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APRILIA MSS Mana GT ABS, Service Station Manual

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APRILIA MSS Mana GT ABS Service Station Manual Download Page 238

- 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

AP8140180

 

Extractor for bushings

020376Y

 

Adapter handle

020357Y

 

32 x 35 mm adaptor

020363Y

 

20-mm Oil seal guide

Refitting the driven pulley shaft bearing

- Heat the transmission cover inside with a heat gun.

- Fit the bearing onto the special tool with a little grease to prevent it from coming out.

- Refit the new bearing with the specific tool.

Specific tooling

020376Y

 

Adapter handle

020359Y

 

42 x 47-mm adaptor

020363Y

 

20-mm Oil seal guide

- Refit the Seeger ring.

Engine

MSS Mana GT ABS

ENG - 238

Summary of Contents for MSS Mana GT ABS

Page 1: ...SERVICE STATION MANUAL 894171 MSS Mana GT ABS ...

Page 2: ... and tested together with the actual vehicle itself All aprilia Original Spare Parts undergo quality control procedures to guarantee reliability and durability The descriptions and illustrations given in this publication are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged aprilia reserves the right at any time and without being required to ...

Page 3: ...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 t...

Page 4: ...OLS 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 ...

Page 5: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 6: ...HED 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 t...

Page 7: ...LUTCH 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 KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN WHEN HANDLING BATTE...

Page 8: ...TS 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 c...

Page 9: ...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 ensure...

Page 10: ...e 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...

Page 11: ...ssure 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 Specification Desc Quantity Type aprilia sport gear with electrically controlled variator double mode sequential and autodrive OIL PUMP Specification Desc Quantity Type Trochoidal Rotor shim washers pressure pump 12 mm 0 47 in scavenge pump 22 mm 0...

Page 12: ...n Desc Quantity 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 Specification Desc Quantity Type Endless without maste...

Page 13: ...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 Specification Desc Quantity High beam light LED Right turn indicator LED Left turn indicator LED General warning LED Fuel reserve LED RPM 1 LED RPM 2 LE...

Page 14: ...260 mm 10 24 in disc brake Ø 25 mm 0 98 in twin plunger calliper Wheels and tyres WHEEL RIMS Specification Desc Quantity Type Light alloy rims with extractable bolt Front 3 50 x 17 Rear 6 00 x 17 TYRES Specification Desc Quantity 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...

Page 15: ...ws 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 i...

Page 16: ...entre 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 L...

Page 17: ...or to engine 4 7 Nm 5 16 lbf ft hex headflanged screw fixing voltage regulator on bracket M6x30 2 10 Nm 7 38 lbf ft 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 lockin...

Page 18: ... on lower U bolt M8x25 4 25 Nm 18 44 lbf ft 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 sc...

Page 19: ...ock 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 partment 14 1 Nm 0 74 lbf ft 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 TBEI screw with front washer for fixing the instrument panel to the side and top fairing...

Page 20: ...M 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 ...

Page 21: ...n coupling clear ance Characteristic Standard clearance 0 015 0 029 mm 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 Characteri...

Page 22: ...FITTING A MAXIMUM CLEARANCE AFTER USE A STANDARD COUPLING 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 ...

Page 23: ...5 016 Cat 2 Standard diameter 45 016 45 022 CRANKSHAFT CONNECTING ROD AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half shaft transmission side 29 9 0 05 A D 0 20 0 60 Half shaft flywheel side 29 9 0 05 B D 0 20 0 60 MSS Mana GT ABS Characteristics CHAR 23 ...

Page 24: ...cting 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...

Page 25: ...howa SAE 5W FUCHS TITAN SAF 1091 Fork oil Sachs AGIP MP GREASE Black smooth textured lithium calcium soap based grease containing EP ex treme pressure additives with optimal water repellent properties ISO L X BCHB 2 DIN 51 825 KP2K 20 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 ...

Page 26: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 27: ...ion 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 MSS Mana GT ABS Special tools S TOOLS 27 ...

Page 28: ...Y Dial gauge magnetic support 020357Y 32 x 35 mm adaptor 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 Special tools MSS Mana GT ABS S TOOLS 28 ...

Page 29: ...scription 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 MSS Mana GT ABS Special tools S TOOLS 29 ...

Page 30: ...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 Special tools MSS Mana GT ABS S TOOLS 30 ...

Page 31: ...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 MSS Mana GT ABS Special tools S TOOLS 31 ...

Page 32: ...iption 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 Special tools MSS Mana GT ABS S TOOLS 32 ...

Page 33: ...cription 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 MSS Mana GT ABS Special tools S TOOLS 33 ...

Page 34: ...661Y 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 Special tools MSS Mana GT ABS S TOOLS 34 ...

Page 35: ...wheel extractor 020714Y Dial gauge mounting 020716Y Connecting rod locking AP0276474 Valve spring compressor adaptor AP8140146 Weight AP8140147 Spacer tool AP8140148 Spacer piston separating plate MSS Mana GT ABS Special tools S TOOLS 35 ...

Page 36: ...rations 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 Special tools MSS Mana GT ABS S TOOLS 36 ...

Page 37: ...5 Axone battery charger 230V 50Hz AP8140187 Engine support stand AP8106702 Flywheel lock calliper spanner AP8202311 Axone battery charger 110V 60Hz AP8140199 Tool panel 8140426 Hooks for panel MSS Mana GT ABS Special tools S TOOLS 37 ...

Page 38: ...Stores code Description 020881Y Panel graphics Special tools MSS Mana GT ABS S TOOLS 38 ...

Page 39: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 40: ...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 ...

Page 41: ...el 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 C...

Page 42: ... 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 T...

Page 43: ...NE 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 B...

Page 44: ... 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 Locking torques...

Page 45: ... Screw the new engine oil filter 1 Locking torques N m 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 MSS Mana GT ABS Maintenance MAIN 45 ...

Page 46: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 47: ...PANEL LIGHTS UP BUT NO FAILURE INDICATION IS SHOWN 2 IS THE FUEL PUMP ACTIVATED YES go to 3 NO go to 7 3 DOES THE MOTOR TURN WHEN THE STARTER BUTTON IS PRESSED YES go to 4 NO go to 12 4 SEE THE ELECTRICAL SYSTEM CHECKS AND CONTROLS ENGINE 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...

Page 48: ...o to 42 19 IS THERE VOLTAGE AT PIN 28 B WHEN THE KEY IS SET TO ON THAT IS IS THERE VOLTAGE ON THE YELLOW RED CABLE OF RETENTION RELAY No 65 AND IS THERE CONTINUITY IN THE CABLE UP TO PIN 28 OF CONNECTOR B OF THE ECU AND IS THE CABLE GROUND INSULATED YES go to 20 NO go to 48 20 DOES THE VOLTAGE IN THE YELLOW RED CABLE OF RETENTION RELAY No 65 DROP TO APPROXIMATELY 0 WHEN THE KEY IS SET TO ON AND TH...

Page 49: ... NOT IN 1ST GEAR POSITION END 32 IS THERE VOLTAGE ON THE YELLOW GREEN CABLE OF THE SWITCH WHEN THE KEY IS SET TO ON AND THE FRONT BRAKE SWITCH PRESSED YES go to 33 NO go to 34 33 CHECK CONTINUITY AND GROUND INSULATION OF THE YELLOW GREEN 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 YES go to 35 NO go to ...

Page 50: ...LE HARNESS PINK BROWN CABLE END 48 RESTORE THE CABLE HARNESS YELLOW RED CABLE END 49 IS THERE CONTINUITY BETWEEN THE STARTER BUTTON BLUE CABLE AND THE GROUND LEAD YES go to 50 NO go to 51 50 CHECK THE RIGHT LIGHT SWITCH CONNECTOR THE CABLES FROM THE 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 ...

