the gearshift stroke category in case of
a new control unit (display of the category in the parameters screen page, see also Driving pulley
position sensor).
Gearshift stroke default value setting: Allows you to enter the default value for the gearshift stroke
category in the event of replacement of the variator components that affect the gearshift stroke. 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 Potenti-
ometer reset procedure (driving pulley). It is also recommended to insert the Gearshift stroke category,
via the gearshift stroke category insertion adjustable parameter, read in the previous control unit (the
value is present in the control unit and on the half-pulley only from vehicles manufactured after February
2008). If you do not enter the Category, the control unit 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.
GEARSHIFT STROKE CATEGORY UPDATE ON THE TRANSMISSION ECU
NOTE
THIS OPERATION MUST BE PERFORMED IF DURING ROUTINE OR EXTRAORDINARY MAIN-

TENANCE, THE GEARSHIFT STROKE CATEGORY SET IN THE TRANSMISSION ECU SHOULD
BE 0.
• Check through the diagnosis instrument for any errors in the transmission ECU from the
"errors" menu. Erase them is necessary.
• Take the measurement of the gearshift stroke to identify the category to which it belongs.
NOTE
THIS PROCEDURE IS ALSO VALID IN THE EVENT OF REPLACING THE TRANSMISSION ECU.
• Perform the gearshift stroke category operations from the "settings" menu of the diagnosis
instrument.
CAUTION
ELE SYS - 119

AFTER ENTERING THE GEARSHIFT STROKE CATEGORY FROM THE "SETTINGS" MENU OF
THE DIAGNOSIS INSTRUMENT, YOU MUST PERFORM A KEY OFF/ON TO STORE THE DATA
ON THE CONTROL UNIT.
• Check that the gearshift stroke category has been stored correctly from the "parameters"
menu of the diagnosis instrument.
• Perform the belt replacement operation from the "parameters" menu of the diagnosis in-
strument.
• To determine the gearshift class category, see the procedure in chapter "Motor - Automatic
transmission - Driving pulley fitting"
See also
Refitting the driving pulley
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
Function
It tells the position of the driving half-pulley to the
transmission ECU.
It is a double track potentiometer, with inversely
proportional voltage variation.
Level in wiring diagram:transmission manage-
ment
Location:
• on the vehicle: on the upper part of the

transmission cover.
• connector: directly on the sensor.
ELE SYS - 120

• Track resistance (pin 1-5 or 2-3): 1.5

kΩ.
• Signal resistance (pin 4-5 or 3-6): Min
1.0 kΩ (released sensor) - Max. 2.5 kΩ
(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 BEGIN-
NING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
CAUTION
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
ELE SYS - 121

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.
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
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
It should be a value between 0.5 and 2.5 mm.
Movement of the first gear in relation to the saved position (wear)
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.
STATUSES
Example value:Invalid data / Valid data
ELE SYS - 122

If the "Invalid Data" message is displayed, it means that the parameter value in the Engineering pa-
rameters screen page is not correct.
Example value:Invalid data / Valid data
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 ob-
serve, 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.
• 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 ob-
serve, with the diagnosis instrument, if the voltage value of the "Driving pulley position
ELE SYS - 123

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.
Troubleshooting
• 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.
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).
ELE SYS - 124

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
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.
Inductive sensor: sinusoidal alternating current is
generated (approximately 0.7 V at idle speed) for
the transmission ECU reading.
Level in wiring diagram:transmission manage-
ment
Location:
• on the vehicle: on the crankcase cover,

driven pulley upper part.
• under the fuel tank (within the protec-
tive rubber cap).
Electrical specifications: Coil resistance at Am-

bient 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 BEGIN-
NING OF THE CHECK AND CONTROL SECTION IN THE
ELECTRICAL SYSTEM CHAPTER.
ELE SYS - 125

CAUTION
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
ERRORS
Driven pulley rotation sensor Code 9004 - no signal/ signal not valid/ below minimum threshold.
Error cause
• If there is no signal: detects an interruption of the electrical circuit to 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 con-
tinuity 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
ELE SYS - 126

0.7 V at idle speed, check the correct position of the sensor. Phase 1: check if upon dis-
connecting 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 shor-
ted to ground connection).
NOTE
THE SPEED SENSOR FAILURE IS ALSO INDICATED ON THE INSTRUMENT PANEL WITH THE
MESSAGE "GEAR ERROR".
THE "VEHICLE SPEED SENSOR" ERROR WILL APPEAR ON THE DIAGNOSIS INSTRUMENT
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
The circuit is made up of a switch that, when acti-
vated, modifies the circuit resistance and conse-
quently the voltage detected.
Level in wiring diagram: transmission manage-
ment
Position:
• gear mode control on vehicle: right light

switch
compartment, along upper frame
Electrical characteristics
Released switch 860 +/- 5% Ohm
Pressed switch 180 +/- 5% Ohm
Pin-out:
ELE SYS - 127

1. power supply + 5 V
2. ground connection
CAUTION
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 ap-
proximately 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.
21….28, control unit PIN C1….C8 and interface PIN interface 31….38
ERRORS
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
ELE SYS - 128

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 change the variator transmission ratio (gear shift
in manual gear mode).
Either control (+) or (-) is made up of a deviator
with both outputs electrically connected to the
transmission ECU.
ment
Position:
• pedal gearshift control on vehicle: ped-

al gearshift lever
• connector: under the fuel tank (inside
the rubber protection housing)
Electrical characteristics
Gear upshift:
• 0 Ohm, between PIN C5 and PIN A7,

• 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)
ELE SYS - 129

• 4 - supply + 12 V (green - black/yellow)

• 8 - supply + 12 V (yellow - blue/yellow)
CAUTION
STATUSES
Pedal gear upshift control
Pedal gear downshift control
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
• 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
ELE SYS - 130

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
• 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
ELE SYS - 131

from PIN A6 to PIN C5 or that PIN C5 does not have a ground connection: check the trans-
mission 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 gear-
shift 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.
Gearshift lever on the handlebar
GEARSHIFT CONTROL ON HANDLEBAR

Function
to change the variator transmission ratio (if trans-
mission in manual mode).
Either control (+) or (-) is made up of a deviator
with both outputs electrically connected to the in-
strument panel: at the same time, the instrument
panel sends the requested command to the trans-
mission ECU, via CAN line.
ment
Position:
• handlebar gearshift control on vehicle:

left light switch
• connector: behind front headlight, un-
der the instrument panel
ELE SYS - 132

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)
• 8 - supply + 12 V (red - blue/yellow)
CAUTION
STATUSES
Handlebar gear upshift control
If the "Invalid Data" message is displayed, it means that a malfunction has been detected.
Handlebar gear downshift control
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
ELE SYS - 133

• 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
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 con-
nector (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 (approxi-
mately 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 con-
tinuity 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 (be-
tween 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
ELE SYS - 134

• 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; discon-
nect 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 sen-
sor. 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 instru-
ment 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
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 con-
nector (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
ELE SYS - 135

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.
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
• Winding resistance < 1 Ohm
• Input: nominal 10A
• Maximum input: 22 A
Pin-out:
1. Red
2. Black
PARAMETERS
Driving pulley control electrical motor duty cycle
Example value: %
It is a speed indicator of the driving half-pulley movement in axial direction.
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
ELE SYS - 136

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 har-
ness; otherwise, replace the transmission ECU.
Drive belt replacement due to wear
• Check through the diagnosis instrument for any errors in the transmission ECU from the
"errors display" menu. Erase them if necessary.
• Take the measurement of the gearshift stroke to identify the category to which it belongs.
NOTE
THIS PROCEDURE IS VALID EVEN IN THE EVENT OF REMOVAL AND/OR REPLACEMENT OF

COMPONENTS OF THE VARIATOR UNIT.
• Replace the transmission belt.
• Perform the potentiometer reset operations from the "Settings" menu of the diagnosis in-
strument. Delete any errors.
• Perform the gearshift stroke category operations from the "settings" menu of the diagnosis
instrument.
CAUTION
AFTER ENTERING THE GEARSHIFT STROKE CATEGORY FROM THE "SETTINGS" MENU OF
THE DIAGNOSIS INSTRUMENT, YOU MUST PERFORM A KEY OFF/ON TO STORE THE DATA
ON THE CONTROL UNIT.
• Check that the gearshift stroke category has been stored correctly from the "parameters"
menu of the diagnosis instrument.
• Perform the belt replacement operation from the "parameters" menu of the diagnosis in-
strument.
• To determine the gearshift class category, see the procedure in chapter "Motor - Automatic
transmission - Driving pulley fitting"
See also
DRIVING PULLEY CONTROL ELECTRICAL MOTOR

