APRILIA Mana GT ABS 2012 Manual Download

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Fork oil seal - Check and clean, replace if necessary

Battery - Check terminal tightening

Wheel bearings - Check and clean, adjust, grease or replace if
necessary

Transmission bolts, nuts and screws tightening - Check and restore
tightening torque

Driving pulley bulb ring nut - Check and restore tightening torque

Control bushing - Grease

30000

(18641

)

Engine oil - Change

Engine oil filter - Replace

Air filter - Clean

Transmission air filter - Clean

Final transmission (chain, crown and pinion) - Replace

Transmission cables - Check, adjust and grease, or replace if necessary

Steering bearings and steering clearance - Check and clean, adjust,
grease or replace if necessary.

Diagnosis for engine control unit and transmission control unit - Check

Brake discs - Check and clean, replace if necessary.

General vehicle operation - Check

Break pads - Check and replace if necessary

Lights circuit - Check, adjust direction or replace if necessary

133

6 Programmed maintenance

Summary of Contents for Mana GT ABS 2012

Page 1: ...tion tips and precautions for using your vehicle It also describes features details and devices to assure you that you have made the right choice We believe that if you follow our suggestions you will soon get to know your new vehicle well and that it will continue to give you satisfactory service for many years to come This booklet is an integral part of the vehicle and must be handed over to the...

Page 2: ...ecks that should be carried out on the vehicle at an authorised aprilia Dealer or Workshop This booklet also contains instructions for simple repairs Any operations not specifically described in this booklet require the use of special tools and or particular technical knowledge for these operations please take your vehicle to an Aprilia Dealer or Authorised Workshop 2 ...

Page 3: ... the booklet that should be read with particular care The different symbols are used to make each topic in the manual simple and quick to locate Before starting the engine read this booklet carefully particularly the SAFE RIDING section Your safety as well as other s does not only depend on the quickness of your reflexes and agility but also on how well you know your vehicle the state of maintenan...

Page 4: ...4 ...

Page 5: ...met compartment 44 Power supply socket 45 Opening the saddle 45 Identification 46 Adjusting the windscreen 47 Windscreen removal 47 Instrument panel removal 48 USE 49 Checks 50 Refuelling 53 Rear shock absorbers adjustment 54 Front fork adjustment 56 Justering af greb til forbremse 57 Rear brake pedal adjustment 57 Gear pedal adjustment 58 Running in 58 Starting up the engine 59 Moving off riding ...

Page 6: ...rs 106 Number plate light 106 Rear view mirrors 107 Front and rear disc brake 109 Periods of inactivity 110 Cleaning the vehicle 111 Transport 114 Chain backlash check 114 Chain backlash adjustment 115 Checking wear of chain front and rear sprockets 115 Chain lubrication and cleaning 116 TECHNICAL DATA 117 Kit equipment 126 PROGRAMMED MAINTENANCE 127 Scheduled maintenance table 128 SPECIAL FITTING...

Page 7: ...Mana GT ABS Chap 01 General rules 7 ...

Page 8: ... area Never let the engine run in an enclosed area If you do work in an enclosed area make sure to use a smoke ex traction 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 RECOM...

Page 9: ...remain in this con dition for a certain time interval after the engine has been switched off Before handling these components make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down Coolant The coolant contains ethylene glycol which under certain conditions can become flammable When ethylene glycol burns it produces an invisible flame which...

Page 10: ...GINE IS STILL HOT THE COOLANT IS PRESSURISED AND MAY CAUSE SCALDING Used engine oil and gearbox oil CAUTION IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BA SIS WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAR...

Page 11: ...T CONTAINS SULPHURIC ACID MAY CAUSE BURNING IF IT COMES INTO CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELECTROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID RINSE WELL WITH PLENTY OF CLEAN WATER IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS IN THE EVENT OF CONTACT WIT...

Page 12: ...TS ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY BEING ACTIVATED Stand BEFORE SETTING OFF MAKE SURE THE STAND HAS BEEN COMPLETELY RETRACTED TO ITS POSITION DO NOT REST THE RIDER OR PASSENGER WEIGHT ON THE SIDE STAND Reporting of defects that affect safety Unless otherwise specified in this Use and Maintenance Booklet do not remove any mechanical or electrical component 12 1 Gene...

Page 13: ...Mana GT ABS Chap 02 Vehicle 13 ...

Page 14: ...02_01 14 2 Vehicle ...

Page 15: ...ts 02_02 key 1 Left side fairing 2 Front left turn indicator 3 Gearshift control on the handlebar 4 Left rear view mirror 5 Helmet compartment toolkit 6 ABS Fuse 7 Main fuses 8 Battery 9 Saddle 10 Passenger saddle 11 Rear light 15 2 Vehicle ...

Page 16: ... Front left brake disc 28 Fuel tank cap 29 Fuel tank 30 Transmission control unit 31 Auxiliary fuses 32 ABS control unit 33 Right rear view mirror 34 Front brake fluid reservoir 35 Expansion tank cap 36 adjustable windscreen 37 Front right turn indicator 38 Front headlamp 39 Right side fairing 40 Expansion tank 41 Front right brake disc 42 Front tone wheel 43 Front ABS sensor 44 Engine control uni...

Page 17: ...Right passenger footrest snap on closed open 53 Rear brake fluid reservoir 54 License plate holder light 55 Rear right turn indicator 02_03 Dashboard 02_03 Instrument panel controls location key 1 Ignition switch steering lock 17 2 Vehicle ...

Page 18: ...ash switch and high beam activation 6 GEAR DOWN control 7 Helmet compartment opening control 8 Instrument panel MODE control 9 Turn indicator control 10 Horn button 11 GEAR UP control 12 Starter button engine stop switch 13 GEAR MODE control 02_04 18 2 Vehicle ...

Page 19: ...ealer to enable these keys or to disable a key that has been lost When the vehicle is delivered and approximately ten seconds after the key is set to ON the instrument panel re quests a personal five digit code to be entered This request is no longer displayed once the personal code is entered For code entering procedure see the CODE MODIFICATION section It is important to remember the personal co...

Page 20: ...T GEAR mode 4 RPM 3 warning light amber yellow active only when in SPORT GEAR mode 5 RPM 2 warning light amber yellow active only when in SPORT GEAR mode 6 RPM 1 warning light amber yellow active only when in SPORT GEAR mode 7 Right turn indicator warning light green 8 General alarm warning light red 9 Low fuel warning light amber yellow 20 2 Vehicle ...

Page 21: ... The MANA logo All warning lights The general layout of the screen displayed for the user is the following ambient temperature Clock Odometer Gear engaged Engine temperature bar Trip journal Additional functions 02_08 Two kilometres after the low fuel warning light turns on the kilometres travelled with low fuel are shown on the digital display 21 2 Vehicle ...