Page 51: ...I WARNING LIGHT FLASHES WITH THE ABS WORD STEADY ON THE DISPLAY THE ABS SYSTEM IS NOT ACTIVATED INSTRUMENT PANEL OFF CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER 1 KEY ON THE INSTRUMENT PANEL DOES NOT TURN ON 2 IS THE FUEL PUMP ACTIVATED ...

Page 52: ...E ELECTRICAL SYSTEM CHAPTER 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 YES go to 3 NO go to 9 3 FIND THE MALFUNCTION SEE ELECTRICAL SYSTEM CHECKS AND CONTROLS CHAPTER AND RESTORE THE CORRECT OPERATION 4 HAS THE INJECTION ECU BEEN REPLACED YES go to 5 NO go to 6 5 WITH AXONE SELECT THROTTLE POSI...

Page 53: ... 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 BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ...

Page 54: ...LVE 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 BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR E...

Page 55: ...ND 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 BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK...

Page 56: ... 6 DELETE THE ERROR WITH THE ERROR CLEARING FUNCTION IN THE DIAG NOSIS FUNCTION OF THE INSTRUMENT PANEL END Troubleshooting MSS Mana GT ABS TROUBL 56 ...

Page 57: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 58: ...ELAY Location on the wiring diagram 29 Location on the vehicle under the helmet compartment to the right in the relay holder FAN CONTROL RELAY Location on the wiring diagram 62 Location on the vehicle under the helmet compartment to the right in the relay holder START UP RELAY Location on the wiring diagram 64 Location on the vehicle under the saddle RETENTION RELAY Location on the wiring diagram ...

Page 59: ...nector 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 ins...

Page 60: ...Front side TABLE A Turn signal extension 1 3 Black nylon clamps TABLE B Turn signal extension 1 3 Black nylon clamps TABLE C 4 Clamps TABLE D 2 Clamps Electrical system MSS Mana GT ABS ELE SYS 60 ...

Page 61: ...nna cable to the support TABLE F Front ABS sensor fitting 3 Black nylon clamps White cable guide TABLE F1 3 Clamps TABLE G 6 ABS grommet Pay attention to the front ABS hose guides pas sage so as not to flatten them MSS Mana GT ABS Electrical system ELE SYS 61 ...

Page 62: ...ar pump con trol unit pipes insert the two pipes in the respective lower clamps 9 Modulator TABLE I 10 Fan connector 11 Key switch connection TABLE J 12 Black clamps 178x4 7x0 16 13 Clamp to chassis 14 Black clamp 178x4 7x0 16 15 Front ABS sensor connector Electrical system MSS Mana GT ABS ELE SYS 62 ...

Page 63: ...ix the left light switch cable and the transmission control cable to the support 17 Clamp that fixes the air temperature sensor cable the left light switch cable and the transmis sion control cable to the support Central part TABLE A COILS 1 Part for fitting ground terminals on coil assembly 2 Cable guide MSS Mana GT ABS Electrical system ELE SYS 63 ...

Page 64: ...L 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 Electrical system MSS Mana GT ABS ELE SYS 64 ...

Page 65: ...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 MSS Mana GT ABS Electrical system ELE SYS 65 ...

Page 66: ...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 Electrical system MSS Mana GT ABS ELE SYS 66 ...

Page 67: ... 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...

Page 68: ...CABLE HARNESS 1 Pick up divider cable harness 2 Fasten the cable harness with a clamp 3 Signal regulator exit with WHITE tape 4 Fasten the upper branch of the control unit with a clamp TABLE Q 17 Big clamp 18 Clamp to chassis Electrical system MSS Mana GT ABS ELE SYS 68 ...

Page 69: ...e 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 M...

Page 70: ...LE 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 Electrical system MSS Mana GT ABS ELE SYS 70 ...

Page 71: ... 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 24 Clamp to chassis 25 Rear ABS sensor connector 26 Black nylon clamp MSS Mana GT ABS Electrical system ELE SYS 71 ...

Page 72: ... 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 Electrical system MSS Mana GT ABS ELE SYS 72 ...

Page 73: ...Note The sensor cable must pass ABOVE the brake pipe TABLE D 2 black nylon clamps MSS Mana GT ABS Electrical system ELE SYS 73 ...

Page 74: ...General wiring diagram KEY 1 MULTIPLE CONNECTORS 2 PULLEY POSITION SENSOR 3 START UP CONTROL RELAY 4 PULLEY SPEED SENSOR Electrical system MSS Mana GT ABS ELE SYS 74 ...

Page 75: ...IAGNOSIS 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 ...

Page 76: ... 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 CONTRO...

Page 77: ...NENT 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...

Page 78: ...e 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...

Page 79: ...ture 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 tu...

Page 80: ...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 DISAB...

Page 81: ...e 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 MSS Ma...

Page 82: ...ATE 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 co...

Page 83: ...ng 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 U...

Page 84: ...H 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 syste...

Page 85: ...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 Operation Operating principle 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 ...

Page 86: ...ancement 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 interrupti...

Page 87: ...ic 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 ...

Page 88: ...E BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER 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 Potentia...

Page 89: ...njection 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 inst...

Page 90: ...nit 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...

Page 91: ...ction Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not 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 i...

Page 92: ...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 ...

Page 93: ...l or tone wheel with wrong number of teeth or wrong tyre size Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is ...

Page 94: ...CAL 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 continu...

Page 95: ...CTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN...

Page 96: ...uity 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 grou...

Page 97: ...ot the temperature indicated by the instrument panel ELECTRICAL ERRORS air temperature sensor P0110 open circuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has been detected at PIN 14 of connector A BROWN If shorted to negative voltage equal to zero has been detected Troubleshooting If the circuit is open shorted to positive che...

Page 98: ...t 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 Operation Operating principle The Marelli injection control unit reads and inter prets a voltage generated by the ...

Page 99: ...0 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...

Page 100: ... 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 cab...

Page 101: ...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 t...

Page 102: ... component and restore the cable harness Fuel pump Electrical characteristics 0 7 0 2 Ohm THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUB...

Page 103: ...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 t...

Page 104: ...e 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 ...

Page 105: ...rted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 10 of connector A BROWN If the circuit is open short circuit to negative voltage equal to zero has been detected Troubleshooting If shorted to positive disconnect the coil connector set the key to ON activate the coil with Axone and check voltage at connector PIN 1 if there is voltage restore the cable h...

Page 106: ... signal THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEV...

Page 107: ...ity 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...

Page 108: ...ault 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 instru...

Page 109: ...tand Up closed circuit continu ity Side Stand Down open circuit infinite resistance Pin out 1 Ground connection 2 Voltage 12V THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT C...

Page 110: ...on to the control unit Operation Operating principle When the sensor is inverted the circuit is closed to ground When the Marelli control unit detects this ground connection it does not enable start up or shuts off the engine Level in wiring diagram Start up enabling switches Location on the vehicle under the saddle front area near the control unit connector near the sensor Electrical characterist...

Page 111: ...ot 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 c...

Page 112: ...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 th...

Page 113: ...RICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE FUEL INJECTION SYSTEM ELECTRICAL ERRORS Fan relay P0481 shorted to positive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 14 of connector B BLUE If the circuit is open shorted to negative voltage equal to zero has been detected If t...

Page 114: ...NENT 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 RUN STOP switch Run stop switch Function It tells the control unit if the driver wishes to enable engine start up or to keep the engine running Operation Operating principle If the driver ...

Page 115: ...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 insu...

Page 116: ...mpartment and the saddle connector if available on the control unit Electrical specifications Pin out see the CONNECTORS section CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE AUTOMATIC TRANSMISSION system ISO SCREEN PAGE Hardware num...

Page 117: ...mple 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 enabl...

Page 118: ...ol 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 Ph...

Page 119: ...gory 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 G...

Page 120: ...re 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 tell...

Page 121: ...AS THEY SHOW THE CONNECTOR COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE AUTOMATI...