Function
ELE SYS - 137

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.
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
• Winding resistance < 1 Ohm
• Input: nominal 10A
• Maximum input: 22 A
Pin-out:
1. Red
2. Black
PARAMETERS
Driving pulley control electrical motor duty cycle
Example value: %
It is a speed indicator of the driving half-pulley movement in axial direction.
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
ELE SYS - 138

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 har-
ness; otherwise, replace the transmission ECU.
Connectors
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
ELE SYS - 139

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.-
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
ELE SYS - 140

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. -
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.-
ELE SYS - 141

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 - 142

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
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
ELE SYS - 143

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
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 - *
ELE SYS - 144

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
ABS Modulator
INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR
• Check the initial position of the lever that couples the connector.
• When the connector is fully inserted,

the distance between the connector
and the ABS control unit must be 7.5
mm (0.29 in).
ELE SYS - 145

• If the initial position of the connector

and the driving lever is not that shown
in fig. 1, the connector will not be prop-
erly coupled and the distance meas-
ured will be greater (12 mm approx.
(0.47 in)). In this case repeat the oper-
ation as described in the two previous
points.
IT IS ADVISABLE TO CREATE A TEMPLATE

TO CHECK THE CORRECT CONNECTOR IN-
SERTION.
• Insert the housing as shown in the fig-

ure.
Can line
CAN line
Function
It allows communication between the Marelli injection control unit, the transmission ECU and the in-
strument 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
ELE SYS - 146

• 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
• 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 con-
ELE SYS - 147

nector: 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 con-
nector: 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.
Troubleshooting
• 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.
ELE SYS - 148

INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Engine from vehicle NA 850 Mana ABS
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 connec-
tor.
• Remove the rear ABS sensor.
• Disconnect the rear stop switch con-

nector.
• Disconnect the fall sensor connector.
• Disconnect the pickup connector.
ENG VE - 150
Engine NA 850 Mana ABS
Inspecting the cover components
- Check the condition of the stator and of the rele-

vant cable harness.
- Check the continuity between the 3 phases.

NOTE
THE VALUES ARE STATED AT AMBIENT TEMPERATURE.
A CHECK WITH THE STATOR AT OPERATING TEMPERA-
TURE MAY RESULT IN VALUES HIGHER THAN THOSE
STATED.
Electric characteristic
Resistance:
0.2 ÷ 1 Ω
- 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 con-
nector.
- Check that the winding is placed so as not to in-

terfere with the heads of the fixing screws.
ENG - 174
NA 850 Mana ABS Engine
Flywheel components check
- Check that the magnets are in good conditions.

- Check that the magnet support cage is not de-
formed 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, mak-

ing 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 se-
quence to the prescribed torque.
- Lubricate the freewheel «rollers».
ENG - 175
Stator installation
- Fit the stator together with the cable harness, fix-

ing 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 MAG-
NETISM OF THE FLYWHEEL. BE SPECIALLY CAREFUL WITH YOUR HANDS.
Flywheel cover screws 11 - 13
Head and timing

Schema
ENG - 176
Removing the intake manifold
- Remove the coolant pipes.
- Undo the six fixing screws.
- Remove the inlet manifold.
Removing the head cover
- Undo the 6 special screws with stop and the rel-

evant rubber gaskets.
- Remove the tappet cover with the relevant gas-
ket.
ENG - 177
Removing the timing control
- As indicated in the photograph, align the refer-

ences on the timing system gear of the rear cylin-
der with the reference on the valves cap.
NOTE
PLACING THE ENGINE AS INDICATED, IT IS IN THE COM-
BUSTION 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 pho-
tograph and remove the tensioner with the rele-
vant gasket.
- Lock the timing system gear with the specific tool,

undo the central fixing screw and collect the wash-
er.
- Release the chain from the sprocket and be care-
ful 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
- 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
ENG - 178
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.
- 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 wash-
ers.
ENG - 179
- Undo the spark plug side screw.
- Undo the two screws inside the head, timing sys-

tem side.
- 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 re-

taining bracket.
NOTE
REMOVING THE FIXING SCREWS MAY BE DIFFICULT. BE
CAREFUL NOT TO DAMAGE THE INTERNAL HEXAGON.
IF NECESSARY, DETACH THE THREADS IN ADVANCE.
ENG - 180
- 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 EXTER-
NAL SHOULDER, CROWN GEAR SIDE.
- Remove the pins and the rocking levers acting

from the transmission-side holes.
Removing the valves
- Using the appropriate tool fitted with an adapter, remove the cotter pins, plates, springs and valves.
Specific tooling
CAUTION
ARRANGE THE VALVES SO AS TO RECOGNISE THEIR
ORIGINAL POSITION ON THE HEAD (FLYWHEEL-SIDE
AND TRANSMISSION-SIDE).
ENG - 181
- Remove the oil seals with the specific tool.
Specific tooling
020431Y Valve oil seal extractor
ENG - 182
- Remove the spring supports.

NOTE
BLOW THE SEATS WITH COMPRESSED AIR TO FACILI-
TATE REMOVING THE SPRING SUPPORTS.
Checking the overhead camshaft
- Check the camshaft bearings for signs of abnor-

mal wear or scores.
- Using a micrometer, measure the camshaft bear-
ings.
STANDARD DIAMETER
Bearing A Ø: 42- 0.060 -0.085 mm
Bearing B Ø: 20- 0.020 -0.041 mm
MINIMUM DIAMETER ALLOWED

Bearing A Ø: 41.910 mm
Bearing B Ø: 19.940 mm
- Using a gauge, measure the height of the cams.
LIMITS ALLOWED
Inlet: 33.740 mm
Outlet: 33.170 mm
Standard axial clearance: 0 ÷ 0.22 mm
Maximum axial clearance allowed: 0.3 mm
ENG - 183
STANDARD HEIGHT
Inlet: 33.988 mm
Outlet: 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:
Ø 13 - 0.010 -0.018 mm
See also
Assembly clearances
Checking the rocker arms
- Check the inside diameter of each rocking lever.
Characteristic
Standard diameter:
Ø 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.
ENG - 184
VALVE STANDARD LENGTH

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

Inlet: 4.96 mm
Outlet: 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 ex-
tent of the deformation using a dial gauge.
Characteristic
Limit value allowed:
0.1 mm
ENG - 185
- 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
- Check that there are no signs of wear on the fay-

ing 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 fine-
grained lapping compound. Upon grinding, keep
the cylinder head with the valve axles in a hori-
zontal position. This will prevent the lapping com-
pound residues from penetrating into the stem-
valve guide coupling.
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT RO-
TATE 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 exhaust valves.
- The test should be carried out by filling the mani-
fold with fuel and checking that the head does not
ooze through the valves when they are just press-
ed by the fingers.
ENG - 186
See also
Installing the
cylinder head
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 compo-
nent.
- Measure the unloaded spring length.

NOTE
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
- Measure the unloaded spring length.
Characteristic
Standard length:
44.4 mm
Limit allowed after use:
42.4 mm
See also
Installing the
cylinder head
Checking the valve guides
Measure the valve guides.
Characteristic
Valve guide:
5+0.012 mm
ENG - 187
- After measuring the valve guide diameter and the

valve stem diameter, check the clearance be-
tween guide and stem.
EXHAUST
Standard clearance: 0.025 - 0.052 mm
Limit allowed: 0.09 mm
INTAKE
Standard clearance: 0.013 ÷ 0.04 mm
Limit allowed: 0.08 mm
See also
Installing the
cylinder head
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 dis-
torted.
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.
ENG - 188
Measure the camshaft seat bearings and rocking

lever support pins with a bore meter
HEAD BEARINGS
Bearing "A" 42 +0.025
Bearing "B" 19.5 -0.2
Bearing "C" 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 seal rings
ENG - 189
- 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
NOTE
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REF-
ERENCE COLOUR ON THE COTTERS SIDE (TURNS WITH GREATER PITCH).
ENG - 190
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
ENG - 191
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
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
ENG - 192