Page 22: ...the key is set to KEY ON and less than 300 km before the scheduled maintenance deadline With the key set to KEY OFF the general alarm warning light flashes to indicate activation of the locking system To minimise battery consumption the light stops flashing after 48 hours 02_10 Alarms 02_10 02_11 02_12 02_13 02_14 02_15 02_16 02_17 02_18 02_19 02_20 02_21 02_22 In case of failure a different icon ...

Page 23: ... SERVICE icon and the red general warning light comes on 02_12 Air temperature sensor failure In case of air temperature sensor failure the instrument panel signals the problem by displaying the symbol steadily at the position where the temperature value is gen erally displayed In this case the red general warning light does not turn on Oil failure In case of failing oil pressure or oil pressure s...

Page 24: ...s condition 02_14 Electronic control unit disconnected alarm In case no connection is detected the disconnection icon is displayed on the instru ment panel and the red general warning light turns on to signal this condition 02_15 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 ...

Page 25: ... to the nature of the alarm F H and M F stands for foot foot pedal H stands for handlebar handlebar control and M is for mode gear mode selection In case of alarms related to the transmission control unit the general alarm warning light is lit and the display shows the word GEAR CAUTION IN CASE THE HANDLEBAR CONTROLS ARE DISABLED THE H SYMBOL WILL BE ALSO SHOWN ON THE DIGITAL DISPLAY 25 2 Vehicle ...

Page 26: ...alarm warning light is off High priority alarm the display shows the word BELT and the alarm warning light comes on simultaneously For high priority alarms the RAIN mode is automatically set see the Transmission chapter 02_21 ABS Alarm For alarms related to the ABS control unit the general alarm warning light comes on and at the same time the display shows the word ABS 26 2 Vehicle ...

Page 27: ... 1 icon 1 on the DIGITAL DISPLAY turns on Press and hold down the MODE control to the right to select the TRIP JOURNAL 2 icon 2 on the DIGITAL DISPLAY turns on In each journal each time the MODE control is briefly pressed to the right or left the following information is displayed in sequence ODOMETER TRIP ODOMETER TRAVELLING TIME MAXIMUM SPEED MEAN SPEED AVERAGE FUEL CONSUMPTION CURRENT FUEL CONS...

Page 28: ...SPEED AVERAGE FUEL CONSUMPTION press and hold down the central key to reset all the indications stored in the active TRIP JOURNAL 02_25 At zero speed when the display shows the MENU press and hold down the central button to access the instrument panel advanced functions 28 2 Vehicle ...

Page 29: ...er Timekeeping starts when the button is pressed If the button is pressed again within 10 seconds after starting time keeping the chronometer is reset After that time and if the button is pressed again the data is stored and the next timekeeping begins Timekeeping is cancelled by pressing and holding down the central button or when speed goes back to zero and the display shows the last time stored...

Page 30: ...BLING on the handlebar CHRONOMETER DIAGNOSIS LANGUAGES SETTINGS The SETTINGS menu consists of the following options EXIT TIME ADJUSTMENT BACKLIGHTING CODE CHANGE CODE RESET C F 12 24 h The functions of the settings menu are indicated in the following sections Once each operation is finished the instrument panel goes back to the main menu 30 2 Vehicle ...

Page 31: ... activated only the hour indicator is shown Each time the MODE selector is pressed to the right the minute value increases each time the MODE selector is pressed to the left the minute value decreases Press the MODE selector central part to store the set value and to exit the clock ad justment function 02_28 BACKLIGHTING This function adjusts the backlighting brightness to three levels Each time t...

Page 32: ...within this function the following message is displayed ENTER OLD CODE After recognising the old code the new code is requested and the display shows the following message ENTER NEW CODE Once the operation is finished the instrument panel shows the SETTINGS menu 32 2 Vehicle ...

Page 33: ...n 20 seconds the operation finishes After recognising the second key the insertion of the new code is required with the message ENTER NEW CODE Once the operation is finished the instrument panel shows the SETTINGS menu CAUTION IF YOU LOSE ONE OF THE SUPPLIED KEYS CONTACT AN aprilia official Deal er C F Select the C F option from the SETTINGS menu for this function This function selects the unit of...

Page 34: ...e H symbol is shown on the digital display CHRONOMETER Select the CHRONOMETER option from the configuration menu to access the chro nometer function When the CHRONOMETER function is selected the screen page shows the following options EXIT START CHRONOMETER VIEW TIMES DELETE TIMES Start chronometer Select this option to display the screen that allows to select which function should be shown at the...

Page 35: ...n confirmation is reques ted Once the operation is finished the display goes back to the chronometer menu DIAGNOSIS Open the configuration menu to display the DIAGNOSIS option This menu interfaces with the systems present on the vehicle and diagnoses them To enable this menu enter an access code available only from official Aprilia dealers LANGUAGES Open the configuration menu to access the LANGUA...

Page 36: ...ignition switch 1 is located at the front of the fuel reservoir The vehicle is supplied with two keys one is the spare key The lights go off when the ignition switch is set to OFF NOTE THE KEY ACTIVATES THE IGNITION SWITCH AND OPERATES THE STEERING LOCK NOTE THE LIGHTS TURN ON AUTOMATICALLY UPON ENGINE START UP 36 2 Vehicle ...

Page 37: ...may be started The key cannot be removed Locking the steering wheel Turn the handlebar fully to the left Turn the key to OFF Push in the key and turn it anticlockwise to the left steer the handlebar slowly until the key is set to LOCK Extract the key CAUTION TO AVOID LOSING CONTROL OF THE VEHICLE NEVER TURN THE KEY TO LOCK WHILE RIDING 02_33 Horn button 02_33 Press it to activate the horn 37 2 Veh...

Page 38: ...r is not deactivated by pushing the button it will be automatically deactivated after a few seconds CAUTION IF THE ARROW WARNING LIGHT FLASHES QUICKLY IT MEANS THAT ONE OR BOTH TURN INDICATOR LIGHT BULBS ARE BURNT OUT 02_35 Passing button 02_35 Uses the high beam flash in case of danger or emergency Releasing the switch deactivates the high beam flash Pushing it forward activates the high beam ste...

Page 39: ...ngine cut off or emergency stop switch Press the switch to the left to stop the engine System ABS 02_38 02_39 The ABS system is a device that prevents wheel locking in case of an emergency braking thus increasing vehicle stability when braking compared with a conventional braking system The ABS system enhances control over the vehicle taking into consideration never to exceed the physical limits o...

Page 40: ...POOR GRIP CREATES A LACK OF STABILITY DIFFICULT TO HANDLE RIDE CAREFULLY AND SEN SIBLY AND ALWAYS BRAKE GRADUALLY DO NOT SPEED RECKLESSLY THE VEHICLE GRIP ON THE ROAD IS SUBJECT TO LAWS OF PHYSICS WHICH NOT EVEN THE ABS SYSTEM CAN ELIMINATE 02_38 Upon starting the vehicle after the initial check of the instrument panel the general alarm warning light 1 flashes and at the same time the display show...