Page 122: ... position for all the other positions indicated by the driving pulley position sensor Driving pulley saved position in first gear Example value 2 06 mm It should be a value between 0 5 and 2 5 mm Movement of the first gear in relation to the saved position wear Example value 0 03 mm Even if the belt is worn the first gear position is modified in relation to the initial position in order to keep th...

Page 123: ...g 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 th...

Page 124: ...ty 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 volta...

Page 125: ... speed of rotation of the fixed half pulley that has four studs Operation Operating principle Inductive sensor sinusoidal alternating current is generated approximately 0 7 V at idle speed for the transmission ECU reading 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 Ele...

Page 126: ...inimum 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 ...

Page 127: ...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 Oper...

Page 128: ... 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 Gear mode switch Code 9005 above maximum threshold below minimum threshold Error cause If above the maximum threshold exces...

Page 129: ...to the transmission ECU Level in wiring diagram transmission manage 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 ...

Page 130: ...interface 21 28 control unit PIN C1 C8 and interface PIN interface 31 38 ERRORS Pedal gear upshift control Code 900D signal not valid for logic reasons blocked control Error cause 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 fo...

Page 131: ...etween 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...

Page 132: ...eck 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 st...

Page 133: ... LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE AUTOMATIC TRANSMISSION system STATUSES Handlebar gear upshift control Example value Releas...

Page 134: ...ere 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 connecto...

Page 135: ...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...

Page 136: ... code 020481Y with the adaptor code 020481Y004 The correspondence between the control unit PIN and the interface PIN is the following control unit PIN A1 A8 and interface PIN interface 11 18 control unit PIN B1 B8 and interface PIN interface 21 28 control unit PIN C1 C8 and interface PIN interface 31 38 ERRORS Driving pulley electrical motor Code 900A excessive actuation time excessive current inp...

Page 137: ...lay 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 ...

Page 138: ...correspondence between the control unit PIN and the interface PIN is the following control unit PIN A1 A8 and interface PIN interface 11 18 control unit PIN B1 B8 and interface PIN interface 21 28 control unit PIN C1 C8 and interface PIN interface 31 38 ERRORS Driving pulley electrical motor Code 900A excessive actuation time excessive current input signal not valid Error cause If activation time ...

Page 139: ...ion 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 p...

Page 140: ...5 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 Electrical system MSS Mana GT ABS ELE SYS 140 ...

Page 141: ...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 MSS Mana GT ABS Electrical system ELE SYS 141 ...

Page 142: ...put 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 Electrical system MSS Mana GT ABS ELE SYS 142 ...

Page 143: ...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...

Page 144: ...e 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 ...

Page 145: ...activation PIN 36 Heated handgrips A PIN 37 Heated handgrips B PIN 38 General ground PIN 39 General ground PIN 40 General ground ABS Modulator INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR Check the initial position of the lever that couples the connector When the connector is fully inserted the distance between the connector and the ABS control unit must be 7 5 mm 0 29 in MSS Mana GT ABS Elec...

Page 146: ...s 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 ...

Page 147: ...e 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 contr...

Page 148: ...trument 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 c...

Page 149: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 150: ...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 Engine from vehicle MSS Mana GT ABS ENG VE 150 ...

Page 151: ... Disconnect the two sensors Remove the clamp Undo and remove the four upper fixing screws MSS Mana GT ABS Engine from vehicle ENG VE 151 ...

Page 152: ... mission cooling housing Undo and remove the two lower fixing screws Undo and remove the internal fixing screw Undo and remove the screw fixing the gearshift lever Remove the gearshift lever Engine from vehicle MSS Mana GT ABS ENG VE 152 ...

Page 153: ... footrest support Remove the transmission cooling cov er Undo and remove the starter motor supply cable fixing nut Slide off the starter motor power supply cable Remove the five clamps placed on the cable harness MSS Mana GT ABS Engine from vehicle ENG VE 153 ...

Page 154: ...speed sensor Undo and remove the two screws fixing the stand sensor Remove the stand sensor Undo and remove the gear sensor fix ing screw Remove the two gearshift pedal sen sors Disconnect the potentiometer connec tor Engine from vehicle MSS Mana GT ABS ENG VE 154 ...

Page 155: ... Remove the variator motor cover Undo and remove the two fixing screws Remove the variator motor Disconnect the horn connectors MSS Mana GT ABS Engine from vehicle ENG VE 155 ...

Page 156: ...the yellow cable connec tor Remove the connector of the voltage regulator cable harness Remove the ground lead Disconnect the intake air sensor from the throttle body Engine from vehicle MSS Mana GT ABS ENG VE 156 ...

Page 157: ...m the throttle body Remove the two retaining straps Disconnect the timing sensor Working on the left side slide off the spark plug tube Working on the right side slide off the spark plug tubes MSS Mana GT ABS Engine from vehicle ENG VE 157 ...

Page 158: ... Disconnect the front coil connector Release the coil ground lead Disconnect the rear coil connector Slide off the six relays from their seats Engine from vehicle MSS Mana GT ABS ENG VE 158 ...

Page 159: ...e water bulb Undo and remove the fixing screw and collect the washer Release the two quick release joints for fuel delivery and return Remove the injector connectors MSS Mana GT ABS Engine from vehicle ENG VE 159 ...

Page 160: ...elease it from the seal clamp Remove the exhaust Slide off the rubber protection Undo and remove the cable holder sheath fixing nut Slide off the throttle grip cable Repeat the same operations for the second throttle grip cable Engine from vehicle MSS Mana GT ABS ENG VE 160 ...

Page 161: ...ove the filter casing Remove the transmission cooling cov er Remove the left footrest plate Remove the exhaust Position the vehicle adequately on the front service stand and on the under sump stand Undo and remove the rear shock ab sorber fixing screw Secure the shock absorber to the chas sis Release the parking brake cable Undo and remove the plate fixing screw and remove the right footrest holde...

Page 162: ...oth brake plate fix ing screws Unscrew and remove the fixing nut Collect the washer Working on the right side hold the fork and with a rubber hammer collect the fork pin Slide off the chain from the pinion Engine from vehicle MSS Mana GT ABS ENG VE 162 ...

Page 163: ... unit to gether with gear and chain Working on the left side unscrew and remove the fixing nuts of the engine bolts Working on the right side slide off the engine bolts Lower the engine MSS Mana GT ABS Engine from vehicle ENG VE 163 ...

Page 164: ...Engine from vehicle MSS Mana GT ABS ENG VE 164 ...

Page 165: ...INDEX OF TOPICS ENGINE ENG ...

Page 166: ...ut NOTE THE DECLARED RPM VALUE IS THAT INDICATED BY THE DIAGNOSTIC TESTER THE RPM READING IS NOT THE REAL ONE BUT IT IS VALID FOR DIAGNOSIS PURPOSES Electric characteristic Input at driving speed 120 A Engine speed 300 400 rpm The start up system has a gear between the motor armature and the crankshaft equipped with a free wheel coaxial to the flywheel and the torque limiter on the intermediate sh...

Page 167: ...ing it to the crankcase Installing the starter motor Check that the O ring is in good conditions and lubricate it Fit the starter motor Tighten the 2 fixing screws to the prescribed tor que Locking torques N m Starter motor retainers 11 Nm 13 Nm 8 11 lb ft 9 59 lb ft Removing the idle gear Check that the toothing is not worn Check the diameter of the two bearings Characteristic Gear bearing diamet...

Page 168: ...D WITH 4 GEARS THAT FUNCTION AS CLUTCH DRIVING PLATES Driven plates consist of 4 Belleville springs with grooved profiles this assembly allows transmitting torques below 100 Nm 73 75 lbf ft In case of incorrect start up procedures the torque limiter prevents any kicks resulting in inversion of rotation direction of the crankshaft which would impair the engine structure The limiter assembly cannot ...