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 driv-

ing pulley to turn the crankshaft until on the fly-
wheel the rear cylinder timing reference mark «1»
is aligned to the crankcase reference, correspond-
ing to the rear piston top dead centre.
- Fit the tone wheel and the timing system gear

with the chain and align the reference marks.
ENG - 193
- Once the reference marks are aligned as indica-

ted 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 clear-

ance of the valves.
Characteristic
Valve clearance
Inlet: 0.15 mm
Outlet: 0.15 mm
ENG - 194
- Turn the crankshaft in the normal operating di-

rection 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.
ENG - 195
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 IN-
SIDE.
- 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 sur-
faces 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 - 196
CYLINDER CHECK
B 43 mm (1.69 in)
Cylinder Ø C 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 - 197
PISTON CHECK
Piston Ø P (aluminium cylinder) 87.968 mm (+/- 0.014 mm) (3.4632 in (+/- 0.0005)in)
A 10 mm (0.393 in)
Piston Ø P (iron cast cylinder) 87.947 mm (+/- 0.014 mm) (3.4625 in (+/- 0.0005)in)
A 10.5 mm (0.413 in)
Inspecting the wrist pin

NOTE
TER.
Inspecting the piston rings

NOTE
TER.
Checking the connecting rod small end

NOTE
TER.
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 INSTALLED WITH THE ARROW
POINTING IN THE DIRECTION OF ROTATION OF THE EN-
GINE, WHILE THE PISTON RINGS MUST BE INSTALLED
WITH THE «TOP» REFERENCE MARKING OR THE BRAND
FACING UPWARD.
ENG - 198
- 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
ENG - 199
any case, the tapered side of the ring must be fac-

ing 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 CY-
LINDRICAL CONTACT SECTION. THIS IS TO OBTAIN A
BETTER BEDDING.
- Offset the piston ring openings by 120º 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 thick-

ness.
- 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 REF-
ERENCE DOWELS.
Specific tooling
AP8140302 tool for sealing ring fitting
020716Y Connecting rod locking
- Remove the specific tool.
ENG - 200
- 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.
ENG - 201
- 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 main-
tained
- 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 VAL-
UE OF THE PISTON CROWN COMPARED WITH THE CYL-
INDER PLANE.
MEASUREMENT «A» ALLOWS TO DETERMINE THE
THICKNESS OF THE GASKET «B» THAT HAS TO BE FIT-
TED 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 CYLIN-
DER BASE «B» SHOULD BE. ON THE OTHER HAND, THE
MORE THE PISTON CROWN IS RECESSED INTO THE CYL-
INDER TOP PLANE, THE SMALLER THE GASKET THICK-
NESS.
Characteristic
Compression ratio
10.5 ± 0.5 : 1
BASE GASKET THICKNESS

Name Measure A Thickness
MEASURE TAKEN «A» - 0.185 ÷ - 0.10 0.4 ± 0.05
MEASURE TAKEN «A» - 0.10 ÷ + 0.10 0.6 ± 0.05
MEASURE TAKEN «A» + 0.10 ÷ + 0.185 0.8 ± 0.05
NOTE
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»
Installing the cylinder head
- 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 - 202
- 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 per-

fectly 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 ***
ENG - 203
*** 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 at 90° in a criss-crossed sequence.
- Tighten the fixing nuts on the outlet side and the

intake side to the prescribed torque.

ENG - 204
- Tighten the two internal screws on the head, tim-

ing system side, to the prescribed torque.

- Fit the coolant temperature sensor with the wash-

er 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 pre-
scribed timing.

Rpm timing sensor screw 7.5 ÷ 8.5 Nm
- Fit the timing control chain on the crankshaft ob-

serving the initial direction of rotation.
- Fit the tensioner pad with the relevant spacer,
tightening the fixing screw to the prescribed tor-
que, using the recommended product.
-

ENG - 205
- 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.
-
- 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.
ENG - 206
- 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
ENG - 207
Installing the intake manifold
- When refitting always install, on both cylinders

between the inlet manifold and the cylinder head,
the inlet manifolds gasket to delete the air leak-
ages related to the deformation of the rubber mani-
fold by aggressive petrol.
- 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
ENG - 208
Crankcase - crankshaft
- Remove the transmission cover, the driving and the driven pulleys, as described in the «Automatic
transmission» chapter.
- 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 re-
moval» 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
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.
ENG - 209
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 cop-
per washers.
- Undo the twelve screws «C» and collect the
washers.
- Fit the specific tool on the flywheel side crank-

shaft, paying special attention that the tool match-
es 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.
ENG - 210
- Detach the crankcase half keeping the crankshaft

connected to crankcase half on the transmission
side.
- Remove the coupling gasket.
ENG - 211
- 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 COR-
RECT 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
ENG - 212
- 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 - 213
CHANNEL IS FITTED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRI-
CATION. 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
MAXIMUM OFF-LINE ALLOWED

A= 0.15 mm
B= 0.010 mm
C= 0.010 mm
D= 0.10 mm
ENG - 214
Inspecting the crankshaft plain bearings
- In order to obtain proper bushing lubrication,

make sure there are both an outstanding lubrica-
tion pressure (4.5 bar) and a good oil flow rate. To
that end, the bushings must be correctly posi-
tioned so as not to obstruct the oil supply channels.
- The main bushings are comprised of 2 half-bear-
ings, 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 HALF-
SHELLS COUPLING SURFACE SINCE THE ENDS ARE RE-
LIEVED 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
ENG - 215
- Bushings are subdivided into 3 categories according to their thickness. (See chart on the "Specifica-
tions" chapter)
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
MAIN BUSHINGS.
CAUTION
DUE TO THE TIP WEIGHT PAY ATTENTION TO THE COR-
RECT COUPLING AND FALLING RISKS OF THE TOOL,
ALWAYS HOLD IT WITH YOUR HANDS.
Specific tooling
020665Y Transmission side crankshaft fitting
tip
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 - 216
- Fit the crankshaft with the driving pulley axle in-

side the transmission side crankcase halves.
NOTE
PLACE THE CONNECTING RODS CORRECTLY.
- At the same time, hold with one hand the crank-

shaft 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 - 217
- Fit the specific tool on the flywheel side crank-

shaft, paying special attention that the tool match-
es the shaft perfectly.
CAUTION
MAIN BUSHINGS.
Specific tooling
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 - 218
- Remove the tip.
Specific tooling
ENG - 219
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.

- Fit the centring bushings, the washers and screw

the fixing nuts to the support.
- Turn the support so as to operate on the trans-
mission side.
- Screw the six screws «A» with the washers and
tighten to the prescribed torque.

- Fit a new oil seal in the transmission side crank-
case half on the driving pulley axle.
- Fit the oil seal manually being careful that the in-
ternal lips are correctly placed on the crankshaft.
- With a pipe of the indicated size, inside Ø XX,X

mm - outside Ø XX,X mm, set the oil seal at the
indicated distance, check with the gauge, accord-
ing to the indications described in the figure.
Lubrication
ENG - 220
Conceptual diagrams
LUBRICATION CIRCUIT
1 FRONT HEAD CAMSHAFTS
2 REAR HEAD CAMSHAFTS
3 CONNECTING ROD BUSHINGS
4 FRONT PISTON LUBRICATION JET
5 REAR PISTON LUBRICATION JET
6 STARTING RING GEAR BUSHING LUBRICATION
7 CRANKSHAFT BUSHINGS
8 WATER PUMP CONTROL TRANSMISSION GEAR SHAFT
LUBRICATION
9 WATER PUMP SHAFT LUBRICATION
10 MINIMUM OIL PRESSURE SENSOR
11 NON-RETURN VALVE
12 OIL CARTRIDGE FILTER
14 BY-PASS VALVE
13 OIL DELIVERY PUMP
16 RECOVERY OIL PUMP
15 FILLER NECK OIL
17 SUCTION ROSE
18 OIL DRAINAGE PLUG
19 OIL TANK
20 OIL TANK FILTER
21 OIL PASSAGE FROM THE HUB TO THE TANK
The RED arrows indicate the oil delivery circuit.
The BLUE arrows indicate the oil recovery circuit.
General characteristics
The lubrication system is divided into two sections:

- high pressure
ENG - 221
- 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 - 222
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
- 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 milli-
metres.
Specific tooling
020331Y Digital multimeter
CONTINUE - point 5
5 - Measure pressure with cold and idling engine.
STANDARD VALUES
20°C Temperature
1400 rpm
~ 4.5 bar

6 - Let the engine warm up and repeat the check with hot oil.
STANDARD VALUES
80°C Temperature
1400 rpm
~ 1.5 bar

7 - Replace the minimum oil pressure.
ENG - 223
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 80°C.
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.
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
15 - Replace damaged components.
16 - Overhaul the engine.
17 - Open the engine crankcase and remove the oil pump, as described in the "Crankcase and Crank-
shaft" 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 DETEC-
TED 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
CONTINUE - go to point 3
ENG - 224
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 - 225
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 ten-

sioner 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 EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED
Specific tooling
- Unscrew the two fixing screws and remove the

crankcase protecting the oil pump.
ENG - 226
- 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 - 227
- Remove the oil pump and the relevant gasket.
- Undo the four indicated screws.
- Remove the by-pass recovery duct with the gas-

ket.
Inspection
- The procedure is described only once but it is valid for both pumps.
ENG - 228
- Undo the two screws and remove the oil pump

cover.
ENG - 229
- Slide off the shaft with the rotor driving pin.

