Aprilia Mana 850 2007
Aprilia Mana 850 2007
Aprilia Mana 850 2007
854171
NA 850 Mana
SERVICE STATION
MANUAL
NA 850 Mana
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee
INDEX OF TOPICS
CHARACTERISTICS CHAR
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ENGINE ENG
SUSPENSIONS SUSP
CHASSIS CHAS
BODYWORK BODYW
PRE-DELIVERY PRE DE
INDEX OF TOPICS
CHARACTERISTICS CHAR
Characteristics NA 850 Mana
Rules
This section describes the vehicle maintenance operations and general safety regulations.
Safety rules
Carbon monoxide
If you need to keep the engine running while working on the vehicle, please ensure that you do so in
an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an
enclosed area, make sure to use a fume extraction system.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND
MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VA-
POURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES
WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPERSE FUEL IN THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN
Hot components
The engine and the exhaust system components become very hot and remain hot for some time after
the engine has been switched off. When handling these components, wear insulating gloves or wait
until the engine and the exhaust system have cooled down.
Coolant
The coolant contains ethylene glycol which, under certain conditions, can become flammable.
When it burns, ethylene glycol produces an invisible flame which however can cause burns.
CAUTION
TAKE CARE NOT TO POUR COOLANT ONTO HOT ENGINE OR EXHAUST SYSTEM COMPO-
NENTS; THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES. WHEN CARRYING
OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN
CHAR - 6
NA 850 Mana Characteristics
THOUGH IT IS TOXIC, COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRAC-
TIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCES-
SIBLE TO ANIMALS AS THEY MAY DRINK IT.
KEEP OUT OF THE REACH OF CHILDREN
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS
UNDER PRESSURE AND MAY CAUSE BURNS.
Used engine oil and transmission oil
CAUTION
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.
WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM-
PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING
THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR
EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY
WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN
Battery electrolyte and hydrogen gas
CAUTION
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
CHAR - 7
Characteristics NA 850 Mana
When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
COMPONENTS REMOVAL
• Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific
wrench.
• Mark positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with distinctive symbols.
• Each component needs to be clearly marked to enable identification during reassembly.
• Clean and wash the dismantled components carefully using a low-flammability detergent.
• Keep mated parts together since they have "adjusted" to each other due to normal wear.
• Some components must be used together or replaced completely.
• Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.
• Only use ORIGINAL Aprilia SPARE PARTS.
• Comply with lubricant and consumables use guidelines.
• Lubricate parts (whenever possible) before reassembling them.
• When tightening nuts and screws, start either from the components with the largest diameter
or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-
cessive steps before applying the tightening torque.
• Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins
and screws with new parts if the thread is damaged.
• When assembling the bearings, make sure to lubricate them well.
• Check that each component is assembled correctly.
• After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on
private grounds or in an area with low traffic.
• Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of
lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand
or batch number facing outward (visible side).
ELECTRICAL CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damage to both the connector and the wiring harness:
Press the relative safety clips, if applicable.
CHAR - 8
NA 850 Mana Characteristics
• Grip the two connectors and disconnect them by pulling them in opposite directions.
• If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully
with a jet of compressed air.
• Ensure that the cables are correctly fastened to the internal connector terminals.
• Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you
will hear them "click" into place).
CAUTION
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.
NOTE
THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM
THE RIGHT WAY ROUND.
TIGHTENING TORQUES
CAUTION
REMEMBER THAT THE TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON WHEELS,
BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE
IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE
TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE
A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH
THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR
EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS
MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.
Running-in
Running the engine in correctly is essential for ensuring engine longevity and functionality. Twisty roads
and gradients are ideal for running in the engine, brakes and suspension effectively. Vary your riding
speed during the running in period. This ensures that components operate in "loaded" conditions and
then "unloaded" conditions, allowing the engine components to cool.
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT
THE END OF THE RUNNING IN PERIOD.
Follow these guidelines:
• Do not twist the throttle grip abruptly and completely when the engine is working at a low
revs, either during or after run-in.