Page 169: ...rter ring gear hub Check the hub outside diameter Characteristic Hub outside diameter 45 665 mm 0 008 0 005 mm 1 79 in 0 0003 0 0002 in Check the inside diameter of the start up gear bushing Check that the toothing is not worn Characteristic Bushing inside diameter 27 mm 0 020 0 041 mm 1 0629 in 0 0008 0 0016 in NOTE IF THE FAULTS FOUND AFFECT THE HUB IT IS EXPEDIENT TO REPLACE THE STARTING RING G...

Page 170: ...F THE BEARING ON THE CRANKSHAFT IN CASE OF IRREGULARITIES REPLACE THE CRANKSHAFT Installing the starter gear Lubricate the internal bushing and the starter ring gear hub surface Fit the starting ring gear on the flywheel by turning it clockwise and inserting the gear at the same time Engine MSS Mana GT ABS ENG 170 ...

Page 171: ... side Removing the flywheel cover Undo the sixteen screws fixing it to the crank case Remove the flywheel cover NOTE THE COVER OFFERS RESISTANCE DUE TO THE FLYWHEEL MAGNETIC FIELD MSS Mana GT ABS Engine ENG 171 ...

Page 172: ...Specific tooling 020713Y Flywheel extractor Fit the specific extractor and unlock the flywheel operating the tool CAUTION THE THREAD IS ANTICLOCKWISE Specific tooling 020713Y Flywheel extractor Once it is unlocked remove the flywheel with the freewheel Undo the plate fixing screw Engine MSS Mana GT ABS ENG 172 ...

Page 173: ... Undo the five fixing screws and remove the oil pump compartment closing bulkhead Remove the intermediate gear Removing the stator Undo the 3 fixing screws and remove the stator with the cable harness MSS Mana GT ABS Engine ENG 173 ...

Page 174: ...G 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 ...

Page 175: ... 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 th...

Page 176: ...orques N m 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 Locking torques N m Flywheel cover screws 11 13 Head and timing Schema Engine MSS Mana...

Page 177: ...Removing the intake manifold Remove the coolant pipes Undo the six fixing screws MSS Mana GT ABS Engine ENG 177 ...

Page 178: ...h 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 E...

Page 179: ...Specific tooling AP8106702 Flywheel lock calliper spanner Repeat the operations for the front cylinder timing system gear Removing the cylinder head The head removal operation is carried out in two separate stages first on the rear cylinder then on the front one If the heads are removed together with the valves and the camshaft follow the recommendations NOTE THE HEADS MUST BE CORRECTLY REMOVED WI...

Page 180: ...y once but they are valid for both heads Remove the spark plugs Unscrew the two fixing nuts and collect the wash ers Undo the spark plug side screw Undo the two screws inside the head timing sys tem side Engine MSS Mana GT ABS ENG 180 ...

Page 181: ...mshaft 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 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 f...

Page 182: ...ling AP0276474 Valve spring compressor adaptor AP8140179 Support for valve fitting removal CAUTION ARRANGE THE VALVES SO AS TO RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD FLYWHEEL SIDE AND TRANSMISSION SIDE Remove the oil seals with the specific tool Specific tooling 020431Y Valve oil seal extractor Engine MSS Mana GT ABS ENG 182 ...

Page 183: ...PRING 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 Specification Desc Quantity Bearing A Ø 42 0 060 0 085 mm Bearing B Ø 20 0 020 0 041 mm MSS Mana GT ABS Engine ENG 183 ...

Page 184: ...mm Maximum axial clearance allowed 0 3 mm STANDARD HEIGHT Specification Desc Quantity 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 als...

Page 185: ... Characteristic Standard value 1 1 3 mm Limit allowed 1 6 mm If the width of the mark on the valve seat is larger than the prescribed limits true the seats with a 45 milling cutter and then grind Replace the head in case of excessive wear or damage VALVE STANDARD LENGTH Specification Desc Quantity Inlet 95 0 0 3 mm Outlet 94 2 0 3 mm Measure the diameter of the valve stem at the three positions in...

Page 186: ...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 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 Engine MSS Mana...

Page 187: ...nto 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 c...

Page 188: ...nt 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 Engine MSS Mana GT ABS ENG 188 ...

Page 189: ...y 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 ...

Page 190: ...ication Desc Quantity 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 Engine MSS Mana GT ABS ENG 190 ...

Page 191: ...e adaptor compress the springs and fit the cotters in their seats Specific tooling AP8140179 Support for valve fitting removal AP0276474 Valve spring compressor adaptor NOTE DO NOT CHANGE THE VALVE FITTING POSITION FIT THE VALVE SPRINGS WITH THE REF ERENCE COLOUR ON THE COTTERS SIDE TURNS WITH GREATER PITCH MSS Mana GT ABS Engine ENG 191 ...

Page 192: ...at 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 Engine MSS Mana GT ABS ENG 192 ...

Page 193: ...ermined by the injection system does in fact correspond with the value actually activated on the engine by means of the stroboscopic light Specific tooling AP8140595 Axone battery charger 230V 50Hz AP8202311 Axone battery charger 110V 60Hz 020330Y Stroboscopic light for timing checking Unscrew the TDC reference inspection cap Connect the stroboscopic light Connect the Axone Start the engine Select...

Page 194: ...e 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 Engine MSS Mana GT ABS ENG 194 ...

Page 195: ...aft 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 Locking torques N m 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 MSS Mana GT ABS E...

Page 196: ...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 ...

Page 197: ...TTING 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 dam...

Page 198: ...der 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 Engine MSS Mana GT ABS ENG 198 ...

Page 199: ...SURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER Checking the connecting rod small end NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP 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 D...

Page 200: ...R 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 id...

Page 201: ...e 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 TH...

Page 202: ...ic 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 Measur...

Page 203: ...O 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 Meas...

Page 204: ... 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 Locking torques N m Head fix...

Page 205: ...n 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 Locking torques N m Exhaust intake head fixing nuts 10 12 MSS Mana GT ABS Engine ENG 205 ...

Page 206: ...plugs and tighten them to the prescribed torque Locking torques N m Spark plug 12 14 Nm Fit the rpm timing sensor and tighten to the pre scribed timing Locking torques N m 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 ...

Page 207: ...acket using a brush Apply the recommended product to the fixing screws and tighten them to the prescribed torque Recommended products Loctite 243 Medium strength threadlock Insert the camshaft retaining bracket so that the countersinks are visible and tighten the 3 fixing screws to the prescribed torque being careful not to damage the internal hexagon Locking torques N m Camshaft retaining bracket...

Page 208: ...ing 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 Locking torques N m Tappet cover fixing screws 7 9 Engine MSS Mana GT ABS ENG 2...

Page 209: ...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 Locking torques N m Inlet manifold fixing screws 11 13 MSS Mana GT ABS Engine ENG 209 ...

Page 210: ...ns as described in the Thermal group and Timing system chapter Before opening the engine crankcase it is advisable to check the axial clearance of the crankshaft Specific tooling 020262Y Crankcase splitting strip 020335Y Dial gauge magnetic support Characteristic Standard clearance 0 10 0 50 mm Increased limit after use 0 60 mm Higher clearances are signs of wear on the supporting surfaces of the ...

Page 211: ...g 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 020664Y Flywheel side crankshaft fitting tip Lubricate the external surface of...

Page 212: ... Detach the crankcase half keeping the crankshaft connected to crankcase half on the transmission side Remove the coupling gasket Engine MSS Mana GT ABS ENG 212 ...

Page 213: ...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 Lubricate the external surface of the tip with petroleum jelly grease MSS Mana GT ABS Engine ENG 213 ...

Page 214: ... 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 IMP...

Page 215: ...es 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...

Page 216: ...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 TAK...