- Remove the two rotors and wash them thorough-
ly.
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 - 230
- 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 thick-

ness 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 - 231
- 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 SE-
RIOUS 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 crank-

case half:
- Fit the by-pass recovery duct, with the gasket and
tighten the four fixing screws to the prescribed tor-
que.

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 - 232
- Fit the oil scavenge pump and the bulkhead of

the oil anti-backflow plate.
- Tighten the two screws indicated to the prescri-
bed 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.

- Fit the oil pressure pump.
ENG - 233
- 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

Oil pump sprocket 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 - 234
Automatic transmission
Transmission cover
- Remove the variator motor, the driven pulley rev-

olution sensor and the driving pulley position sen-
sor.
CAUTION
FOR VEHICLES INCLUDED IN THE FOLLOWING RANGE
ZD4RC000_7S000002 - ZD4RC000_7S000737
IN ORDER TO FIT THE DRIVING PULLEY POSITION SEN-
SOR CORRECTLY, SEE THE "Engine" CHAPTER, "Trans-
mission 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 - 235
- 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 - 236
- Place the transmission cover on a wooden sur-

face and use the special tool so that it is adequate-
ly supported.
- Extract the bearing with the specific tool.
NOTE
BELL MUST BE PLACED INTO THE TRANSMISSION COV-
ER, 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
020357Y 32 x 35 mm adaptor
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
- Refit the Seeger ring.
ENG - 237
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
Fitting the bearings supporting the electric motor driving shafts
- Heat the transmission cover inside with a heat gun.
ENG - 238
- Fit the bearings on the specific tools and refit the

new bearings.
Specific tooling
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 - 239
Removing the driving pulley
Inspecting the clutch drum
- Make sure that the clutch bell is not worn or dam-

aged.
- 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
- 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 - 240
- Screw until the clutch is completely disassem-

bled.
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 - 241
- 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 DAM-
AGING THE THREADING.
Specific tooling
020456Y Ø 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 - 242
- Remove the roller bearing with the specific tool,

supporting the fixed half-pulley with the bell.
Specific tooling
020375Y 28 x30 mm Punch
020483Y 30-mm guide
Inspecting the driven fixed half-pulley
- Check that the belt contact surface is free from

wear.
- Measure the outside diameter of the pulley bush-
ing.
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 ex-
ternal O-rings.
- Measure the inside diameter of the movable half-
pulley bushing.
Characteristic
Maximum diameter allowed:
55.05 mm
Standard diameter:
55.00 +0.035 0.00 mm
ENG - 243
Refitting the driven half-pulley bearing
- Fit a new roller bearing with the specific tool.

NOTE
PLACE THE BEARING WITH THE WORDS AND THE BUILT-
IN 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
- Fit a new ball bearing with the specific tool.
Specific tooling
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 MACHIN-
ING END RADIUS; AT THE BASE OF THE HALF-PULLEY.
ENG - 244
- 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 brand grease for roller bearings with an oper-
ating temperature range of -30°C...+140°C (-22°F...+284°F), a drop point of 150°C...230°C (302°F...
446°F), high corrosion protection qualities and good water and rust resistance.
Inspecting the clutch spring
- Measure the length of the movable driven half-

pulley spring, when unloaded.
Characteristic
Standard length:
190.2 mm
Limit allowed after use:
182 mm
ENG - 245
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 CON-
TACT WITH OIL OR GREASE WHICH COULD MAKE THE
CONTACT SURFACES BETWEEN THE BELT AND THE
HALF-PULLEYS SLIPPERY.
Specific tooling
- 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 pre-

scribed 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 - 246
- Screw the tool so as to separate the two half-

pulleys.
- Position the belt.
- Unscrew until the tool frees from the half-pulley

and remove it.
ENG - 247
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 ex-
tracting the pulley).
ENG - 248
- Remove the movable pulley unit.
- Remove the driven pulley with the belt.
- Remove the clutch bell.
- Remove the driving half-pulley.
ENG - 249
- Remove the spacer.

NOTE
THE SPACER IS CONICAL, UPON REFITTING PAY ATTEN-
TION TO INSERT IT WITH THE SMALLER DIAMETER FAC-
ING THE INSIDE.
- Undo the five fixing screws and remove the air

switch.
- Unscrew the control bushing from the driving pul-

ley.
CAUTION
ALWAYS REPLACE THE TWO O-RINGS AND FIT WITH

GREASE TO PREVENT PINCHING.
- Remove the ring nut and the stop washer from

the driving pulley with a wrench available in the
market.
CAUTION
THE SAFETY WASHER MUST BE REPLACED AT EACH

REMOVAL.
ENG - 250
- Remove the complete advancement bushing.
- Undo the four fixing screws and remove the bear-

ing support.
- Remove the slider support with the relevant slid-

ers from the movable driving half-pulley.
ENG - 251
Driving pulley components check
- Check that the internal bushings are not abnor-

mally 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
35.050 mm
Standard diameter
35.000 +0.034 -0.009 mm
- Measure the outside diameter of the sliding bush-

ing.
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 - 252
- 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
10.040 mm
Standard diameter
10.000 +0.005 -0.030 mm
PROCEDURE FOR MEASURING THE GEAR-

SHIFT CLASS
• Insert the advancement bushing into

the hole, taking care that the teeth en-
gage with the slider supports and the
grooves of the advancement bushing
itself.
ENG - 253
• Position and tighten the pulley control

bushing to the end of stroke.
• Turn over the complete movable driv-

ing half-pulley and insert the spacer
until it stops.
• Using a depth gauge, measure the pro-

trusion of the spacer with respect to the
upper edge of the movable driving half-
pulley.
CAUTION
ONCE MEASURED, UNDO THE ADVANCEMENT BUSHING

BY ABOUT HALF A TURN.
CLASSES CONVERSION TABLE

CLASS CHECK POSITION VALUE (mm)
1 21.82 - 21.94
2 21.95 - 22.04
3 22.05 - 22.14
4 22.15 - 22.24
5 22.25 - 22.34
ENG - 254
6 22.35 - 22.44
7 22.45 - 22.54
8 22.55 - 22.68
- Fit the plate with the sliders on the movable driv-

ing half-pulley.
- Fit the bearing support being careful with the

dowel pin and tighten the four screws with Loctite
270.
ENG - 255
- Fit the advancement bushing.
- Fit the stop washer and tighten the ring nut with
the level surface facing upwards.
CAUTION
ALWAYS REPLACE THE TWO O-RINGS AND FIT WITH

GREASE TO PREVENT PINCHING.
CAUTION
THE SAFETY WASHER MUST BE REPLACED AT EACH

REMOVAL.
- Grease the control bushing with suitable grease,

as shown in figure.
- Screw the control bushing to the complete mov-
able 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 THERE IS A CORRECT GEAR BETWEEN THE
TOOTHED BUSHING AND THE SLIDER SUPPORT.
CAUTION
NO OTHER ELEMENT OF THE TRANSMISSION MUST BE