• During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged
braking. That is to permit the adequate adjustment of the pad friction material to the brake
discs.
AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE
CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE
SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
CHAR - 9
Characteristics NA 850 Mana
Vehicle identification
Write down the chassis and engine number in the specific space in this booklet. The chassis number
is handy when purchasing spare parts.
CAUTION
ENGINE NUMBER
The engine number is printed on the base of the
engine crankcase, left hand side.
Engine No. ....................
CHASSIS NUMBER
The chassis number is stamped on the right side of the headstock.
Chassis No. ....................
DIMENSIONS
Specification Desc./Quantity
Max. length 2180 mm (85.83 in)
Max. width 800 mm (31.50 in)
Max. height 1130 mm (44.49 in)
CHAR - 10
NA 850 Mana Characteristics
Specification Desc./Quantity
Saddle height 810 mm (31.89 in)
Wheelbase 1470 mm (57.87 in)
Kerb weight (full fuel tank) 230 kg (507 lb)
Engine
ENGINE
Specification Desc./Quantity
Model M290 Duel
Type 90° longitudinal V-twin, 4-stroke, 4 valves per cylinder, single
overhead camshaft.
No. of cylinders 2
Overall cylinder capacity 839.3 cm³ (51.22 cu.in)
Bore / stroke 88 x 69 mm (3.46 x 2.72 in)
Valve clearance Inlet: 0.15 mm (0.0059 in)
Outlet: 0.15 mm (0.0059 in)
Compression ratio 10 - 10.6 : 1
Electric starter
Engine idle speed 1400 ± 100 rpm
TIMING SYSTEM 4 valves, single overhead camshaft, chain-driven.
MAX. torque 71 Nm at 4,500 rpm
Clutch Automatic
Lubrication system Dry sump system with separate oil tank
Lubrication pressure 3.5 ÷ 4 bar
Minimum lubrication pressure (100 °C - 212 °F) 0.8 bar
Air filter With dry cartridge filter
Cooling Forced-circulation coolant system.
GEARBOX
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 (0.87 in)
Fitting clearances Lobe ends: 0.04 - 0.1 mm (0.0016 - 0.0039 in)
External rotor radial clearance 0.05 - 0.12 mm (0.0020 - 0.0047 in)
Flatness 0.015 mm (0.00059 in)
BY-PASS
Specification Desc./Quantity
Type with piston
Piston diameter 13.984 - 13.957 mm (0.5505 - 0.5495 in)
Unloaded spring length 52 mm (2.05 in)
Calibration pressure 4.5 bar (450 kPa) (65 PSI)
OIL FILTER
Specification Desc./Quantity
Type paper filter with pressure relief and anti-drain by-passes
CHAR - 11
Characteristics NA 850 Mana
Transmission
GEAR RATIO
Specification Desc./Quantity
Primary drive gear ratio Belt primary drive (2.079 - 0.831)
Secondary drive gear ratio Gear secondary drive (23/59)
Final drive gear ratio 18/40
Capacities
CAPACITY
Specification 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 master link) and with sealed links. No. of links
100
Model 525 ZRPK
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Battery 12V - 12 Ah
Main fuses 30A - 40A
Secondary fuses 3A, 10A, 15A, 20A
Alternator (permanent magnet type) 13.5 V - 450 W at 6000 rpm
Electric starter
Ignition Electronic, inductive, high-efficiency, integrated with the injec-
tion system, with variable advance separate HV coil.
CHAR - 12
NA 850 Mana Characteristics
Specification Desc./Quantity
Ignition advance Three-dimensional map managed by control unit
SPARK PLUGS
Specification Desc./Quantity
Standard spark plugs NGK CR7EKB
Spark plug electrode gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Resistance 5 kOhm
BULBS
Specification Desc./Quantity
Low-beam light 12 V - 55 W H11
High-beam light 12 V - 55 W H11
Front daylight running light 12V - 5W
Turn indicator light 12V - 10W
License plate light 12V - 5W
Rear daylight running light / stop light LED
Rpm indicator lighting LED
Multifunction display lighting LED
WARNING LIGHTS
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 LED
RPM 3 LED
RPM 4 LED
CHASSIS
Specification Desc./Quantity
Type High strength steel tubular perimeter frame.