Page 217: ...AUTION FAILURE TO OBSERVE THIS RULE CAN DAMAGE THE 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 Lubricate the external surface of the tip with petroleum jelly grease NOTE LUBRICATE THE BUSHINGS WITH ENGINE OIL BEFORE FITTING THE CRANKS...

Page 218: ... 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 Engine MSS Mana GT ABS ENG 218 ...

Page 219: ...ULE CAN DAMAGE THE MAIN BUSHINGS Specific tooling 020664Y Flywheel side crankshaft fitting tip Lubricate the external surface of the tip with petroleum jelly grease NOTE LUBRICATE THE BUSHINGS WITH ENGINE OIL BEFORE FITTING THE CRANKSHAFT Pay attention and fit the flywheel side crankcase half until there is a complete coupling MSS Mana GT ABS Engine ENG 219 ...

Page 220: ... Remove the tip Specific tooling 020664Y Flywheel side crankshaft fitting tip Engine MSS Mana GT ABS ENG 220 ...

Page 221: ...n the trans mission side Screw the six screws A with the washers and tighten to the prescribed torque Locking torques N m Crankcase engine coupling screws M6 11 13 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 ...

Page 222: ...TION 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 Gene...

Page 223: ... 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 bor...

Page 224: ...nd 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 Specification Desc Quantity 20 C Temperature 1400 rpm 4 5 bar YES point 6 NO point 12 6 Let the engine warm ...

Page 225: ... 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 I...

Page 226: ...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 s...

Page 227: ...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 AP8106702 Flywheel lock calliper spanner Unscrew the two...

Page 228: ...rom 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 Engine MSS Mana GT ABS ENG 228 ...

Page 229: ...ump 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 MSS Mana GT ABS Engine ENG 229 ...

Page 230: ... Undo the two screws and remove the oil pump cover Engine MSS Mana GT ABS ENG 230 ...

Page 231: ...OMPONENTS 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 MSS Mana GT ABS Engine ENG 231 ...

Page 232: ...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 Engine MSS Mana GT ABS ENG 232 ...

Page 233: ...0 1 mm Check all the conditions indicated above fit the plug and tighten the fixing screws to the prescribed torque Locking torques N m 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 Locking torques N m By pass scavenge pipe fixing screws 11 13 Make su...

Page 234: ...en to the prescribed torque Locking torques N m 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 Locking tor...

Page 235: ...belleville washer with the specific tool and tighten to the prescribed torque CAUTION PLACE THE BELLEVILLE WASHER WITH THE CONVEX PART FACING THE OIL PUMP CONTROL CROWN Specific tooling AP8106702 Flywheel lock calliper spanner Locking torques N m Oil pump sprocket gear screw 10 14 Fit the tensioner pad and tighten the two screws to the prescribed torque Locking torques N m Chain tensioner slider o...

Page 236: ...HICLES 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 Engine MSS Mana GT ABS ENG 236 ...

Page 237: ...e 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 MSS Mana GT ABS Engine ENG 237 ...

Page 238: ... AREA OF MAXIMUM STURDINESS Specific tooling AP8140180 Extractor for bushings 020376Y Adapter handle 020357Y 32 x 35 mm adaptor 020363Y 20 mm Oil seal guide Refitting the driven pulley shaft bearing Heat the transmission cover inside with a heat gun Fit the bearing onto the special tool with a little grease to prevent it from coming out Refit the new bearing with the specific tool Specific tooling...

Page 239: ...ring Removing the bearings supporting the electric motor driving shafts Remove the gear Extract the two bearings with the specific tool Specific tooling AP8140180 Extractor for bushings Fitting the bearings supporting the electric motor driving shafts Heat the transmission cover inside with a heat gun MSS Mana GT ABS Engine ENG 239 ...

Page 240: ...unch 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 Engine MSS Mana GT ABS ENG 240 ...

Page 241: ...lutch Remove the clutch with the driven pulley using the specific tool CAUTION WHILE PERFORMING THESE OPERATIONS AVOID CONTACT WITH OIL OR GREASE WHICH COULD MAKE THE CONTACT SURFACES BETWEEN THE BELT AND THE HALF PULLEYS SLIPPERY Specific tooling 020659Y Tool to remove clutch and repl belt Place the clutch assembly on the tool by inserting the pins in the ventilation holes Fit the centring bushin...

Page 242: ...s 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 Engine MSS Mana GT ABS...

Page 243: ...nap 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 020376Y Adapter handle 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 AP8140180 Extractor for bushings MSS Ma...

Page 244: ... 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 d...

Page 245: ...y fitted use the specific tool Specific tooling 020478Y Punch for roller casing AP8140180 Extractor for bushings Fit a new ball bearing with the specific tool Specific tooling 020376Y Adapter handle 020477Y 37 mm Adaptor 020364Y 25 mm Guide Fit the Seeger ring Refitting the driven pulley Fit the new oil seals Fit the new O rings NOTE THE O RINGS COME IN TWO DIFFERENT SIZES THE LARGE ONE IS FITTED ...

Page 246: ...essary to prevent the presence of grease beyond the O rings Recommended products 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 resis...

Page 247: ...ERY Specific tooling 020659Y Tool to remove clutch and repl belt Compress the spring and fit the clutch on the driven pulley bushing NOTE BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END Screw the locking ring nut and tighten to the pre scribed torque Locking torques N m Clutch ring nut 65 75 With a specific tool separate the two half pulleys and fit the belt according to its direct...

Page 248: ... 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 Engine MSS Mana GT ABS ENG 248 ...

Page 249: ...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 MSS Mana GT ABS ...

Page 250: ... Remove the movable pulley unit Remove the driven pulley with the belt Remove the clutch bell Remove the driving half pulley Engine MSS Mana GT ABS ENG 250 ...

Page 251: ...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 MSS Mana GT ABS Engine ENG 251 ...

Page 252: ...e 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 Engine MSS Mana GT ABS ENG 252 ...

Page 253: ...abnormally worn and measure its inside diameter CAUTION DO NOT LUBRICATE OR CLEAN BUSHINGS Characteristic Max diameter admitted 35 050 mm Standard diameter 35 000 0 034 0 009 mm Measure the outside diameter of the sliding 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 dia...

Page 254: ...THE MAXIMUM CLEARANCE ALLOWED AS THIS CAN CAUSE NOISE PROBLEMS Characteristic Maximum clearance allowed 0 4 mm Measure the inside diameter of the two bushings Characteristic Max diameter admitted 10 040 mm Standard diameter 10 000 0 005 0 030 mm Refitting the driving pulley Fit the plate with the sliders on the movable driv ing half pulley Engine MSS Mana GT ABS ENG 254 ...

Page 255: ... Loctite 270 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 MSS Mana GT ABS Engine ENG 255 ...

Page 256: ...ed 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 Preassemble the belt on the rear pulley with a special tool Specific tooling 020659Y Tool to remove clutch and repl belt Fit the unit following the removal steps but in reverse order with the specific t...

Page 257: ...TING 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...

Page 258: ...spect 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 Specification Desc Quantity 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 6 22 35 22 44 7 22 45 22 54 8 22 55 22 68 Engine MSS Mana GT ABS ENG 258 ...

Page 259: ...t 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...

Page 260: ...nion unit axle bearing until it abuts against the bottom of the seat with the specific tool Specific tooling 020376Y Adapter handle 020363Y 20 mm Oil seal guide 020359Y 42 x 47 mm adaptor Flywheel side crankcase half Heat up the crankcase using the thermal gun Fit the oil seal until it abuts against the bottom of the seat using the specific tool Specific tooling 020376Y Adapter handle 020655Y 62x6...

Page 261: ... driven pulley shaft bearing up to the stop against the bottom of the seat with the specific tool Specific tooling 020376Y Adapter handle 020655Y 62x68 mm Adaptor 020662Y 50 mm guide MSS Mana GT ABS Engine ENG 261 ...