Page 41: ... the ABS disabled indication remains NOTE SHOULD THIS OCCUR CONTACT AN aprilia Official Dealer NOTE THE ABS SYSTEM HAS BEEN DESIGNED AND DEVELOPED CONSISTENTLY WITH THE REST OF THE VEHICLE TO BE USED ON TARMAC ROADS AND IT IS NOT SUITABLE FOR OFF ROAD USE IF THE VEHICLE IS USED ON UNSURFACED AND OR SPECIFICALLY ROUGH ROADS THE ABS SYSTEM MAY GET DISABLED AUTOMATICALLY IN ANY CASE THE BRAKING SYSTE...

Page 42: ... IMPORTANT TO CHECK THAT THE DISTANCE BETWEEN TONE WHEEL AND SENSOR IS THE ONE SPECIFIED FOR CHECKING AND ADJUSTMENT CON TACT AN Authorised APRILIA Workshop IN THE CASE OF A MOTORCYCLE WITH THE ABS SYSTEM BRAKE PADS WITH FRICTION MATERIALS THAT ARE NOT TYPE APPROVED WILL JEOPARDISE BRAKING DRASTICALLY REDUCING RIDING SAFETY Characteristic Distance between tone wheel and rear sensor 0 1 2 00 mm 0 0...

Page 43: ...e switch when the vehicle is started The modulated signal is the password by which the appropriate central unit recog nises the key and only after this occurs it allows the engine start up CAUTION THE IMMOBILIZER SYSTEM CAN MEMORISE UP TO FOUR KEYS DATA STORAGE OPERATION CAN ONLY BE PERFORMED AT THE DEALER S DATA STORAGE PROCEDURE CANCELS THE EXISTING CODES THEREFORE IF A CUSTOMER WANTS TO PROGRAM...

Page 44: ... opening device 3 under the passenger saddle lift the passenger saddle in order to access it CAUTION NEVER OPEN THE HELMET COMPARTMENT WHEN THE MOTORBIKE IS MOV ING WHEN THE HELMET COMPARTMENT IS OPEN THE HANDLEBAR CANNOT BE TURNED WHICH COMPROMISES VEHICLE HANDLING AND CONSE QUENTLY THE SAFETY OF BOTH BIKE AND PEOPLE ALWAYS CHECK THAT THE HELMET COMPARTMENT IS CORRECTLY CLOSED TO PREVENT THE GLOV...

Page 45: ...t 02_45 Opening the saddle 02_45 Rest the vehicle on its stand Insert the key 1 in the lock Turn the key 1 anticlockwise lift the passenger saddle 2 To lock the saddle 2 Place the passenger saddle 2 in its position and press to trip the lock BEFORE SETTING OFF MAKE SURE THAT THE SADDLE IS CORRECTLY LOCKED INTO POSITION 45 2 Vehicle ...

Page 46: ...NTIFICATION CODES IS A SERIOUS PUNISH ABLE CRIME HOWEVER THE LIMITED WARRANTY FOR NEW VEHICLES WILL BE VOID IF THE VEHICLE IDENTIFICATION NUMBER VIN HAS BEEN MODI FIED OR NOT PROMPTLY DETERMINED CHASSIS NUMBER The chassis number is stamped on the right side of the headstock Chassis No ENGINE NUMBER The engine number is stamped on the base of the right side engine crankcase Engine No 46 2 Vehicle ...

Page 47: ...en 1 Adjust the windshield to the desired position Tighten the two fixing screws for the windscreen 1 02_48 Windscreen removal 02_48 The following operations are necessary to remove the windscreen Undo and remove the two fixing screws for the windscreen 1 and collect the washers Remove the windscreen by slowly sliding it upwards 47 2 Vehicle ...

Page 48: ...9 The following operations are necessary to remove the control panel Remove the windscreen Undo and remove the 6 screws 1 Remove the control panel together with the instrument panel Disconnect the instrument panel connector 48 2 Vehicle ...

Page 49: ...Mana GT ABS Chap 03 Use 49 ...

Page 50: ...CTION IS DE TECTED OR SUSPECTED CHECKING TAKES VERY LITTLE TIME BUT CON SIDERABLY INCREASES SAFETY 03_01 This vehicle has been programmed to indicate in real time any operation failure stored in the electronic control unit memory Every time the ignition switch is turned to KEY ON the alarm LED warning light turns on for about three seconds on the instrument panel PRE RIDE CHECKS Front and rear dis...

Page 51: ...ssible strange body that might be stuck in the tread design Brake levers Check they function smoothly Lubricate the joints and adjust the travel if necessary Steering Check that the rotation is uniform smooth and there are no signs of clearance or slackness Centre side stand Check it works properly Check that there is no resistance when the side stand is pulled up and down and that the spring tens...

Page 52: ...evel and refill if necessary Check the circuit for leaks or obstructions Check that the tank cap closes correctly Engine stop switch ON OFF Check function Lights warning lights horn rear stop light switch and electrical devices Check function of horn and lights Replace bulbs or repair any faults noted Tone wheels Check that the tone wheels are perfectly clean and in good conditions 52 3 Use ...

Page 53: ... Use unleaded premium petrol minimum octane rating of 95 NORM and 85 NOMM Refuel CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCES TO THE FUEL WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PER FECTLY CLEAN DO NOT FILL THE TANK UP TO THE RIM FUEL MAXIMUM LEVEL MUST AL WAYS BE BELOW THE LOWER EDGE OF THE FILLER NECK SEE FIGURE after refuelling Screw the cap 1 clockwise Tighten the cap ...

Page 54: ...spring preloading 3 CAUTION THE SHOCK ABSORBER STANDARD SETTING IS ADJUSTED TO MEET TOU RIST RIDING HOWEVER THIS SET CAN BE ADJUSTED TO SPECIFIC NEEDS ACCORDING TO VEHICLE USE TO COUNT THE CLICKS OF SET SCREWS 1 ALWAYS START FROM THE MOST RIGID SETTING SET SCREW FULLY CLOCKWISE IN ORDER TO AVOID DAMAGES DO NOT FORCE THE SET SCREWS 1 TO TURN BEYOND THE END OF THE STROKE ON BOTH SIDES CAUTION IF THE...

Page 55: ...aulic rebound damping of the shock absorber can be adjusted by acting on screw 1 Strictly observe the adjustment pro cedure described below Uneven or bumpy roads HARD adjustment Turn the screw 1 rightwards clockwise Normal or regular roads SOFT adjustment Turn the screw 1 leftwards anticlockwise use the adjustment knob 2 to adjust the spring 3 preload for the adjustment follow the procedure descri...

Page 56: ...ading knob 2 in the STD position 38 clicks 7 1 2 notches on the graduated scale the rebound adjustment screw 1 in the STD position 6 clicks 03_05 Front fork adjustment 03_05 CAUTION THIS FORK CANNOT BE ADJUSTED Operating the front brake lever press the handlebar repeatedly to send the fork fully down The stroke should be soft and there should be no oil marks on the stems Check the tightening of al...