Steering inclination angle 24°
Trail 103 mm (4.05 in)
CHASSIS HEIGHTS
Specification Desc./Quantity
A1 386.4 ± 0.5 mm (15.21 ± 0.02 in)
A2 702.6 ± 0.5 mm (27.66 ± 0.02 in)
B1 225.5 ± 0.6 mm (8.88 ± 0.02 in)
B2 187.2 ± 0.6 mm (7.37 ± 0.02 in)
CHAR - 13
Characteristics NA 850 Mana
SUSPENSIONS
Specification Desc./Quantity
Front Upside-down hydraulic action telescopic fork, Ø 43 mm (1.69
in) stems
Travel 120 mm (4.72 in)
Rear Oscillating swingarm and adjustable hydraulic single shock ab-
sorber
Wheel travel 120 mm (4.72 in)
Brakes
BRAKES
Specification Desc./Quantity
Front Double floating disc, Ø 320 mm (12.60 in), radially-mounted
callipers with four plungers- two of them Ø 27 mm (1.06 in), 2
diam. 32.03 mm (1.26 in) and 4 pads
Rear Ø 260 mm (10.24 in) disc brake, Ø 25 mm (0.98 in) twin-plunger
calliper
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 kPa) (36.26 PSI)
Rear 180/55 ZR17" (73W)
Inflation pressure 1 passenger: 2.5 bar (250 kPa) (36.26 PSI)
2 passengers: 2.8 bar (280 kPa) (40.61 PSI)
Supply
FUEL SYSTEM
Specification Desc./Quantity
Type Electronic injection (Multipoint)
Throttle diameter 38 mm (1.50 in)
Fuel Premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)
Tightening Torques
LUBRICATION
Name Torque in Nm
Engine oil drainage plug 21 - 29
Oil pump compartment cover bulkhead screws 3-4
Engine oil filter 12 - 16
CHAR - 14
NA 850 Mana Characteristics
Name Torque in Nm
Chain tensioner slider - oil pump 2-3
Oil pump screws 5-6
By-pass scavenge pipe fixing screws 11 - 13
Lubrication circuit upper bulkhead 3-4
Oil pump sprocket gear screw 10 - 14
Screws fixing oil pump to crankcase 5-6
Minimum oil pressure sensor 12 - 14
Water pump gear fixing screws 5-6
TRANSMISSION COVER
Name Torque in Nm
Driving pulley screw 175 - 195
Driven pulley nut 153 - 187
Driving pulley ring nut 65 - 75
External driving pulley ring nut 80 - 90
External transmission cover screws 5-7
Internal transmission cover screws 11 - 13
Air deflector screws 3-4
Air outlet grid screws 3-4
FLYWHEEL COVER
Name Torque in Nm
Flywheel fixing nut 116 - 128
Stator clamps 8 - 10
Screws fixing freewheel to flywheel 13 - 15
Flywheel cover screws 11 - 13
CHASSIS
Name Torque in Nm
hex headflanged screw fixing coil support - M6x20 (2) 10 Nm (7.38 lbf ft)
Lower self-locking M4 nut fixing coils (8) 3 Nm (2.21 lbf ft)
Self-locking M10 nut fixing shock absorber (1) 50 Nm (36.88 lbf ft)
DAX M14 nut fixing engine to chassis (2) 80 Nm (59 lbf ft)
CHAR - 15
Characteristics NA 850 Mana
Name Torque in Nm
TBEI screw fixing rubber rings with groove for saddle - M6x30 10 Nm (7.38 lbf ft)
(2)
TCEI screw fixing tank front rubber rings - M8x20 (2) 25 Nm (18.44 lbf ft)
FOOTPEGS
Name Torque in Nm
Non-slip bolt on driver footrest (2) 25 Nm (18.44 lbf ft)
hex headflanged screw for footrest finish - M6x12 (8) 10 Nm (7.38 lbf ft)
TBEI flanged screw fixing heelrests - M5x16 (4) 6 Nm (4.42 lbf ft)