Page 262: ... shaft axle and the toothed wheel Operating on the specific tool extract the bearing Specific tooling AP8140180 Extractor for bushings Flywheel side crankcase half Remove the oil seal and the bearing with the specific tool Specific tooling 020376Y Adapter handle 020662Y Guide 50 mm 020360Y 52x55 mm Adaptor Removing the driven pulley shaft bearing Slide off the toothed wheel pinion unit axle Engine...

Page 263: ...e 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 020376Y Adapter handle 020483Y 30 mm guide 020358Y 37 x 40 mm adaptor MSS Mana GT ABS Engine ENG 263 ...

Page 264: ... 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 Heat up the crankcase using the thermal gun Insert the driven pulley shaft bearing up to the stop against the bottom of the seat with the specific tool Specific tooling 020376Y Adapter handle 020483Y 30 mm guide 020655Y 62x68 mm Adapt...

Page 265: ... 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 MSS Mana GT ABS Engine ENG 265 ...

Page 266: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 267: ... 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 MSS Mana GT ABS Power supply P SUPP 267 ...

Page 268: ...Power supply MSS Mana GT ABS P SUPP 268 ...

Page 269: ...MSS Mana GT ABS Power supply P SUPP 269 ...

Page 270: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 271: ...l 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 MSS Mana GT ABS Suspensions SUSP 271 ...

Page 272: ...t 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 Suspensions MSS Mana GT ABS SUSP 272 ...

Page 273: ...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 cl...

Page 274: ...heel 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 wit...

Page 275: ... 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 MSS Mana GT ABS Suspensions SUSP 275 ...

Page 276: ...ing 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 Suspensions MSS Mana GT ABS SUSP 276 ...

Page 277: ...40 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 MSS Mana GT ABS Suspensions SUSP 277 ...

Page 278: ...tom 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 Suspensions MSS Mana GT ABS SUSP 278 ...

Page 279: ...e tool fasten the stem in the vice Unscrew the top plug by using a span ner Specific tooling AP8140149 Protection for fitting operations 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 MSS Mana GT ABS Suspensions SUSP 279 ...

Page 280: ...TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE 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 AP8140149 Protection for fitting operations 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 unscre...

Page 281: ...IONS REFER TO THE SACHS 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 AP8140149 Protection for fitting operations ...

Page 282: ...the spring and insert the separating plate on the lock nut of the cover Specific tooling 020888Y Pliers for pre fill pipe AP8140148 Spacer piston separating plate Loosen the nut Remove the sleeve cap Slide off the preloading pipe Suspensions MSS Mana GT ABS SUSP 282 ...

Page 283: ...SE 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 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 MSS Mana GT...

Page 284: ...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 Disassembling the fork NOTE THE FOLLOWING OPERATIONS REFER TO THE MARZOCCHI FORKS NOTE THE FOLLOWING OPERATIONS REFER TO BOTH STEMS Suspensions MSS...

Page 285: ... Drain the fork oil Remove the sleeve Remove the oil seal Remove the retainer ring Remove the dust gaiter MSS Mana GT ABS Suspensions SUSP 285 ...

Page 286: ...NS DESCRIBED BELOW ARE VALID FOR BOTH STEMS Drain the fork oil Place the stanchion on a work table in upright position Be careful not to damage the stanchion when placing it in a vice in horizontal position using the appropriate protections Unscrew and remove the bottom screw and collect the special washer See also Draining oil Suspensions MSS Mana GT ABS SUSP 286 ...

Page 287: ...move the retainer ring the metal ring and three rubber rings 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 MSS Mana GT ABS Suspensions SUSP 287 ...

Page 288: ...rom the stem NOTE THE FOLLOWING OPERATIONS REFER TO THE SHOWA FORKS NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS Drain the fork oil Place the stanchion on a work table in upright position Fit the special tool Specific tooling AP8140147 Spacer tool Suspensions MSS Mana GT ABS SUSP 288 ...

Page 289: ...special tool down Take out the Seeger ring With the help of a second operator Insert the special tool between the nut and the preloading pipe Specific tooling AP8140148 Spacer piston separating plate Loosen the nut Remove the sleeve cap MSS Mana GT ABS Suspensions SUSP 289 ...

Page 290: ...n when placing it in a vice in horizontal position using the appropriate protec tions Specific tooling AP8140149 Protection for fitting operations Unscrew and remove the bottom screw and collect the special washer Slide off the pumping member together with the spring Suspensions MSS Mana GT ABS SUSP 290 ...

Page 291: ...UTION DO NOT DAMAGE THE STEM DURING THE OPERATION Slide off the stem forcefully 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 Checking the components Stem Check the sliding surface for scorings and or scratches MSS Mana GT ABS Suspensions SUSP 291 ...

Page 292: ... is in good conditions Check that the spring length is within the limit value Replace the spring if its length does not fall within the limit values SPRING MINIMUM LENGTH WHEN UNLOADED 300 8 mm 11 84 in Check that the following components are in good conditions sliding bushing guide bushing piston If there are signs of excessive wear or damage replace the affected component CAUTION REMOVE ANY IMPU...

Page 293: ...us 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 AP8140189 Oil seal fitting tool for Ø 43 mm 1 69 in orifices AP8140146 Weight Fit the Seeger ring on the sleeve seat MSS Mana GT ABS Suspensions SUSP 293 ...

Page 294: ...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 fi...

Page 295: ... seat 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 MSS Mana GT ABS Suspensions SUSP 295 ...

Page 296: ...ER TO THE SHOWA FORKS NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS 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 be...

Page 297: ... of the specific weight Specific tooling AP8140146 Weight Fit the Seeger ring on the sleeve seat Fit the dust gaiter Screw the specific perforated rod on the pumping member threaded rod Specific tooling AP8140150 Perforated rod for piston air bleed MSS Mana GT ABS Suspensions SUSP 297 ...

Page 298: ...ING OPERATIONS REFER TO THE MARZOCCHI FORKS RIGHT STEM Place the stanchion on a work table in upright position 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 Characteristic Fork oil quantity right stem Marzocchi 490 cc 29 90 cu in Oil level from sleev...

Page 299: ... screw the cap till the end of the stroke Insert a spanner on the nut under the plug the cover allowing to tighten the plug to the tightening torque Tighten the sleeve cap to the prescri bed tightening torque LEFT STEM Place the stanchion on a work table in upright position MSS Mana GT ABS Suspensions SUSP 299 ...

Page 300: ...der the plug the cover allowing to tighten the plug to the tightening torque Tighten the sleeve cap to the prescri bed tightening torque NOTE THE FOLLOWING OPERATIONS REFER TO THE SACHS FORKS NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS Place the stanchion on a work table in upright position Fill the sleeve with the adequate quality and type of oil indicated on the recommended prod...

Page 301: ... 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 Insert the two washers Fit the preloading pipe together with the spring centring Tighten the appropriate tool on the pumping member pin rod MSS Mana GT AB...

Page 302: ...insert the stop ring and the plate separating the spacer pumping member between the ring and the nut Specific tooling AP8140148 Spacer piston separating plate 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 Tighten the sleeve cap to the prescri bed tightening torque NOTE...

Page 303: ...BLES 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 cm 32 65 cu in Oil level from sleeve rim without the spring and with pumping member fully down 122 mm 4 80 in Fit the preloading pipe together with the spring centring Fit the special too...

Page 304: ...r between the ring and the nut Specific tooling AP8140148 Spacer piston separating plate Insert the sleeve cap and screw the nut Being careful not to damage the stan chion when placing it in a vice in ver tical position using the appropriate protection Specific tooling AP8140149 Protection for fitting operations Tighten the sleeve cap Suspensions MSS Mana GT ABS SUSP 304 ...

Page 305: ... 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 MSS Mana GT ABS Suspensions SUSP 305 ...