GREASED.
ENG - 256
- Preassemble the belt on the rear pulley with a special tool.
Specific tooling
- Fit the unit following the removal steps but in reverse order with the specific tool being careful to tighten
to the prescribed torques.
CAUTION
IN THE EVENT OF REPLACEMENT OF ONE OR MORE OF THE FOLLOWING COMPONENTS:
• SPACER (DIAM. 40 mm, LENGTH 50.5 mm)
• SLIDER SUPPORT
• BEARING SUPPORT (SLIDING) BUSHING
• BEARING SUPPORT
• FIXED DRIVING HALF-PULLEY
• MOVABLE DRIVING HALF-PULLEY
1) TO PREVENT THE RISK OF THE VARIATOR LOCKING IN SEVENTH GEAR, IN THE TRANS-
MISSION ECU SET THE "DEFAULT" VALUE OF THE GEARSHIFT STROKE AS SHOWN IN THE
CHAPTER "ELECTRICAL SYSTEM/CHECK AND CONTROLS/DRIVE PULLEY POSITION SEN-
SOR/ADJUSTABLE PARAMETERS".
2) NEVER TURN THE KEY TO ON BEFORE COMPLETING THE FITTING OF THE UNIT AND CON-
NECTING WITH THE DIAGNOSIS INSTRUMENT.
3) PERFORM THE POTENTIOMETER RESET PROCEDURE BY CONNECTING THE DIAGNOSIS
INSTRUMENT AND ENTERING INTO MANAGING "AUTOMATIC TRANSMISSION/AUTODIA/PO-
TENTIOMETER RESET/ADJUST".
4) PERFORM THE GEARSHIFT STROKE CATEGORY INSERTION PROCEDURE FROM THE
"SETTINGS" MENU OF THE DIAGNOSIS INSTRUMENT. PERFORM A KEY OFF/ON TO STORE
THE DATA.
5) CHECK THAT THE GEARSHIFT STROKE CATEGORY HAS BEEN STORED CORRECTLY
FROM THE DIAGNOSIS INSTRUMENT MENU.
ENG - 257
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 cov-
er 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.
ENG - 258
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
ENG - 259
- Flywheel side crankcase half:

- Fit the oil seal until it abuts against the bottom of the seat using the specific tool.
Specific tooling
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
020662Y 50 mm guide
ENG - 260
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.
- 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
020662Y Guide 50 mm
Removing the driven pulley shaft bearing
- Slide off the toothed wheel (pinion unit axle).
ENG - 261
- Slide of the driven pulley shaft from one side and

remove the oil seal from the other side with a
screwdriver.
- Remove the Seeger ring.
- With the specific tool, remove the bearing.
Specific tooling
020483Y 30 mm guide
ENG - 262
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= Ø30 -0.01 -0.02 mm
B= Ø20 -0.01 -0.02 mm
Diameter for pinion unit shaft:
C= Ø20 -0.01 -0.02 mm
D= Ø30 -0.013 -0.026 mm
Refitting the driven pulley shaft bearing
- Insert the driven pulley shaft bearing up to the stop against the bottom of the seat with the specific
tool.
Specific tooling
020483Y 30 mm guide
ENG - 263
- Fit the Seeger ring.
- 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 - 264
INDEX OF TOPICS
POWER SUPPLY P SUPP

Power supply NA 850 Mana ABS
Circuit diagram
In case of problems with the fuel system, the following operations must be carried out:
• Replace the fuel pump with the new model with only one exit.
• Replace the front injector with the new one with a single fuel duct as shown in figure A old
and A new.
• Delete the pipe highlighted in green in figures B, C, D and E.
P SUPP - 266
NA 850 Mana ABS Power supply
P SUPP - 267
Power supply NA 850 Mana ABS
P SUPP - 268
INDEX OF TOPICS
SUSPENSIONS SUSP
Suspensions NA 850 Mana 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 - 270
NA 850 Mana ABS Suspensions
• Unscrew the screws fixing the front

mudguard and remove it.
• Unscrew the screws fixing the front pli-

ers 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 - 271
• Tap the wheel axle slightly with a rub-

ber mallet so that the hole on the op-
posite 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 FOL-
LOWS.
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.
SUSP - 272
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 AXLE
• Use a dial gauge to check the wheel

axle eccentricity. Replace the wheel
axle if the eccentricity exceeds the limit
value.
Characteristic
Maximum eccentricity:
0.25 mm (0.0098 in)
• Using a dial gauge, check that the ra-

dial (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 - 273
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 - 274
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 - 275
18.Ring
19.Guide bushing
20.Sliding bushing
21.Special washer
22.Screw M10x1.5
24.Spring Centring
FRONT FORK - MARZOCCHI

pos. Description Type Quantity Torque Notes
1 Screws (fasten onto fork hubs) M8x40 4 25 Nm (18.44 lb ft) -
2 Bottom screw M10x25 2 50 Nm (36.88 lb ft) -
3 Cap 2 20 Nm (14.75 lb ft) -
4 Nut on pumping member pin M8x1.25 2 20 Nm (14.75 lb ft) -
SUSP - 276
FRONT FORK - SACHS

pos. Description Type Quantity Torque Notes
1 Screws (fasten onto fork hubs) M8x40 4 25 Nm (18.44 lb ft) -
2 Bottom screw - 2 30 Nm (22.13 lb ft) Loctite 242
3 Cap 2 20 Nm (14.75 lb ft) -
4 Nut on pumping member pin 2 20 Nm (14.75 lb ft) -
Removing the fork legs
• Remove the ABS sensor.
• Remove the front wheel.

• Support the stanchion and loosen the
screws on the upper and then the lower
plate.
• Remove the stanchion.
SUSP - 277
Draining oil
NOTE
THE FOLLOWING OPERATIONS REFER TO THE SHOWA FORKS.
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.
• Being careful not to damage the stan-

chion when placing it in a vice, in ver-
tical position, using the appropriate
protection.
Specific tooling
• Unscrew the sleeve cap.
SUSP - 278
• Drain the oil into a container of suitable

capacity to collect fluids.
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.

DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND
TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED
OIL COLLECTION CENTRE.
See also
Removing the
fork legs
NOTE
THE FOLLOWING OPERATIONS REFER TO THE MARZOCCHI FORKS.
NOTE
THE STEMS ARE DIFFERENT.
RIGHT STEM.
• Using the appropriate tool fasten the

stem in the vice.
• Unscrew the top plug by using a span-
ner.
Specific tooling
• Pull out the plug connected to the com-

plete pumping member pin.
• Insert a spanner on the nut under the
plug to lock it by allowing to unscrew
and remove the plug.
SUSP - 279
• Remove the spring paying attention to

drain the oil correctly from the spirals
before taking it out.
• Drain the oil of the fork by collecting the

preload pipe.

See also
Removing the
fork legs
LEFT STEM.
• Using the appropriate tool fasten the

stem in the vice.
• Unscrew the top plug by using a span-
ner.
Specific tooling
• Pull out the plug connected to the com-

plete pumping member pin.
plug to lock it by allowing to unscrew
and remove the plug.
SUSP - 280

capacity to collect fluids.

See also
Removing the
fork legs
NOTE
THE FOLLOWING OPERATIONS REFER TO THE SACHS FORKS.
NOTE
NOTE
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS GET A CONTAINER WITH SUITABLE
CAPACITY TO COLLECT THE OIL.
• Remove the fork.

protection.
Specific tooling
See also
Removing the
fork legs
• Unscrew the sleeve cap.
SUSP - 281
• Using the specific tool, fixed to the pre-

loading pipe, compress the spring and
insert the separating plate on the lock
nut of the cover.
Specific tooling
020888Y Pliers for pre-fill pipe
• Loosen the nut.
• Remove the sleeve cap.
• Slide off the preloading pipe
SUSP - 282
• Remove the two washers.
• Remove the spring allowing the oil to

drip inside the stanchion.

capacity to collect fluids, pumping out
oil a few times.
• Collect the lower washer.

Disassembling the fork

NOTE
NOTE
• Drain the fork oil.
• Place the stanchion on a work table in upright position.
SUSP - 283
• Fit the special tool.
Specific tooling
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
• Loosen the nut.
SUSP - 284
• Remove the sleeve cap.
• Slide off the preloading pipe together

with the spring centring.
• Be careful not to damage the stanchion

when placing it in a vice, in horizontal
position, using the appropriate protec-
tions.
Specific tooling
• Unscrew and remove the bottom screw

and collect the special washer.
SUSP - 285
• Slide off the pumping member together

with the spring.
• Remove the dust guard using a screw-

driver 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 - 286
• If necessary, remove the sliding bush-

ing, guide bushing, ring, oil seal, Seeg-
er ring and dust guard from the stem.
See also
Draining oil
NOTE
NOTE
THE FOLLOWING OPERATIONS REFER TO BOTH STEMS.
• Drain the fork oil.
• Remove the sleeve.
• Remove the oil seal.
SUSP - 287
NOTE
• Fit the dust gaiter (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 Ø 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
• Fit the Seeger ring on the sleeve seat.
SUSP - 292
• Fit the dust gaiter.
• Screw the specific perforated rod on

the pumping member threaded rod.
Specific tooling
• 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 tor-
que.
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)
NOTE
NOTE
SUSP - 293
• Insert the upper bushing (3), the

spacer pipe (2) and the lower bushing
(1) in the sleeve.
• Fasten the stem in the vice.