Page 57: ...rew 3 until the lever 1 is at the desired distance 03_07 Rear brake pedal adjustment 03_07 The control levers have been ergonomically fitted when assembling the vehicle If necessary the position of the levers can be personalised Rest the vehicle on its stand Partially undo the screw 1 Turn the cam 2 until the adequate position for the pedal 3 is obtained Tighten the screw 1 and check the cam is st...

Page 58: ...RUCTIONS IN THIS WORKSHOP BOOKLET AVAILABLE ALSO AT ANY DEALER Running in Running the engine in correctly is essential for ensuring engine longevity and func tionality 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 en sures that components operate in loaded conditions and then unloaded condit...

Page 59: ...G THE VEHICLE 03_09 03_10 Starting up the engine 03_09 03_10 03_11 03_12 03_13 03_14 THIS VEHICLE HAS REMARKABLE POWER AND SHOULD BE USED GRADU ALLY AND WITH MAXIMUM CAUTION Do not carry objects in the top fairing between the handlebar and the instrument panel so that handlebar can turn freely and the instrument panel is visible at all times FAILURE TO OBSERVE THIS WARNING COULD LEAD TO UNCONSCIOU...

Page 60: ...hat the parking brake is disengaged Make sure that the stand has been fully retracted Make sure the light switch 1 is set to the low beam light position Set the engine stop switch 2 to RUN Turn the key 3 and set the ignition switch to ON At this stage The multifunction display shows the ignition screen for 2 seconds On the instrument panel all warning lights 4 and the backlighting are on for 2 sec...

Page 61: ...12 TO AVOID EXCESSIVE BATTERY CONSUMPTION DO NOT HOLD DOWN THE STARTER BUTTON 2 MORE THAN TEN SECONDS IF THE ENGINE FAILS TO START AFTER THIS TIME WAIT TEN SECONDS AND PRESS THE STARTER BUTTON 2 AGAIN PRESS THE STARTER BUTTON 2 BUT DO NOT ACCELERATE AND RELEASE IT AS SOON AS THE ENGINE STARTS 61 3 Use ...

Page 62: ...03_14 Engage at least a break lever and do not accelerate until you set off Press the starter button 2 to the right DO NOT SET OFF SUDDENLY WHEN THE ENGINE IS COLD RIDE AT LOW SPEED FOR SEVERAL KILOMETRES THIS WILL ALLOW THE ENGINE TO WARM UP AND REDUCE POLLUTING EMISSIONS AND FUEL CONSUMPTION IF THE WORD SERVICE IS SHOWN ON THE MULTIFUNCTION DISPLAY DURING REGULAR ENGINE OPERATION THIS MEANS THAT...

Page 63: ...RRIED SO AS TO AVOID TROUBLE WHEN MANOEUVRING BEFORE RIDING MAKE SURE THAT THE SIDE STAND IS COMPLETELY RE TRACTED OTHERWISE THE VEHICLE WILL TURN OFF WHEN YOU ACCELER ATE 03_16 To set off Operate one brake Start the engine Adjust the rear view mirror angle correctly CAUTION WITH THE VEHICLE AT A STANDSTILL PRACTICE USING THE REAR VIEW MIRRORS THE MIRRORS ARE CONVEX SO OBJECTS MAY SEEM FARTHER AWA...

Page 64: ...or the first riding kilometres limit the speed in order to warm up the engine DO NOT EXCEED THE MAXIMUM RECOMMENDED ENGINE SPEED Speed up by gradually twisting the throttle grip 2 Pos A without exceeding the recommended revs Shift the gear if in manual mode see transmission section 64 3 Use ...

Page 65: ...a lower gear called downshift is carried out When riding downhill and when braking in order to increase the braking power by using engine compression When going uphill when the engaged gear does not suit the speed high gear moderate speed and the number of engine revs falls CAUTION DOWNSHIFT ONE GEAR AT A TIME WHEN SHIFTING TO A LOWER GEAR DOWNSHIFTING MORE THAN ONE GEAR AT A TIME COULD OVERREV TH...

Page 66: ...AY RESULT IN FRIC TION GASKET OVERHEATING AND CONSEQUENTLY IN POOR BRAKING TAKE ADVANTAGE OF THE ENGINE COMPRESSION AND SHIFT UP GEARS USING THE BRAKES ALTERNATIVELY NEVER RIDE WITH THE ENGINE OFF WHEN GOING DOWNHILL WHEN RIDING ON WET SURFACES OR WITH POOR GRIP SNOW ICE MUD ETC RIDE AT A MODERATE SPEED AVOIDING SUDDEN BRAKING OR MA NOEUVRES THAT MAY LEAD TO LACK OF GRIP AND CONSEQUENTLY TO FALLS ...

Page 67: ...AKE SURE THE VEHICLE AND SPECIALLY ITS HOT PARTS DO NOT POSE ANY RISK TO PEOPLE OR CHILDREN DO NOT LEAVE YOUR VEHICLE UNAT TENDED WITH THE ENGINE ON OR THE KEY IN THE IGNITION SWITCH CAUTION IF THE VEHICLE FALLS OR IS ON A STEEP INCLINE FUEL CAN LEAK FUEL USED TO DRIVE INTERNAL COMBUSTION ENGINES IS HIGHLY FLAM MABLE AND CAN BECOME EXPLOSIVE UNDER CERTAIN CONDITIONS DO NOT REST THE RIDER OR PASSEN...

Page 68: ...VERTER Vehicle owners are warned that the law may prohibit the following the removal of any device or element belonging to a new vehicle or any other action by anyone leading to render it non operating if not for maintenance repair or replacement reasons in order to control noise emission before the sale or delivery of the vehicle to the ultimate buyer or while it is used using the vehicle after t...

Page 69: ...ush the side stand with your right foot and extend it completely 3 Lean the vehicle until the stand touches the ground Turn the handlebar fully leftwards Pull the parking lever MAKE SURE THAT THE GROUND ON WHICH THE MOTORCYCLE IS PARKED IS STABLE EVEN AND FREE OF OBSTACLES CAUTION MAKE SURE THE VEHICLE IS STABLE 03_22 BEFORE SETTING OFF MAKE SURE THE STAND HAS BEEN COMPLETELY RETRACTED TO ITS POSI...

Page 70: ...in sequential mode the words SPORT GEAR and the gear number are displayed in the instrument panel The SPORT GEAR mapping has no power limits and is suitable for sporting appli cations 03_24 When in AUTO DRIVE mode gear shifting is automatic riders only need to operate the throttle and the brakes Gear are shifted continuously truly suitable for riding in the city or for tours When the transmission ...