Page 306: ... that oil in the clutch and front brake tanks does not spill out Unscrew and remove the top bolt on the headstock and retrieve the washer Operating from both sides loosen the screws fixing the stanchions to the up per plate Undo and remove the two screws fixing the instrument panel support to the fork upper plate Suspensions MSS Mana GT ABS SUSP 306 ...

Page 307: ...ards the instrument panel Adjust the steering bearings preload ing by tightening the ring nut with the specific tool When refitting the U bolt position the two referen ces facing the front part of the vehicle Rear MSS Mana GT ABS Suspensions SUSP 307 ...

Page 308: ...ion buffer holder 8 10x20 Pin 9 TCEI screw M10x30 10 Anti vibration buffer rubber ring 11 Anti vibration buffer pin 12 Crown z 40 13 Sprocket carrier assembly 14 Anti vibration buffer spacer 15 Bearing 30x55x13 16 Seeger ring for d55 hole 17 Sealing ring 38x52x7 18 Self locking nut M10 19 Rear wheel spacer Suspensions MSS Mana GT ABS SUSP 308 ...

Page 309: ...ear cover Rest the vehicle on its centre stand Undo and remove the two fixing screws Remove the rear brake calliper Undo and remove the two fixing screws Remove the parking brake calliper MSS Mana GT ABS Suspensions SUSP 309 ...

Page 310: ... Working from the vehicle right side un screw and remove the rear wheel pin fixing nut and collect the washer Loosen the right chain set screw Suspensions MSS Mana GT ABS SUSP 310 ...

Page 311: ...RTS ARE IN GOOD CONDITION ESPECIALLY THOSE LISTED AS FOL LOWS REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel ROTATION CHECK Manually rotate the inside ring of each bearing Rotation must be constant smooth and noiseless If one or both bearings do not fall within the control parameters Replace both wheel bearings MSS Mana GT ABS Suspensions SUSP 311 ...

Page 312: ...ACE 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 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...

Page 313: ... 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 MSS Mana GT ABS Suspensions SUSP 313 ...

Page 314: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 315: ...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 MSS Mana GT ABS Chassis CHAS 315 ...

Page 316: ...crew 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 Chassis MSS Mana GT ABS CHAS 316 ...

Page 317: ...tection 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 MSS Mana GT ABS Chassis CHAS 317 ...

Page 318: ...remove the screw on the plate Undo and remove the muffler tip fixing screw Remove the muffler tip Removing the exhaust manifold FRONT CYLINDER MANIFOLD Loosen the nut tightening the clamp Remove the clamp Chassis MSS Mana GT ABS CHAS 318 ...

Page 319: ...N m Manifolds fixing clamp 2 18 Nm 13 28 lbf ft REAR CYLINDER MANIFOLD Loosen the nut tightening the flange Move the flange Remove the exhaust manifold of the rear cylinder CAUTION UPON REFITTING TIGHTEN THE CLAMP LOCKING NUT TO THE PRESCRIBED TORQUE Locking torques N m Manifolds fixing clamp 2 18 Nm 13 28 lbf ft MSS Mana GT ABS Chassis CHAS 319 ...

Page 320: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 321: ...sis 9 Key 10 CVT ECU control unit 11 fuses ABS ECU control unit pin configuration PIN 1 GND Ground connection PIN 2 PCC1 Vehicle identification ground connection PIN 4 IGN Key PIN 8 WL Alarm warning light PIN 11 R_SIGN Rear ABS sensor signal PIN 12 R_GND Rear ABS sensor ground connection MSS Mana GT ABS Braking system BRAK SYS 321 ...

Page 322: ...2 Vehicle identification ground connection PIN 16 ISO_K K line diagnosis PIN 18 KL30 Power supply Foreword key 1 Rear brake calliper 2 Modulator 3 Front bleed valve 4 Front brake reservoir 5 Front brake callipers 6 Rear brake pump 7 Rear brake reservoir Braking system MSS Mana GT ABS BRAK SYS 322 ...

Page 323: ...Operating diagram ABS functional diagram key 1 Front system circuit 2 Front brake pump 3 Front brake lever 4 Rear system circuit MSS Mana GT ABS Braking system BRAK SYS 323 ...

Page 324: ...ed of the wheels in order to assess potential wheel slippage When in standby the system does not intervene at all when the rider brakes the braking system is the same as the one without ABS Stages in ABS cycle the following operations refer to the front circuit but are also applicable to the rear one A Brake activation the rider starts braking as he would usually do B Pressure reduction it coincid...

Page 325: ...ignals 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...

Page 326: ...osis 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 th...

Page 327: ...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 ...

Page 328: ...s 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 measure ment Notes Vehicle manufacturing date Frame number Software version Vehicle code Mana Shiver Dorso duro Scarabeo The vehicle code stored in the control unit is read Vehicle identification a...

Page 329: ...ensors engine revs engine temperature etc or values set by the control unit injection time ignition advance etc ENGINE PARAMETER READING Characteristic Value example Unit of measure ment Notes 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 MSS Mana GT ABS Braking system BRAK SYS 329 ...

Page 330: ...umber 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 ...

Page 331: ... irregularly Faulty sensor or signal interference Rear speed sensor 5DA2 the signal decreases periodically Possible tone wheel fault due to deformations or dirt possible alterations on the wheel bearing sur face In very rare cases abnormal tone wheel vibrations Rear speed sensor 5DA3 no signal or speed measured too low in rela tion to the front wheel Faulty sensor or missing sensor tone wheel or e...

Page 332: ... 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 ADJUSTABLE PARAMETERS Characteristic Value example Unit of measure ment Notes 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 AB...

Page 333: ...es from the hose guide 6 MODULATOR REMOVAL Remove the helmet compartment By undoing the nuts remove and cover the brake oil pipes following this sequence 4 3 1 2 ABS GROUND LEAD Pay attention to correctly connect the ABS system ground leads MSS Mana GT ABS Braking system BRAK SYS 333 ...

Page 334: ...tting 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 Braking system MSS Mana GT ABS BRAK SYS 334 ...

Page 335: ...ms 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 MSS Mana GT ABS Braking system BRAK...

Page 336: ... support 20 Rear calliper support bracket 21 Parking calliper 22 Parking brake lever unit 23 Parking brake lever 24 Parking brake control complete transmission 25 Complete rear brake oil tank 26 Rear brake disc D 260 27 TE flanged screw M8x20 28 Rear brake pad torque 29 Rear brake calliper pin and springs 30 Bleeding Kit 31 TCEI screw M6x20 32 TCEI screw M6x30 33 Notched washer 6 4x11xh 0 7 34 Rin...

Page 337: ...val 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 MSS Mana GT ABS Braking system BRAK SYS 337 ...

Page 338: ...rake 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 Braking system MSS Mana GT ABS BRAK SYS 338 ...

Page 339: ... 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 ...

Page 340: ...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...

Page 341: ...lever and the brake pedal If after bleeding the pedal or the lever stroke is too long check that there are no leaks in the braking system and if everything is ok continue bleeding operations using Axone as described Detach the bleed hoses and close the bleed screws again to the correct tightening torque BRAKE BLEEDING AFTER CALLIPER RE PLACEMENT VEHICLE PREPARATION The operations are described for...

Page 342: ...correct tightening torque BLEEDING USING AXONE This type of bleeding has to be carried out if after all the checks the brake lever and the pedal are still spongy The operations described here are valid for both systems even though the description refers to the front system FRONT With Axone properly connected select the function FRONT BRAKE BLEEDING PROCE DURE The pump starts rotating While the pum...

Page 343: ...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 Always fill the reservoir up to the reference MAX and refit the cap Check the stroke and the sensitivity of both the lever and the brake pedal If af...

Page 344: ...g 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 Braking system MSS Mana GT ABS BRAK SYS 344 ...

Page 345: ... 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 MSS Mana GT ABS Braking system BRAK SYS 345 ...

Page 346: ... 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 Braking system MSS Mana GT ABS BRAK SYS 346 ...