TCEI screw fixing footrest support to fork pin - M10x63 (2) 50 Nm (36.88 lbf ft)
Lower self-locking flanged M10 nut fixing footrest support to 30 Nm (22.13 lbf ft)
stand bolt (2)
Lower screw fixing rider footrest 25 Nm (18.44 lbf ft)
STAND
Name Torque in Nm
Bolt fixing screwed stand to fork (1) 10 Nm (7.38 lbf ft)
Stand bolt safety lock nut - M10x1.25 (1) 30 Nm (22.13 lbf ft)
Self-locking nut fixing centre stand front bolt (1) 50 Nm (22.13 lbf ft)
TCEI screw fixing switch - M5x25 (2) 6 Nm (4.42 lbf ft)
SWINGARM
Name Torque in Nm
Rear wheel bolt nut fixing fork pin (1) 90 Nm (66.38 lbf ft)
Chain tensioner pad set screw (2) manual
Serpress M8 nut fixing chain tensioner screws (2) manual
M5x15 TBEI screw with washer fixing chain crankcase (4) 6 Nm (4.42 lbf ft)
M5x12 TBEI screw fixing chain slider (2) 3 Nm (2.21 lbf ft) - Loctite 243
Rear brake calliper support lock pin (1) 50 Nm (36.88 lbf ft) - Loctite 243
FRONT SUSPENSION
Name Torque in Nm
Stainless steel TCC M8x30 screw fixing stanchions on upper 25 Nm (18.44 lbf ft)
plate (2)
Stainless steel TCC M8x30 screw fixing stanchions on lower 25 Nm (18.44 lbf ft)
plate (4)
Headstock ring nut - M25x1 (1) tighten to 20 Nm (14.75 lbf ft) - unscrew and tighten to 7 Nm
(5.16 lbf ft)
Headstock cap - M22x1 (1) 100 Nm (73.76 lbf ft)
Screw fixing fork feet on wheel pin - M8x40 (4) 25 Nm (18.44 lbf ft)
TCEI screw fixing handlebar U-bolts to upper plates - M10x60 50 Nm (36.88 lbf ft)
(2)
REAR SUSPENSION
Name Torque in Nm
Self-locking M10 nut fixing shock absorber to fork (1) 50 Nm (36.88 lbf ft)
ENGINE
Name Torque in Nm
TEF screw fixing gear control unit - M6x16 (4) 10 Nm (7.37 lbf ft)
TBEI screw with washer fixing micro-switch bracket - M5x9 (1) 6 Nm (4.42 lbf ft)
TCEI screw fixing pin lever to gearshift lever - M6x16 (1) 10 Nm (7.38 lbf ft)
TCEI screw fixing gearshift lever to engine pin - M6x16 (1) 10 Nm (7.38 lbf ft) - knurled washer
Self-tapping screw fixing air deflector cover on air deflector (4) 1 Nm (0.74 lbf ft)
Self-tapping screw fixing mesh filter on air deflector (2) 1 Nm (0.74 lbf ft)
Self-tapping screw fixing filter cover to air deflector (1) 1 Nm (0.74 lbf ft)
TCCIC screw with shank fixing air deflector to engine (4) 7 Nm (5.16 lbf ft)
hex headflanged screw fixing voltage regulator on bracket - 10 Nm (7.38 lbf ft)
M6x30 (2)
CHAR - 16
NA 850 Mana Characteristics
FILTER BOX
Name Torque in Nm
SWP screw assembling filter support to filter box - M5x19 (6) 2 Nm (1.47 lbf ft)
SWP screw fixing filter box cover - M5x19 (3) 2 Nm (1.47 lbf ft)
hex headflanged screw fixing filter box to chassis - M6x25 (2) 10 Nm (7.37 lbf ft)
EXHAUST SYSTEM
Name Torque in Nm
Self-locking flanged nut tightening exhaust manifolds to heads 25 Nm (18.44 lbf ft)
(4)
TBEI flanged screw fixing exhaust front protection (4) 8 Nm (5.9 lbf ft)
M8 flanged self-locking nut fixing silencer (1) 25 Nm (18.44 lbf ft)
M10 screw fixing compensator on footrest support (2) 30 Nm (22.13 lbf ft)