Page 71: ...de has been designed for tourist purposes with engine speeds lower than those in the sport mode less vibration and lower consumption levels The RAIN mode is ideal for riding in the city and to maximise safety when riding on low grip road surfaces It is not an anti skid system but only one that allows smooth gear shifting to avoid jerks when setting off managing power reduction delivered at low spe...

Page 72: ...TOURING SPORT RAIN TOURING 03_27 03_28 The actual gear engaged is shown in the central part of the display only in the SE QUENTIAL mode 72 3 Use ...

Page 73: ...03_29 03_30 03_31 73 3 Use ...

Page 74: ...03_32 03_33 03_34 74 3 Use ...

Page 75: ... displayed next to the gear Suggestion to prevent theft CAUTION WHEN USING A DISC LOCKING DEVICE PAY UTMOST ATTENTION TO RE MOVE IT BEFORE RIDING FAILURE TO OBSERVE THIS WARNING MAY CAUSE SERIOUS DAMAGE TO THE BRAKING SYSTEM AND ACCIDENTS WITH CON SEQUENT PHYSICAL INJURIES OR EVEN DEATH 75 3 Use ...

Page 76: ...FIED BY DATA IN THE USE MAINTENANCE BOOKLET 03_37 Basic safety rules 03_37 03_38 03_39 03_40 03_41 Follow the instructions given below attentively to avoid injuring persons damaging property or the vehicle in the event of the rider or the passenger falling off the vehicle and or the vehicle falling or overturning When getting on and off the vehicle make sure nothing is restricting your movements d...

Page 77: ...so as not to cause a loss of stability for vehicle and rider CAUTION THE RIDER MUST INSTRUCT THE PASSENGER ON HOW TO GET ON AND OFF THE VEHICLE SAFELY THE VEHICLE IS EQUIPPED WITH PASSENGER FOOTRESTS TO FACILITATE GETTING ON OR OFF THE VEHICLE THE PASSENGER MUST ALWAYS USE THE LEFT FOOTREST TO GET ON AND OFF THE VEHICLE NEVER ATTEMPT TO GET OFF THE VEHICLE BY JUMPING OR STRETCHING YOUR LEG TO REAC...

Page 78: ...OUND 03_40 Place both feet on the ground straighten and balance the vehicle keeping it upright in riding position CAUTION THE RIDER MUST NOT EXTRACT OR ATTEMPT TO EXTRACT THE PASSENGER FOOTRESTS WHILE SEATED BECAUSE THIS MIGHT COMPROMISE VEHICLE STABILITY AND BALANCE 03_41 Have the passenger fold out the two passenger footrests Give instructions as necessary to help the passenger mount the vehicle...

Page 79: ...SIDE AND BE READY TO PUT YOUR LEFT FOOT ON THE GROUND Place both feet on the ground and keep the vehicle balanced in the upright position Give instructions as necessary to help the passenger dismount the vehicle RISK OF FALLING AND OVERTURNING MAKE SURE THE PASSENGER HAS GOT OFF THE VEHICLE DO NOT REST YOUR WEIGHT ON THE SIDE STAND Lean the vehicle until the stand touches the ground Grasp the hand...

Page 80: ...CAUTION MAKE SURE THE VEHICLE IS STABLE 80 3 Use ...

Page 81: ...Mana GT ABS Chap 04 Maintenance 81 ...

Page 82: ...T WITH BOTH WHEELS ON THE GROUND ON A SOLID AND LEVEL SURFACE NOTE PER RISCALDARE IL MOTORE E PORTARE L OLIO MOTORE IN TEMPERA TURA D ESERCIZIO NON LASCIARE FUNZIONARE IL MOTORE AL MINIMO DEI GIRI CON VEICOLO FERMO LA PROCEDURA CORRETTA PREVEDE DI EF FETTUARE IL CONTROLLO DOPO UN VIAGGIO O DOPO AVER PERCORSO 10 mi 15 km CIRCA SU UN PERCORSO EXTRAURBANO SUFFICIENTI PER POR TARE IN TEMPERATURA L OLI...

Page 83: ...r below the reference mark on the dipstick 04_04 Engine oil top up 04_04 04_05 TOP UP THE ENGINE OIL WHEN THE ENGINE IS WARM IN ORDER TO AVOID DAMAGING THE ENGINE OIL LEVEL MUST NEVER EX CEED THE MAX MARK ON THE CRANKCASE OR DROP BELOW THE MIN MARK ON THE DIPSTICK 04_05 Fill with engine oil as required Unscrew and remove the cap 1 When using a funnel or any other element make sure it is perfectly ...

Page 84: ...n the sight glass 2 of the right crankcase The oil should reach the MAX oil level reference mark on the specific sight glass 2 on the right crankcase Engine oil change 04_06 04_07 04_08 04_09 CHANGING ENGINE OIL AND ENGINE OIL FILTER CAN PROVE DIFFICULT IF YOUR ARE INEXPERIENCED CONTACT AN OFFICIAL APRILIA DEALER IF REQUIRED IF YOU WISH TO PERFORM THESE OPERATIONS YOURSELF FOLLOW THESE INSTRUCTION...

Page 85: ...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 I...

Page 86: ...ne maintenance table Remove the engine oil filter 3 Never reuse an old filter Screw the new engine oil filter 3 Locking torques N m Engine oil filter 1 16 Nm 11 80 lbf ft Tyres This vehicle is fitted with tyres without inner tubes Tubeless CHECK TYRE INFLATION PRESSURE REGULARLY AT AMBIENT TEMPERA TURE 86 4 Maintenance ...

Page 87: ...ADLY WORN TYRES MAY COMPROMISE TRACTION AND HANDLING REPLACE TYRES WHEN WORN OR IF THERE IS A PUNCTURE IN THE TREAD AREA BIGGER THAN 5 mm 0 197 in BALANCE WHEELS AFTER A TYRE IS MENDED USE ONLY TYRE SIZES INDI CATED BY THE MANUFACTURER CHECK THAT THE INFLATION VALVES HAVE THEIR CAPS FITTED TO AVOID UNEXPECTED FLAT TYRES REPLACEMENT REPAIR MAINTENANCE AND BALANCING OPERATIONS ARE HIGHLY IMPORTANT A...

Page 88: ... country where the vehicle is used Spark plug dismantlement Working from both sides remove the two spark plug tubes With the specific supplied wrench unscrew and remove the spark plugs two per cylinder Removing the sides 04_10 04_11 04_12 04_13 04_14 04_15 NOTE THE FOLLOWING OPERATIONS REFER TO ONE SIDE OF THE VEHICLE BUT APPLY TO BOTH SIDES 88 4 Maintenance ...

Page 89: ... Open the helmet compartment Undo and remove the two fixing screws for the steering lock protection 1 and collect the two washers 04_11 Undo and remove the screw 2 04_12 Lower the helmet compartment Remove the steering lock protection 3 89 4 Maintenance ...