Page 347: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 348: ...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 Cooling system MSS Mana GT ABS COOL SYS 348 ...

Page 349: ...e 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 MSS Mana GT ABS Cooling system COOL SYS 34...

Page 350: ...ar 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 ele...

Page 351: ...ALL 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 MSS Mana GT ABS Cooling system COOL SYS 351 ...

Page 352: ... 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 C...

Page 353: ...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 MSS Mana GT ABS Cooling system COOL SYS 353 ...

Page 354: ...e 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 Cooling system MSS Mana GT ABS COOL SYS 354 ...

Page 355: ...roduce 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 MSS Mana GT ABS Cooling system COOL SYS 355 ...

Page 356: ... 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 Cooling system MSS Mana GT ABS COOL SYS 356 ...

Page 357: ...OPS 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 MSS Mana GT ABS Cooling system COOL SYS 357 ...

Page 358: ...ghten to the prescribed torque NOTE DO NOT LUBRICATE THE O RING WITH PETROLEUM GREASE TO AVOID DEFORMATION Locking torques N m 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 Cooling system MSS Mana ...

Page 359: ... the clamp and slide off the manifold Drain off the system Remove the clamp Release the sleeve Undo and remove the fixing screw Disconnect the electric fan connector MSS Mana GT ABS Cooling system COOL SYS 359 ...

Page 360: ...mp 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 See also Side fairings Side fairings Cooling system MSS Mana GT ABS COOL SYS 360 ...

Page 361: ...ansion tank Right bottom side removal Drain off the system Undo and remove the fixing screw Undo and remove the fixing screw Release the clamps and slide off the two sleeves MSS Mana GT ABS Cooling system COOL SYS 361 ...

Page 362: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 363: ... 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 MSS Mana GT ABS Bodywork BODYW 363 ...

Page 364: ...g fixing screws and extract it Partially extract the internal instrument panel support Disconnect the instrument panel con nector and remove it all Headlight assy Remove the instrument panel Remove the side fairings Cut the clamp 1 Disconnect the connectors Bodywork MSS Mana GT ABS BODYW 364 ...

Page 365: ...move the front fairing fixing screws 2 and remove the fairing Remove the clamp 3 Remove the front headlight assembly See also Instrument panel Side fairings Side fairings MSS Mana GT ABS Bodywork BODYW 365 ...

Page 366: ...ove the license plate support Slide off the cable Taillight assy Remove the license plate support Undo and remove the two fixing screws Undo and remove the two fixing screws Undo and remove the two fixing screws Bodywork MSS Mana GT ABS BODYW 366 ...

Page 367: ... Undo and remove the two fixing screws Undo and remove the fixing screw Slide off the light cover Slide off the light MSS Mana GT ABS Bodywork BODYW 367 ...

Page 368: ...LD BE TIGHTENED TO THE SPECIFIED LOCKING TORQUE Locking torques N m Lower screw fixing rider footrest 25 Nm 18 44 lbf ft Undo and remove the central fixing screw and collect the washer The following operations are only applicable to re move the left footrest holder plate Unscrew and remove the rear fixing nut and collect the washer Remove the passenger footrest sup port Bodywork MSS Mana GT ABS BO...

Page 369: ...ment Working on both sides unscrew and remove the two top fixing screws Working on both sides release the two bottom fixing snap in rivets Remove the cover Remove the side fairing fastening screws Remove the side fairing See also Seat Side fairings MSS Mana GT ABS Bodywork BODYW 369 ...

Page 370: ...tment Undo and remove the two fixing screws for the upper central small fairing 1 and collect the two washers Lower the helmet compartment Remove the central small fairing 2 Remove the screws 6 Remove the rear screw 7 Bodywork MSS Mana GT ABS BODYW 370 ...

Page 371: ...connec tor Remove the side fairing License plate holder Remove the saddle Undo and remove the two fixing screws Undo and remove the two screws fixing the passenger grab handle Remove the passenger grab handle Remove the two spacers MSS Mana GT ABS Bodywork BODYW 371 ...

Page 372: ...from both sides undo and remove the side screw Undo and remove the two lower fixing screws Partially slide off with great care the li cense plate support Remove the locking clamp Bodywork MSS Mana GT ABS BODYW 372 ...

Page 373: ...sconnect 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 MSS Mana GT ABS Bodywork BODYW 373 ...

Page 374: ... license plate sup port 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 Bodywork MSS Mana GT ABS BODYW 374 ...

Page 375: ... the side fairings Undo and remove the two fixing screws Remove the plastic radiator protection Disconnect the two horn connectors Undo the screw on the sleeve clamp through the hole in the helmet com partment MSS Mana GT ABS Bodywork BODYW 375 ...

Page 376: ...s 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 See also Side fairings Side fairings Bodywork MSS Mana GT ABS BODYW 376 ...

Page 377: ... 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 MSS Mana GT ABS Bodywork BODYW 377 ...

Page 378: ...emove the side fairings Working from both sides undo and re move the protection front fixing screw Working from both sides undo and re move the protection upper fixing screw Working from both sides undo and re move the protection rear fixing screw Bodywork MSS Mana GT ABS BODYW 378 ...

Page 379: ...e 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 MSS Mana GT ABS Bodywork BODYW 379 ...

Page 380: ...ixing screws Working from both sides undo and re 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 Bodywork MSS Mana GT ABS BODYW 380 ...

Page 381: ...p 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 MSS Mana GT ABS Bodywork BODYW 381 ...

Page 382: ... From both sides undo and remove the three helmet compartment external fix ing screws Undo and remove the helmet compart ment internal fixing screw Bodywork MSS Mana GT ABS BODYW 382 ...

Page 383: ...emove the helmet compartment Fuel tank Remove the saddle Remove the license plate support 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 MSS Mana GT ABS Bodywork BODYW 383 ...

Page 384: ...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 Bodywork MSS Mana GT ABS BODYW 384 ...

Page 385: ... 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 MSS Mana GT ABS Bodywork BODYW 385 ...

Page 386: ...and at the same time pull the coupler up at 90 and slightly rotate it Disconnect the fuel pump connector Undo and remove the two fixing screws Slide off the tank Remove the cloth from the tank and screw the cap again Bodywork MSS Mana GT ABS BODYW 386 ...

Page 387: ...ides undo and remove the two screws Remove the front mudguard by sliding it forwards and slightly pressing it so it passes through the forks Windscreen Remove the top fairing fixing screws and extract it MSS Mana GT ABS Bodywork BODYW 387 ...

Page 388: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 389: ...ixing 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 ...

Page 390: ...Y 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 WHE...

Page 391: ...sent 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...

Page 392: ...T bushes from the inside of the windshield Insert the low T bushes in their holes on the bodywork Fit the windshield between the bodywork and the front glass cover Tighten the screws Insert the cheese head screws from in side the fairing Fix the turn indicators with the check nuts Pre delivery MSS Mana GT ABS PRE DE 392 ...

Page 393: ...kcase 22 210 211 214 221 355 Crankshaft 22 210 213 215 217 Cylinder 20 179 181 187 189 196 197 201 203 D Display 51 331 Drive chain 12 E ECU 55 139 Electric fan 112 349 Electrical system 12 58 59 389 Engine oil 42 Engine temperature sensor 95 Exhaust 316 318 Exhaust manifold 318 F Fairings 360 365 369 370 376 Filter box Fork 276 278 280 281 284 292 Front wheel 271 273 Fuel 102 383 Fuel pump 102 Fu...

Page 394: ...r 107 R Radiator 358 Rear wheel 308 311 Recommended products 25 Run Stop switch 114 S Saddle Shock absorbers 312 Side fairings 370 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 361 383 Throttle body 106 Transmission 12 116 120 127 143 236 259 Tyres 14 W Warning lights Water pump 351 Wiring diagram 74 ...

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