Manifolds fixing clamp (2) 18 Nm (13.28 lbf ft)
COOLING SYSTEM
Name Torque in Nm
Radiator TCEI fixing screw - M6x35 (2) 10 Nm (7.38 lbf ft)
Heat protection fixing screw - M5x10 (1) 6 Nm (4.42 lbf ft)
Heat protection fixing screw - M6x16 (3) 10 Nm (7.38 lbf ft)
Expansion tank TCEI fixing screw - M6x25 (1) 10 Nm (7.38 lbf ft)
Electric fan fixing screw (3) 0.3 Nm (0.22 lbf ft)
Radiator cover TBEI fixing screw - M5x12 (4) 6 Nm (4.42 lbf ft)
FRONT WHEEL
Name Torque in Nm
TE flanged screw fixing brake disc on wheel - M8x20 (12) 30 Nm (22.13 lbf ft) - Loctite 243
REAR WHEEL
Name Torque in Nm
TE flanged screw fixing brake disc on wheel - M8x20 (5) 30 Nm (22.13 lbf ft) - Loctite 243
Anti-vibration buffer holder TCEI fixing screw - M10x30 (5) 50 Nm (36.88 lbf ft) - Loctite 2701
Self-locking M10 nut fixing crown on sprocket carrier (5) 50 Nm (36.88 lbf ft)
Rear wheel bolt fixing nut (1) 120 Nm (88.51 lbf ft)
TE flanged screw fixing pinion cover to engine - M5x25 (3) 6 Nm (4.42 lbf ft)
Pinion fixing nut (1) 170 Nm (125.38 lbf ft)
FRONT BRAKE
Name Torque in Nm
hex headflanged screw fixing calliper - M10x1.25x55 (4) 50 Nm (36.88 lbf ft)
Union with breather fixing pipe to callipers - M10x1 (2) 25 Nm (18.44 lbf ft)
Union fixing pipe to pump - M10x1 (1) 25 Nm (18.44 lbf ft)
TEF screw fixing braking system to lower plate - M6x16 (1) 10 Nm (7.38 lbf ft)
REAR BRAKE
Name Torque in Nm
Screw fixing pin on brake lever - M6x16 (1) 10 Nm (7.38 lbf ft)
Screw fixing lever on footrest support (1) 25 Nm (18.44 lbf ft) - Loctite 243
Brake pipe union on pump and calliper - M10x1 (1) 25 Nm (18.44 lbf ft)
Hydraulic stop switch (1) 25 Nm (18.44 lbf ft)
M6 Lock nut for fork (1) 10 Nm (7.38 lbf ft)
Parking brake calliper retainer - M8x21 (2) 25 Nm (18.44 lbf ft) - Loctite 243
Hydraulic calliper retainer - M8x29 (2) 25 Nm (18.44 lbf ft) - Loctite 243
hex headscrew fixing pump on footrest plate - M6x25 (2) 10 Nm (7.38 lbf ft) - Loctite 243
Oil tank hex head fixing screw - M6x15 (1) 10 Nm (7.38 lbf ft)
Upper TCEI screw fixing parking lever unit - M6x30 (2) 10 Nm (7.38 lbf ft)
Lower TCEI screw fixing parking lever unit - M6x20 (1) 10 Nm (7.38 lbf ft)
Brake pipe support bracket fixing screw (2) 25 Nm (18.44 lbf ft)
Parking brake cable guide fixing screw (1) 10 Nm (7.38 lbf ft)
CHAR - 17
Characteristics NA 850 Mana
ELECTRICAL COMPONENTS
Name Torque in Nm
Hex head flanged screw fixing horn - M8x16 (1) 25 Nm (18.44 lbf ft)
TBEI flanged screw fixing multiple relay support - M6x16 (2) 10 Nm (7.38 lbf ft)
Self-locking M5 nut fixing single relay support (1) 6 Nm (4.42 lbf ft)
Voltage regulator hex head flanged fixing screw - M6x30 (2) 10 Nm (7.38 lbf ft)
Shear head screw fixing ignition lock - M8x40 (2) up to the breaking point
TCEI screw fixing ignition lock - M8x40 (1) 25 Nm (18.44 lbf ft)
TANK
Name Torque in Nm
Fuel pump fixing ring nut (1) 20 Nm (14.75 lbf ft)
SADDLE
Name Torque in Nm