Page 90: ...04_13 Unscrew and remove the screw 4 04_14 Undo and remove the front lower screw 5 04_15 Release the snap on front cowl 6 that is located on the inner side of the fairing 90 4 Maintenance ...

Page 91: ...r filter 04_16 04_17 Undo and remove the six screws fixing the filter casing cover Remove the filter casing cover Undo and remove the three screws fixing the air filter Remove the air filter COVER THE HOLE WITH A CLEAN CLOTH SO THAT NO FOREIGN ELEMENTS GET INTO THE INLET DUCTS 91 4 Maintenance ...

Page 92: ...EK MEDICAL ADVICE IMMEDIATELY CAUTION TAKE CARE NOT TO POUR COOLANT ONTO HOT ENGINE OR EXHAUST SYS TEM COMPONENTS THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES WHEN CARRYING OUT MAINTENANCE OPERATIONS IT IS ADVISA BLE TO WEAR LATEX GLOVES CONTACT AN Official APRILIA Dealer FOR REPLACEMENT DO NOT DISPOSE OF THE FLUID INTO THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN DO NOT REMOVE THE...

Page 93: ...s on the ground Turn the handlebar to the left keeping the vehicle upright Make sure that the coolant level in the expansion tank is between the MAX MAX maximum level and MIN MIN minimum level refer ence marks 04_19 Otherwise Remove the right side fairing Remove the filler cap 1 Top up with recommended coolant until the coolant level is near the MAX reference mark Do not exceed this level or the c...

Page 94: ...l to the reservoir edge Check that the fluid in the reservoir is above the MIN reference mark For the rear break keep the vehicle upright and check that the fluid in the reservoir is parallel to the reservoir edge Make sure that the fluid level in the reservoir is above the LOWER reference mark If the fluid does not reach at least the LOWER MIN reference mark Check brake pads and disc for wear If ...

Page 95: ... 1 Remove the battery cover 2 Unscrew and remove the screw 3 of the negative terminal Move the negative lead 4 aside Unscrew and remove the screw 5 of the positive terminal Move the positive lead 6 aside Hold the battery 7 firmly and lift it out of its compartment Put the battery 7 away on a level surface in a cool and dry place CAUTION UPON REFITTING CONNECT THE LEAD TO THE POSITIVE TERMINAL FIRS...

Page 96: ...lmet compartment was closed open it Place the battery 7 in its housing Fasten the positive cable 6 to the positive terminal tightening the screw 5 Fasten the negative cable 4 to the negative terminal tightening the screw 3 Position the battery cover 2 Tighten the two fixing screws 1 for the battery cover Close the helmet compartment Checking the electrolyte level WARNING THIS VEHICLE IS FITTED WIT...

Page 97: ...he battery charger CAUTION WHEN RECHARGING OR USING THE BATTERY BE CAREFUL TO HAVE THE ROOM ADEQUATELY AIRED DO NOT BREATH GASES RELEASED WHEN THE BATTERY IS RECHARGING Switch on the battery charger Characteristic RECHARGE MODES Recharge Ordinary Electric Current 1 0 A Time 8 10 hours Recharge Fast Electric Current 10 A Time 0 5 hours 97 4 Maintenance ...

Page 98: ...necessary to recharge the battery to avoid sulphation Remove the battery In winter or when the vehicle is out of use for prolonged periods check charge level frequently about once a month to prevent deterioration Recharge it fully with an ordinary charge If the battery is still on the vehicle disconnect the cables from the terminals Fuses 04_26 04_27 04_28 04_29 04_30 04_31 Check fuses in case of ...

Page 99: ...screws fixing the battery cover 2 Remove the battery cover 1 Open the cover of the auxiliary fuse box 3 Take out one fuse at a time and check whether the filament 4 is broken Before replacing the fuse find and solve whenever possible the problem that caused it to blow If the fuse is damaged replace it with one of the same amperage To check the main fuses carry out the same operations described abo...

Page 100: ...ssion ECU power supply Resistance module 15A B Low high beam lights Heated hand grips OPT 15 A C Fuel pump Coils Injectors Electric fan Lambda probe Start up control relay 20A D Injection load relay Electric fan relay Injection control unit power supply Engine Stop 10A E Injection control unit permanent power supply 3A 100 4 Maintenance ...

Page 101: ...Instrument panel Turn indicators Glove box light Injection main relay 30A E Transmission ECU permanent power supply 40A THE 30A SPARE FUSE IS IN THE TOOLKIT BOX 04_31 ABS FUSE The ABS fuse is placed inside the helmet compartment J ABS fuse 20 A 101 4 Maintenance ...

Page 102: ...LEAVE PRINTS ON THE BULB AS THIS MAY CAUSE IT TO OVERHEAT OR EVEN BLOW OUT IF YOU TOUCH THE BULB WITHOUT WEARING GLOVES CLEAN OFF PRINTS WITH ALCOHOL TO AVOID DAMAGING THE BULB DO NOT FORCE ELECTRICAL CABLES BULB LAYOUT In the front headlight there are one low beam light bulb 6 one high beam light bulb 5 one tail light bulb 2 04_33 HIGH LOW BEAM BULB REPLACEMENT Remove the windscreen Remove the co...

Page 103: ... a bulb of the same type adequately 04_35 HIGH BEAM LIGHT BULB Release the bottom of the cover 4 Hold the bulb holder turn and remove it Pull the bulb out of the bulb holder Install a bulb of the same type adequately CAUTION INSERT THE BULB IN THE BULB HOLDER AND PLACE IT IN ITS SEAT MAKING SURE THE REFERENCE FITTINGS MATCH 103 4 Maintenance ...

Page 104: ...ulb 2 and replace it with another of the same type Check the proper insertion of the bulb in the bulb holder CAUTION CAREFULLY REMOVE THE POSITION LIGHT BULB HOLDER WITHOUT PULL ING ON THE ELECTRIC WIRES 04_37 Headlight adjustment 04_37 04_38 NOTE IN COMPLIANCE WITH LOCAL LEGISLATION SPECIFIC PROCEDURES MUST BE FOLLOWED WHEN ALIGNING THE LIGHTS 104 4 Maintenance ...

Page 105: ...e of the front headlight use a short crosshead screwdriver on the specific screw 1 SCREW it clockwise to raise the light beams UNDO the screw anticlockwise to lower the light beam NOTE CHECK THAT THE LIGHT BEAM VERTICAL DIRECTION IS CORRECT 04_39 Front direction indicators 04_39 Rest the vehicle on its stand Loosen and remove screw 1 Remove glass 2 Press bulb 3 slightly and turn it anticlockwise P...

Page 106: ...htly and turn it anticlockwise Pull the bulb 3 out of its fitting Insert a bulb of the same type adequately WARNING IF PARABOLE 4 STICKS OUT OF ITS FITTING INSERT IT AGAIN PROPERLY 04_41 Number plate light 04_41 04_42 Rest the vehicle on its stand Unscrew and remove the fixing screw 1 and collect the nut 106 4 Maintenance ...