• Insert the previous greased oil seal (4),
the retainer ring (5), the dust gaiter (6)
and the spacer bowl (7).
• Place the bowl spacer (7) and the dust

gaiter (6) in seat with the specific tools.
Specific tooling
(1.69 in) orifices
AP8140146 Weight
SUSP - 294
• Remove the external oil seal grip and

with specific tools push it to stop.
• Refit the grip.
Specific tooling
(1.69 in) orifices
AP8140146 Weight
NOTE
NOTE
• Fit the dust gaiter (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
(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 - 295
• Fit the dust gaiter.
• If previously removed, insert in the

pumping member pin the three rubber
rings, the metal ring and the stop ring.
• Screw the nut on the pumping member
pin.
• Fit the pumping member.
SUSP - 296
• Fit the centring plate.

• Fit the pumping member together with
the centring plate in the sleeve.
• Insert the special washer in the screw.
• Scatter the screw thread with the spe-
cific product.
• Tighten the screw.
UPON REFITTING, REPLACE THE SAFETY WASHER WITH

A NEW ONE
-
Filling oil
NOTE
NOTE
• Fill the sleeve with the adequate quality and type of oil indicated on the recommended prod-
ucts 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 STANCHIONS.
Characteristic
Fork oil quantity (for each stem):
535 cm³ (32.65 cu.in)
Oil level (from sleeve rim, without the spring
and with pumping member fully down)
122 mm (4.80 in).
SUSP - 297
• Fit the preloading pipe together with

the spring centring.
Specific tooling
• 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
• Insert the sleeve cap and screw the
nut.
SUSP - 298

protection.
Specific tooling
• Tighten the sleeve cap.
NOTE
RIGHT STEM

ucts table.
WARNING
Characteristic
Fork oil quantity (right stem) (Marzocchi)
490 cc (29.90 cu in)
Oil level (from sleeve rim, without the spring
with preload pipe and with stem at end of
stroke)
50 mm (1.97 in)
SUSP - 299
• Insert the preload pipe.
• Fit the spring being careful to check

that the tightened part faces upwards.
• Compress the spring to be able to

screw the cap till the end of the stroke.

plug the cover allowing to tighten the
plug to the tightening torque.
SUSP - 300
• Tighten the sleeve cap, to the prescri-

bed tightening torque.
LEFT STEM

ucts table.
Characteristic
Fork oil quantity (left stem) (Marzocchi)
505 cc (30.82 cu in)
• Unscrew the plug manually until the

stop.

plug the cover allowing to tighten the
plug to the tightening torque.
SUSP - 301

NOTE
NOTE
ucts table.
WARNING
THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER

TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL
MUST BE THE SAME IN BOTH STANCHIONS.
Characteristic
Fork oil quantity (for each stanchion) (Sachs)
435 +/- 5 cc (26.54 +/- 0.30 cu in)
Sachs oil level (from sleeve rim, without the
spring with preload pipe and with stem at end
of stroke)
125 +/- 2 mm (4.92 +/- 0.08 in).
• Insert the lower washer.

• Fit the spring.
SUSP - 302
• Insert the two washers.
• Fit the preloading pipe together with

the spring centring.
• Tighten the appropriate tool on the pumping member pin rod.
Specific tooling
Specific tooling
020888Y Pliers for pre-fill pipe
• 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
SUSP - 303
• Tighten completely the nut on the

pumping member pin rod.
• Insert the sleeve cap on the pumping
member pin rod and tighten it.
• Tighten the nut, on the cover to the
specified torque.

Steering bearing
Key:
1. Folk lower plate
SUSP - 304
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
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.
SUSP - 305
• Working from the vehicle right side, un-

screw and remove the rear wheel pin
fixing nut and collect the washer.
SUSP - 309
• Loosen the right chain set screw.
• 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 FOL-
LOWS.
REAR WHEEL BEARINGS
SUSP - 310
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.
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.
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 AXLE
• Use a dial gauge to check the wheel

axle eccentricity (1). Replace the
wheel axle if the eccentricity exceeds
the limit value (1).
Characteristic
Maximum eccentricity:
0.25 mm (0.0098 in)
SUSP - 311
REAR WHEEL RIM
• Using a dial gauge, check that the ra-

dial (A) and the axial eccentricity (B) of
the rim (2) do not exceed the limit val-
ue.
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
Removing
• Place the vehicle on the service stand

under the oil sump carefully.
• Undo and remove the front shock ab-
sorber fixing screw and collect the col-
lar.
• Undo and remove the rear fixing screw

and collect the collar.
• Remove the rear shock absorber.
SUSP - 312
INDEX OF TOPICS
CHASSIS CHAS
Chassis NA 850 Mana 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 - 314
NA 850 Mana 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 - 315
Chassis NA 850 Mana 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 - 316
Braking system NA 850 Mana 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 SYSTEM STARTS WORKING, A VIBRATION 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 UN-
EVEN OR SLIPPERY ROADS, OR WITH POOR GRIP CREATES LACK OF STABILITY DIFFICULT
TO HANDLE. THEREFORE, RIDE CAREFULLY AND SENSIBLY AND ALWAYS BRAKE GRADU-
ALLY. 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 - 324

NA 850 Mana ABS Braking system
Riding with an active ABS system
• At engine start-up, the "general warn-

ing" 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, resist-
ance 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 - 325

• 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 WARN-
ING LIGHT TURNED ON
2. CONNECT AXONE
DOES AXONE COMMUNICATE? (NO, go to 3; YES, go to 4)
3. PERFORM THESE CHECKS:
• A. Ground connection PIN 1
• B. +12V at PIN 18
• C. +12V at PIN 4 with key ON
4. ARE THERE ANY ERRORS? YES, go to point 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 - 326

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, map-
ping, control unit programming date
ISO SCREEN PAGE

Characteristic Value/example Unit of Notes
measure
ment
Vehicle manufacturing date
Frame number
Software version
Vehicle code Mana/Shiver/Dorso- The vehicle code stored in the control unit is read.
duro/Scarabeo
Vehicle identification according to Mana/Shiver/Dorso- The vehicle type (Mana/Shiver/Dorsoduro) is de-
the status of Pin 2 and 15 of the ABS duro/Scarabeo fined according to the connection found for PIN 2
control unit connector and PIN 15 of the ABS control unit connector. see
table on workshop booklet
BRAK SYS - 327

NOTE: the "X" in the table identifies the con-

nector pin is grounded.
Parameter reading screen page
ENGINE PARAMETER READING

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

measure
ment
Front wheel speed 0 km/h With stopped wheel, 0 Km/h is displayed
Rear wheel speed 0 km/h With stopped wheel, 0 Km/h is displayed
Battery voltage 11.9 V
BRAK SYS - 328

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
measure
ment
Front brake bleeding procedure Useful in case of lever sponginess although the
bleeding has been done as in a regular braking
system
Rear brake bleeding procedure Useful in case of lever sponginess although the
bleeding has been done as in a regular braking
system
ABS warning light For Shiver and Dorsoduro models, the ABS warn-
ing light is caused to flash. For the Mana model,
both the EFI warning light and the ABS word flash
on the display.
Ambient parameter error reading (1) The ambient parameters are 4: Number of error
detections, Operation cycles from the last detec-
tion, Battery voltage, Speed.
Ambient parameter error reading (2) Number of error detections: number of times the
error has been detected by the control unit;
Ambient parameter error reading (3) for example, if it indicates 2, it means that the error
has been detected (ATT), then it has not been de-
tected for a while (sent to the MEM) and then it
has been detected again.
Ambient parameter error reading (4) Operation cycles from the last reading: a cycle is
counted if the following occurs: key ON and speed
over 20 km/h.
Ambient parameter error reading (5) If for example 5 is shown, it means that the last
time the error has been measured was 5 cycles
ago.
Error clearing (1) Press "enter" to transfer errors from the memory
(MEM) to the historical record (STO).
Error clearing (2) In the next connection between Axone and the
control unit, the historical errors (STO) are no lon-
ger shown.
BRAK SYS - 329