hex headflanged screw fixing saddle rotation bracket - M6x20 10 Nm (7.38 lbf ft)
(2)
Countersunk head, self-tapping screw fixing saddle hinges to 1.5 Nm (1.11 lbf ft)
saddle bottom - 5 (4)
Driver saddle rear hex headflanged fixing screw - M6x20 (2) 10 Nm (7.38 lbf ft)
Driver saddle lateral TCB fixing screw - 4.2x16 (2) 1 Nm (0.74 lbf ft)
FRONT BODYWORK
Name Torque in Nm
Front mudguard TBEI fixing screw - M5x12 (4) 6 Nm (4.42 lbf ft)
Right/left SWP crosshead flanged screw fixing helmet com- 1.5 Nm (1.11 lbf ft)
partment - M5x20 (9)
Battery cover TBEI fixing screw - M5x12 (2) 6 Nm (4.42 lbf ft)
Screw fixing shock absorber to helmet compartment - M6x20 10 Nm (7.38 lbf ft)
(1)
Self-locking M8 nut fixing shock absorber to helmet compart- 25 Nm (18.44 lbf ft)
ment (1)
Door switch TCB fixing screw - 3.9x14 (1) 1 Nm (0.74 lbf ft)
Lock TBEI fixing screw - M6x16 (2) 10 Nm (7.38 lbf ft)
CHAR - 18
NA 850 Mana Characteristics
Name Torque in Nm
Self-locking M6 nut fixing injection ECU to support (2) 10 Nm (7.38 lbf ft)
hex headflanged screw fixing cable harness ground cable on 10 Nm (7.38 lbf ft)
injection ECU - M6x12 (2)
Self-tapping screw fixing ECU support to compartment - 4.2x12 1 Nm (0.74 lbf ft)
(2)
hex headflanged screw fixing helmet compartment to chassis 10 Nm (7.38 lbf ft)
- M6x20 (4)
Right air deflector TBEI flanged fixing screw - M5x12 (2) 6 Nm (4.42 lbf ft)
TBEI flanged screw fixing right air deflector to expansion tank 4 Nm (2.95 lbf ft)
- M5x9 (1)
Left air deflector TBEI flanged fixing screw - M5x12 (3) 6 Nm (4.42 lbf ft)
Fairing TBEI flanged fixing screw - M5x12 (10) 6 Nm (4.42 lbf ft)
Steering lock housing TBEI fixing screw - M6x30 (2) 6 Nm (4.42 lbf ft)
Latch support TCB fixing screw - 4.2x16 (2) 1 Nm (0.74 lbf ft)
Stainless steel self-tapping screw for plast. fixing helmet com- 1 Nm (0.74 lbf ft)
partment (14)
Rear cover TBEI fixing screw - M5x12 (2) 6 Nm (4.42 lbf ft)
Rear cover TCB fixing screw - 4.2x16 (2) 1 Nm (0.74 lbf ft)
REAR BODYWORK
Name Torque in Nm
Grab handle hex headflanged fixing screw - M8x45 (2) 25 Nm (18.44 lbf ft)
Left tail section self-tapping fixing screw - 3.8 (3) 1 Nm (0.74 lbf ft)
hex headflanged screw fixing license plate holder frame - 10 Nm (7.38 lbf ft)
M6x20 (2)
License plate holder TBEI fixing screw - M5x12 (4) 6 Nm (4.42 lbf ft)
License plate holder TBEI fixing screw - M5x9 (2) 6 Nm (4.42 lbf ft)
License plate holder self-tapping fixing screw - 5 (2) 1.5 Nm (1.11 lbf ft)
License plate holder self-tapping fixing screw - 4.2 (5) 1 Nm (0.74 lbf ft)
Tank cover TCEI fixing screw - M6x16 (4) 10 Nm (7.38 lbf ft)
Countersunk head screw fixing mesh stud bolt - M8x35 (2) 25 Nm (18.44 lbf ft)
Tank protection TBEI fixing screw - M5x12 (1) 6 Nm (4.42 lbf ft)
Overhaul data
Assembly clearances
CHAR - 19
Characteristics NA 850 Mana
- Pistons and cylinders are classified according to their diameter. The coupling is carried out in pairs
(M-M, N-N, O-O, P-P).