Page 107: ...e bulb 3 and replace it with another of the same type 04_43 04_44 Rear view mirrors 04_43 04_44 Park the vehicle on its centre stand on safe and level ground Move the protection casing 1 HOLD THE REAR VIEW MIRROR 4 TO AVOID DROPPING IT BY ACCIDENT 107 4 Maintenance ...

Page 108: ... CARE DO NOT SCRATCH OR SPOIL THEM Remove the rear view mirror 4 CAUTION REPEAT THE PROCEDURE TO REMOVE THE OTHER MIRROR AFTER REFITTING ADJUST THE REAR VIEW MIRRORS CORRECTLY AND TIGHTEN THE NUTS IN ORDER TO ENSURE STABILITY After refitting Adjust the rear view mirror angle correctly 108 4 Maintenance ...

Page 109: ...sc and pads as follows look from the back for the front brake callipers 1 on the right side of the vehicle look from above downwards for the rear brake calliper 2 CAUTION EXCESSIVE WEAR OF THE FRICTION MATERIAL MAKES THE PAD METAL SUPPORT GET INTO CONTACT WITH THE DISC WHICH RESULTS IN A MET ALLIC NOISE AND SPARKS IN THE CALLIPER THEREFORE BRAKING EFFI CIENCY AND DISC SAFETY AND INTEGRITY ARE AT R...

Page 110: ...cooter Besides it is necessary to carry out general repairs and checks before garaging the motorcycle as one can forget to do so afterwards Proceed as follows Remove the battery Wash and dry the vehicle Polish the painted surfaces Inflate the tyres Set the vehicle in a room with no heating or humidity with minimum temper ature variations and not exposed to sun rays Wrap and tie a plastic bag aroun...

Page 111: ...ST RIDE THE VEHICLE AT MODERATE SPEED FOR A FEW KILOMETRES IN AN AREA AWAY FROM TRAFFIC 04_49 Cleaning the vehicle 04_49 04_50 04_51 Clean the motorcycle frequently if exposed to adverse conditions such as Air pollution cities and industrial areas Salinity and humidity in the atmosphere seashore areas hot and wet weath er Special environmental seasonal conditions use of salt anti icing chemical pr...

Page 112: ...RE RIDE CHECKS 04_50 To clean off dirt and mud deposited from painted surfaces soften caked dirt with a low pressure water jet Sponge off using a car body sponge soaked in a car body shampoo and water solution 2 4 parts of shampoo in water Then rinse with plenty of water and dry with a chamois leather To clean the engine outer parts use de greasing detergent brushes and old cloths Anodised or pain...

Page 113: ...ECTLY TO THE FOLLOWING PARTS WHEEL HUBS CONTROLS ON THE RIGHT AND LEFT SIDE OF THE HANDLEBAR BEARINGS BRAKE PUMPS INSTRUMENTS AND GAUGES EX HAUST SILENCER IGNITION SWITCH STEERING LOCK DO NOT USE ALCO HOL OR SOLVENTS TO CLEAN ANY RUBBER OR PLASTIC SADDLE COMPO NENTS USE WATER AND MILD SOAP CAUTION DO NOT USE SOLVENTS OR PETROL BY PRODUCTS ACETONE TRICHLORO ETHYLENE TURPENTINE PETROL THINNERS TO CL...

Page 114: ... FLUIDS DRAINED 04_53 Chain backlash check 04_53 To check the clearance Stop the engine Rest the vehicle on its stand Check that the vertical oscillation at a point between the pinion and the crown on the lower branch of the chain is approx 28 30 mm 1 10 1 18 in Move the vehicle forward so as to check the chain vertical oscillation in other positions too backlash should remain constant during all ...

Page 115: ...wing parts and make sure that the chain pinion and sprocket do not have Damaged rollers Loosened pins Dry rusty flattened or jammed chain links Excessive wear Missing sealing rings Excessively worn or damaged pinion or sprocket teeth CAUTION IF THE CHAIN ROLLERS ARE DAMAGED THE PINS ARE LOOSENED AND OR THE SEAL RINGS ARE MISSING OR DAMAGED THE WHOLE CHAIN APPARA TUS PINION SPROCKET AND CHAIN SHOUL...

Page 116: ...bricate the chain whenever necessary After washing and drying the chain lubricate it with spray grease for sealed chains THE TRANSMISSION CHAIN HAS RUBBER O RINGS BETWEEN THE SIDE PLATES OF THE CHAIN ITSELF THAT ARE USED TO HOLD THE GREASE UT MOST ATTENTION IS REQUIRED WHEN ADJUSTING LUBRICATING WASHING OR REPLACING THE CHAIN CHAIN LUBRICANTS AVAILABLE ON THE MARKET CAN CONTAIN SUBSTAN CES THAT DA...

Page 117: ...Mana GT ABS Chap 05 Technical data 117 ...

Page 118: ...osition Saddle height 810 mm 31 89 in Wheelbase 1465 mm 57 68 in Kerb weight full fuel tank 238 kg 524 lb 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 cm 51 22 cu in Bore stroke 88 x 69 mm 3 46 x 2 72 in 118 5 Technical data ...

Page 119: ...0 rpm Clutch Automatic Lubrication system Dry sump system with separate oil tank 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 CAPACITY Fuel reserve included 16 l 3 52 UKgal 4 23 USgal 119 5 Technical data ...

Page 120: ...nt 2 5 l 0 55 UK gal 0 66 USgal Seats 2 Vehicle max load rider passenger luggage 210 kg 463 lb 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 DRIVE CHAIN Type Endless without master link and with sealed links No of links 100 Model 525 ZRPK 120 5 Technical data ...

Page 121: ... unleaded petrol minimum octane rating 95 NORM and 85 NOMM CHASSIS Type High strength steel tubular perimeter frame Steering inclination angle 24 Trail 103 mm 4 05 in SUSPENSIONS Front Upside down hydraulic action telescopic fork Ø 43 mm 1 69 in stems Travel 120 mm 4 72 in 121 5 Technical data ...

Page 122: ...e 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 WHEEL RIMS Type Light alloy rims with extractable bolt Front 3 50 x 17 Rear 6 00 x 17 122 5 Technical data ...

Page 123: ...enger 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 SPARK PLUGS Standard spark plugs NGK CR7EKB Spark plug electrode gap 0 6 0 7 mm 0 024 0 028 in Resistance 5 kOhm 123 5 Technical data ...

Page 124: ...ric starter Ignition Electronic inductive high efficiency integrated with the injection system with variable advance separate HV coil Ignition advance Three dimensional map managed by control unit 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 124 5 Technical data ...

Page 125: ... 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 125 5 Technical data ...