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
measure
ment
Front speed sensor: 5D90 electric Electrical fault in sensor or cable harness
malfunction
Front speed sensor: 5D91 the signal Faulty sensor or signal interference
works irregularly
Front speed sensor: 5D92 the signal Possible tone wheel fault due to deformations or
decreases periodically dirt; possible alterations on the wheel bearing sur-
face. In very rare cases, abnormal tone wheel
vibrations
Front speed sensor: no signal or Faulty sensor or missing sensor/tone wheel or ex-
speed measured too low in relation cessive distance between the sensor and the tone
to the rear wheel 5D93 wheel or tone wheel with wrong number of teeth
Front speed sensor: 5D94 no accel- Faulty sensor or missing sensor/tone wheel or ex-
eration after pressure reduction cessive distance between the sensor and the tone
wheel
Front speed sensor: 5D95 excessive Faulty sensor/tone wheel, or tone wheel with
measured speed wrong number of teeth or wrong tyre size
Rear speed sensor: 5DA0 electric Electrical fault in sensor or cable harness
malfunction
Rear speed sensor: 5DA1 the signal Faulty sensor or signal interference
works irregularly
Rear speed sensor: 5DA2 the signal Possible tone wheel fault due to deformations or
decreases periodically dirt; possible alterations on the wheel bearing sur-
face. In very rare cases, abnormal tone wheel
vibrations
Rear speed sensor: 5DA3 no signal Faulty sensor or missing sensor/tone wheel or ex-
or speed measured too low in rela- cessive distance between the sensor and the tone
tion to the front wheel wheel or tone wheel with wrong number of teeth
Rear speed sensor: 5DA4 no accel- Faulty sensor or missing sensor/tone wheel or ex-
eration after pressure reduction cessive distance between the sensor and the tone
wheel
Rear speed sensor: excessive meas- Faulty sensor or tone wheel with wrong number of
ured speed 5DA5 teeth or wrong tyre size
Control unit: missing valve calibra- Possible control unit fault
tion 5DD2
Control unit 5DD3 Possible control unit fault
Recirculation pump 5DF0 Possible control unit fault
Recirculation pump 5DF1 Possible control unit fault
Control unit 5DF2 Possible control unit fault
Low electric voltage - long period Voltage too low measured for 30 seconds at PIN
measurement 5DF3 18 of the ABS control unit:
Control unit 5DF5 Possible control unit fault
High electric voltage 5DF7 Excessive voltage measured at PIN 18 of the ABS
control unit
Vehicle code 5E59 Inconsistency detected between memory coding
(ISO/Vehicle code) and what is measured at cable
harness identification PIN (ISO screen page, Ve-
BRAK SYS - 330


measure
ment
hicle identification line - Pins 2-15 of ABS control
unit)
Control unit F000 Possible control unit fault
CAUTION
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 CON-
TINUITY OF THE RED-ORANGE/RED CABLE BETWEEN PIN 18 OF THE ABS CONTROL UNIT
CONNECTOR AND THE BATTERY POSITIVE POLE.
Adjustable parameters screen page
measure
ment
Coding (1) Used for re-coding the control unit or coding a new
one.
Coding (2) Vehicle identification is done according to the con-
nection of PINS 2 and 15 of the ABS control unit
connector and is stored in the control unit memory.
Coding (3) 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 - 331

Modulator
• Remove the rear system pipes from

their hooks (5) and the front system
pipes from the hose guide (6).
MODULATOR REMOVAL

• 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 - 332

• 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 - 333

• 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 - 334

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
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 - 335


40.Cable guide
41.Cap
42.Brake pump fixing screws
Removal
REAR BRAKE CALLIPER
• Undo and remove both rear brake cal-

liper 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 - 336

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 - 337

• Remove both pins.
• Collect the anti-vibration springs.
• Extract one pad at a time.

CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE 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 RE-

PLACEMENT
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.
BRAK SYS - 338

• 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 in-
stalled 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, previ-

ously filled up.
BRAK SYS - 339

• So that the brake fluid remains in the

ABS control unit, first remove the pro-
tective caps of the braking circuit un-
ions and connect the respective pipes.
Once all the braking circuits have been con-

nected, 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.
• 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.
BRAKE BLEEDING AFTER CALLIPER RE-

PLACEMENT
VEHICLE PREPARATION - The operations are
described for the front system, but they are al-
so 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 de-
vice so as to avoid fluid flowing out from
the open system.
• Close the bleed screws of the front cal-
liper and remove the bleed bottle.
• Replace the damaged calliper with a
new one.
• Unlock the brake lever.
BRAK SYS - 340

• 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.
described.
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 PROCE-
DURE".
• 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 - 341

Changing the brake fluid
BRAKE FLUID REPLACEMENT

VEHICLE PREPARATION
• Connect the bleeding unit to the reser-

voir of the braking system.
Max. filling pressure to be applied to the sys-

tem= 3 bar (300 kPa - 43.51 PSI).
PURGING PROCESS TO CHANGE THE BRAK-
ING 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 res-
ervoir 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 remain-
ing bleed valves of the system and
close them all to the prescribed tight-
ening torque.
• Remove the bleeding unit.
described.
PARKING BRAKE
BRAK SYS - 342

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.
• Slide off the two pins and remove the two brake pads.
CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER
PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
BRAK SYS - 343

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 lever-

age.
• Hook the cable by the lever section again.
• Fasten the hook in the leverage set screw.
BRAK SYS - 344

• 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 - 345

INDEX OF TOPICS
COOLING SYSTEM COOL SYS

NA 850 Mana 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. 75°C 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 - 347

Cooling system NA 850 Mana 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 - 348

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 - 349

• 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 wa-

ter pump cover and the gasket.
COOL SYS - 350

- 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 neces-

sary.
During seal disassembly, the ceramic may split.
COOL SYS - 351

- 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 seal-

ing, using the screws supplied with the tool.
CAUTION
FASTEN IT CORRECTLY WITHOUT "TEARING" THE
PLATE
COOL SYS - 352

- 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 trans-
mission-side crankcase half.
- Slide off the idle gear.
COOL SYS - 353

- 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 - 354

- 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 lb 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 - 355

- 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 val-

ues).
- 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 - 356

- Screw the rotor. (anticlockwise thread).

Water pump rotor 4 - 5 Nm (2.95 - 3.69 lb 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 lb 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 - 357

• Remove the clamp and slide off the

manifold.
• Remove the clamp.

• Release the sleeve.
• Undo and remove the fixing screw.
• Disconnect the electric fan connector.
COOL SYS - 358

• Undo and remove the radiator lower

fixing screw.
• Release the sealing clamp of the radi-

ator lower pipe.
• Release the sealing clamp of the ex-

pansion tank upper pipe and release
the pipe.
• Release the sealing clamp of the ex-

pansion tank lower pipe and release
the pipe.
COOL SYS - 359

Removing the expansion tank
• Right bottom side removal.

• Release the clamps and slide off the

two sleeves.
COOL SYS - 360

INDEX OF TOPICS
BODYWORK BODYW
Bodywork NA 850 Mana 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 - 362
NA 850 Mana ABS Bodywork
Instrument panel
• Remove the headlamp.

• Undo and remove the two screws.
• Remove the cover.
• Disconnect the instrument panel con-

nector.
• Remove the instrument panel.
See also
Headlight assy.
Headlight assy.
• Undo and remove the right screw on

the upper steering plate.
BODYW - 363
• Undo and remove the left screw on the

upper steering plate and collect the
washer and the collar.
• Working from the left side, undo and

remove the screw. Collect the nut from
the opposite side.
• Move the front headlight assembly for-
wards.
• Slide off and disconnect the connec-

tors.
• Cut the clamps placed inside, on the
connectors assembly.
• Remove the right side clamps between
the main cable harness and the front
headlight assembly.
• Remove the front headlight assembly.
Disassembling the lock

• Remove the license plate support.
• Slide off the cable.
BODYW - 364
Taillight assy.

• Undo and remove the two fixing
screws.

screws.

screws.

screws.
BODYW - 365
• Slide off the light cover.
• Slide off the light.
Rider footrest plate
The following operations also apply to both foot-

rest holder plates.
• Undo and remove the lower fixing

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)
BODYW - 366
• Undo and remove the central fixing

The following operations are only applicable to re-

move the left footrest holder plate.
• Unscrew and remove the rear fixing nut

and collect the washer.
• Remove the passenger footrest sup-

port.
Side body panels
• Remove the helmet compartment cov-

er.
• Working on both sides, undo and re-
move the three side fairing fixing
screws.
Side fairings
NOTE
BODYW - 367
THE FOLLOWING OPERATIONS REFER TO ONE SIDE OF THE VEHICLE, BUT APPLY TO BOTH.
• 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 front upper plastic hook

(3).
• Undo and remove the front lower screw
(4).
• Remove the plastic hook (5).