Page 126: ...ch 1 One 8 10 mm 0 31 0 39 in double open ended spanner 2 One 11 13 mm 0 43 0 51 in double open ended spanner 3 One 16 mm 0 63 in box spanner with 13 mm 0 52 in welded hex 4 Twin screwdriver 5 L shaped hex Allen key CH4 6 L shaped hex Allen key CH5 7 Extractor for blade fuses 8 One 30A fuse One 40A fuse Maximum weight allowed 1 5 kg 3 3 lb 126 5 Technical data ...

Page 127: ...Mana GT ABS Chap 06 Programmed maintenance 127 ...

Page 128: ...to solve it All scheduled services must be carried out at the specified intervals and mileage as soon as the predetermined mileage is reached Carrying out scheduled services on time is essential for the validity of your warranty For further information regarding Warranty procedures and Scheduled Maintenance please refer to the Warranty Booklet NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTE...

Page 129: ... if necessary Coolant Check top up or change if necessary Tyres Check and replace if necessary Tyre pressure Adjust Bolts nuts and screws tightening Check and restore tightening torque Transmission gears and anti vibration buffer Check check tightening adjust and replace if necessary Suspensions and setting Check and adjust if necessary Braking systems Check Safety switches Check Fork oil seal Che...

Page 130: ...ean Final transmission chain crown and pinion Check and clean adjust grease or replace if necessary Transmission cables Check adjust and grease or replace if necessary Steering bearings and steering clearance Check and clean adjust grease or replace if necessary Diagnosis for engine control unit and transmission control unit Check Brake discs Check and clean replace if necessary Parking brake call...

Page 131: ... gears and anti vibration buffer Check check tightening adjust and replace if necessary Suspensions and setting Check and adjust if necessary Braking systems Check Safety switches Check Fork oil seal Check and clean replace if necessary Battery Check terminal tightening Wheel bearings Check and clean adjust grease or replace if necessary Transmission bolts nuts and screws tightening Check and rest...

Page 132: ...le operation Check Parking brake calliper Check and adjust if necessary Spark plug Replace Break pads Check and replace if necessary Lights circuit Check adjust direction or replace if necessary Brake fluid Check top up or replace if necessary Coolant Check top up or change if necessary Tyres Check and replace if necessary Tyre pressure Adjust Bolts nuts and screws tightening Check and restore tig...

Page 133: ...gine oil filter Replace Air filter Clean Transmission air filter Clean Final transmission chain crown and pinion Replace Transmission cables Check adjust and grease or replace if necessary Steering bearings and steering clearance Check and clean adjust grease or replace if necessary Diagnosis for engine control unit and transmission control unit Check Brake discs Check and clean replace if necessa...

Page 134: ...htening Check and restore tightening torque Transmission gears and anti vibration buffer Check check tightening adjust and replace if necessary Suspensions and setting Check and adjust if necessary Braking systems Check Safety switches Check Fork oil seal Check and clean replace if necessary Battery Check terminal tightening Fuel pipes Check and clean replace if necessary Wheel bearings Check and ...

Page 135: ...djust grease or replace if necessary Diagnosis for engine control unit and transmission control unit Check Brake discs Check and clean replace if necessary General vehicle operation Check Break pads Check and replace if necessary Lights circuit Check adjust direction or replace if necessary Brake fluid Check top up or replace if necessary Coolant Check top up or change if necessary Spark plug Repl...

Page 136: ...if necessary Parking brake calliper Check and adjust if necessary Transmission bolts nuts and screws tightening Check and restore tightening torque Driving pulley bulb ring nut Check and restore tightening torque Control bushing Grease AT 50000 KM 34069 MI Engine oil Change Engine oil filter Replace Air filter Clean Transmission air filter Clean Final transmission chain crown and pinion Check and ...

Page 137: ... Tyres Check and replace if necessary Tyre pressure Adjust Bolts nuts and screws tightening Check and restore tightening torque Transmission gears and anti vibration buffer Check check tightening adjust and replace if necessary Suspensions and setting Check and adjust if necessary Braking systems Check Safety switches Check Fork oil seal Check and clean replace if necessary Battery Check terminal ...

Page 138: ...and grease or replace if necessary Steering bearings and steering clearance Check and clean adjust grease or replace if necessary Diagnosis for engine control unit and transmission control unit Check Brake discs Check and clean replace if necessary General vehicle operation Check Break pads Check and replace if necessary Lights circuit Check adjust direction or replace if necessary Brake fluid Che...

Page 139: ...ry Battery Check terminal tightening Fuel pipes Check and clean replace if necessary Wheel bearings Check and clean adjust grease or replace if necessary Parking brake calliper Check and adjust if necessary Transmission bolts nuts and screws tightening Check and restore tightening torque Driving pulley bulb ring nut Check and restore tightening torque Control bushing Grease AT 70000 KM 43496 MI En...

Page 140: ...ection or replace if necessary Brake fluid Check top up or replace if necessary Coolant Check top up or change if necessary Tyres Check and replace if necessary Tyre pressure Adjust Bolts nuts and screws tightening Check and restore tightening torque Transmission gears and anti vibration buffer Check check tightening adjust and replace if necessary Suspensions and setting Check and adjust if neces...

Page 141: ...e if necessary Transmission cables Check adjust and grease or replace if necessary Steering bearings and steering clearance Check and clean adjust grease or replace if necessary Diagnosis for engine control unit and transmission control unit Check Brake discs Check and clean replace if necessary General vehicle operation Check Break pads Check and replace if necessary Lights circuit Check adjust d...

Page 142: ... necessary Battery Check terminal tightening Wheel bearings Check and clean adjust grease or replace if necessary Parking brake calliper Check and adjust if necessary Transmission bolts nuts and screws tightening Check and restore tightening torque Driving pulley bulb ring nut Check and restore tightening torque Control bushing Grease RECOMMENDED PRODUCTS Product Description Specifications ENI i R...

Page 143: ...xtreme pressure additives with optimal water repellent properties ISO L X BCHB 2 DIN 51 825 KP2K 20 AGIP CHAIN GREASE SPRAY Recommended CHAIN LUBRICANT 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 with organic inhibition additives Red ready to use ASTM D 3306 ASTM D 4656 ASTM D ...

Page 144: ...144 6 Programmed maintenance ...

Page 145: ...Mana GT ABS Chap 07 Special fittings 145 ...

Page 146: ...Accessories index Side panniers Case Centre stand Mudflap Luggage rack 146 7 Special fittings ...

Page 147: ...ne oil 10 82 84 Engine stop 39 F Fork 56 Fuel 8 Fuses 98 G Gearbox oil 10 H Headlight 104 Helmet compartment 44 Horn 37 I Identification 46 Immobilizer 43 Instrument panel 19 48 M Maintenance 81 127 128 Maintenance Table 128 Mirrors 107 R rear view mirrors 107 S Saddle 45 Scheduled maintenance 128 Shock absorbers 54 Spark plug 88 Stand 12 69 Start up 39 Stop switch 39 T Technical data 117 Transmis...

Page 148: ...ity control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only and are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publication beforehand to make any changes to...

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