• Remove the rear screw (6).
• Remove the side fairing (7).
BODYW - 368
License plate holder

screws.
• Undo and remove the two screws fixing

the passenger grab handle.
• Remove the passenger grab handle.
• Remove the two spacers.
• Operating from both sides, undo and

remove the side screw.
BODYW - 369
• Undo and remove the two lower fixing

screws.
• Partially slide off with great care the li-

cense plate support.
• Remove the locking clamp.
• Disconnect the rear light connector.
BODYW - 370
• Disconnect the rear turn indicator con-

nector.
• Hold the license plate support assem-

bly.
• Undo and remove the two screws fixing
the key lock.
• Remove the key lock.
• Loosen the three screws and remove

the hose guides.
• Remove the clamp.

• Slide off the entire license plate sup-
port.
BODYW - 371
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 hel-

met compartment.
• Remove the steering lock protection.
BODYW - 372
• Undo and remove the three fixing

screws.
• Remove the left small fairing.

screws.
• Remove the plastic radiator protection.
• Disconnect the two horn connectors.
• Undo the screw on the sleeve clamp

through the hole in the helmet com-
partment.
BODYW - 373
• Remove the filter box fixing screw in-

side the glove-box.
• Remove the filter box fixing screw

which is on the left of the chassis.
• Release the blow by tube from the en-

gine crankcase, working on the right of
the vehicle.
• Take the filter box away from the vehi-

cle and release the blow by tube from
the filter box.
• Remove the filter box.
BODYW - 374
Helmet bay

• 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 - 375
• Close the helmet compartment.

• Slide off the cover.
• Reopen the helmet compartment.
• Remove the side fairings.
• Working from both sides, undo and re-

move the protection front fixing screw.

move the protection upper fixing
screw.

move the protection rear fixing screw.
BODYW - 376

move the protection rear upper fixing
screw.
• Remove the lower screw fixing the fair-

ing to the chassis.
• Disconnect the control unit connectors.
• Undo and remove the ground lead fix-

ing screw.
• Remove the ground lead.
BODYW - 377

move the compartment plastic part fair-
ing upper fixing screws.

move the compartment plastic part fair-
ing lower fixing screws.
• Move the compartment plastic part fair-

ing.
• Disconnect the faston connectors of

the helmet compartment light control
switch.
• Remove the battery.
BODYW - 378
• Disconnect the gear control ECU con-

nector.
• 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 - 379
• From both sides undo and remove the

three helmet compartment external fix-
ing screws.
• Undo and remove the helmet compart-

ment internal fixing screw.
BODYW - 380
• Slide off the fuse box.
• Lift the helmet compartment and dis-

connect the helmet compartment
opening actuator connector.
Fuel tank

• Remove the fuel cap by rotating it an-
ticlockwise.
• 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 - 381

screws.
• 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 under-

seat cover.
CAUTION
CHECK THAT THE FOUR MUSHROOM-HEAD RUBBER
RINGS DO NOT PROTRUDE FROM THEIR POSITIONS.
BODYW - 382
• 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 - 383
• 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.

screws.
• Slide off the tank.

• Remove the cloth from the tank and
screw the cap again.
BODYW - 384
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.
BODYW - 385
INDEX OF TOPICS
PRE-DELIVERY PRE DE
NA 850 Mana ABS Pre-delivery
Carry out the listed checks before delivering the motorcycle.

WARNING
HANDLE FUEL WITH CARE.
Aesthetic inspection
- Paintwork
- Fitting of Plastic Parts
- Scratches
- Dirt
Tightening torques inspection
- Safety fasteners:
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 starter
- Engine stop via emergency stop switch and side stand
- Helmet compartment electrical opening switch (if present)
PRE DE - 387
Pre-delivery NA 850 Mana ABS
- 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 NEG-
ATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-

TAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUN-
DANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
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 - 388
NA 850 Mana ABS Pre-delivery
- 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 - 389
A
ABS: 145, 320, 327
Air filter: 45
Air temperature sensor: 96, 111
B
Brake: 334, 337, 342
Brake calliper: 334, 337
Brake fluid: 342
Bulbs:
C
CAN line: 146
Chain: 12, 191
Chain tensioner: 191
Clutch: 175, 240, 241, 245, 246, 248
Coil: 103
Connectors: 139
coolant: 349
Coolant: 349
Crankcase: 22, 209, 210, 213, 220, 354
Crankshaft: 22, 209, 212, 214–216
Cylinder: 20, 178, 180, 186–188, 195, 196, 200, 202
D
Display: 51, 330
Drive chain: 12
E
ECU: 55, 139
Electric fan: 112, 348
Electrical system: 12, 58, 59, 387
Engine oil: 42
Engine temperature sensor: 95
Exhaust: 315, 317
Exhaust manifold: 317
F
Fairings: 367
Filter box:
Fork: 275, 277, 279–281, 283, 291
Front wheel: 270, 272
Fuel: 102, 381
Fuel pump: 102
Fuses: 87
H
Handlebar: 132, 274
Head cover: 177, 207
Headlight: 363
I
Identification: 10
Instrument panel: 51, 111, 363
L
License plate holder: 369
M
Magneto flywheel: 172
Maintenance: 7, 40, 334
Maintenance Table:
Mudguard: 385
O
Oil filter: 45
Oil pressure sensor: 107
R
Radiator: 357
Rear wheel: 307, 310
Recommended products: 24
Run/Stop switch: 114
S
Saddle:
Shock absorbers: 312
Side fairings: 367
Side stand: 109
Side stand sensor: 109
Spark plug: 41
Spark plugs:
Speed sensor: 90, 125
Stand: 109
Start-up: 84
Starter motor: 166, 167
T
Tank: 360, 381
Throttle body: 106
Transmission: 12, 116, 120, 127, 143, 235, 258
Tyres: 14
W
Warning lights:
Water pump: 350
Wiring diagram: 74

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Aprilia Mss 850

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SERVICE STATION MANUAL

NA 850 Mana ABS

NA 850 Mana ABS

THE VALUE OF SERVICE

SPECIAL TOOLS S-TOOLS

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

POWER SUPPLY P SUPP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE-

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,

BEFORE DISASSEMBLING COMPONENTS

THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISHABLE CRIME.

Dimensions and mass

OIL MINIMUM PRESSURE INDICATOR SWITCH

HEAD LUBRICATION CONTROL JET

PISTON COOLING NOZZLE

CRANKCASE VENTILATION CHECK

Frame and suspensions

Wheels and tyres

THERMAL GROUP AND TIMING SYSTEM

CRANKCASE AND CRANKSHAFT

HANDLEBAR / CONTROLS / TRANSMISSION

LIGHTS / INSTRUMENT PANEL

ENGINE MAIN RETAINERS

Cylinder - piston assy.

COUPLING CATEGORIES BETWEEN THE PISTON AND THE ALUMINIUM CYLINDER

Rod small end - pin - piston

ROD SMALL END - PIN COUPLING CLEAR-

PIN - PISTON COUPLING CLEARANCE

PISTON BEARINGS DIAMETER

FITTING CLEARANCE PISTON RINGS- SEALING RINGS

Maximum clearance after use: B = 0.10 mm

Crankcase - crankshaft - connecting rod

Crankshaft bearing diameter.

CRANKSHAFT / CONNECTING ROD AXIAL CLEARANCE

- Measure the inside diameter of the connecting

Recommended products chart

Product Description Specifications

SPECIAL TOOLS S-TOOLS

020262Y Crankcase splitting strip

020306Y Punch for fitting the valve seal rings

020330Y Stroboscopic light for timing checking

020331Y Digital multimeter

Stores code Description

020358Y 37 x 40-mm adaptor

020359Y 42 x 47-mm adaptor

020360Y 52 x 55-mm adaptor

020362Y 12 mm guide for oil seal in kick start pedal

Stores code Description

020364Y 25-mm Guide

020365Y 22 mm (0.87 in) guide

020375Y 28x30 mm punch

020376Y Adapter handle

020408Y 72x75-mm (2.83x2.95 in) adaptor

Stores code Description

020424Y Punch for fitting driven pulley roller casing

020434Y Fitting for oil pressure check

020439Y 17-mm guide for oil seal

020431Y Valve oil seal extractor

Stores code Description

020455Y 10-mm guide for oil seal on water pump

020470Y Pin snap ring fitting tool