COUPLING CATEGORIES BETWEEN THE PISTON AND THE CAST IRON CYLINDER
Name Initials Cylinder Piston Play on fitting
Cylinder - Piston M 87.990 - 87.997 87.933 - 87.940 0.050 - 0.064
Cylinder - Piston N 87.997 - 88.004 87.940 - 87.947 0.050 - 0.064
Cylinder - Piston O 88.004 - 88.011 87.947 - 87.954 0.050 - 0.064
Cylinder - Piston P 88.011 - 88.018 87.954 - 87.961 0.050 - 0.064
NOTE
THE ROTATION DIRECTION OF THE ENGINE AND OPPOSITE TO RUNNING, CONSEQUENTLY
THE PISTONS ARE ORIENTED IN A DIFFERENT WAY WHEN INSTALLING:
THE FRONT CYLINDER PISTON (RUNNING FRONT) MUST BE FITTED WITH THE ARROW TO-
WARDS THE INTAKE.
THE REAR CYLINDER PISTON, UNLIKE THE FRONT ONE, MUST BE FITTED WITH THE ARROW
TURNED TOWARDS THE EXHAUST.
THE PISTON RINGS MUST BE FITTED WITH THE "TOP" REFERENCE OR THE TRADEMARK
FACING UP.
Characteristic
Standard clearance:
0.015 - 0.029 mm
Characteristic
Standard clearance:
0.001 - 0.010 mm
Characteristic
Standard diameter:
CHAR - 20
NA 850 Mana Characteristics
22 + 0.006 +0.001 mm
Piston rings
* Fit piston rings «2» and «3» with the mark «TOP» facing up.
** Position the opening in the rings as shown in this figure.
*** Value «A» of the sealing ring inside the cylinder.
CHAR - 21
Characteristics NA 850 Mana
Measure the diameters as indicated in the figure by positions A and B, on both x and y axes.
CRANKSHAFT
Specification Desc./Quantity
Cat. 1 Standard diameter: 45.010 ÷ 45.016
Cat. 2 Standard diameter: 45.016 ÷ 45.022
CHAR - 22
NA 850 Mana Characteristics
Characteristic
Crankshaft-crankcase axial clearance (H)
0.1 ÷ 0.45 mm (when cold)
Characteristic
Standard diameter:
22 + 0.025 +0.015 mm
Depending on the type of crankshaft/crankcase coupling, the following types of bushings listed in the
table should be used.
CHAR - 23
Characteristics NA 850 Mana
KEY
X = Crankshaft category
Y = Crankcase half-shells category
A = Red
B = Blue
C = Yellow
RECOMMENDED PRODUCTS
Product Description Specifications
ENI i-RIDE Aprilia Racing 5W-40 Engine oil Use top-branded oils that meet or exceed
the requirements of JASO MA, MA2 - API
SL - ACEA A3 specifications
AGIP ARNICA SA 32 Fork oil (Marzocchi) SAE 0W - ISO-L-HV
AGIP FORK 5W Fork oil (Showa) SAE 5W
FUCHS TITAN SAF 1091 Fork oil (Sachs) -
AGIP MP GREASE Black smooth textured lithium-calcium ISO L-X-BCHB 2 - DIN 51 825 KP2K-20
soap based grease containing EP (ex-
treme pressure) additives with optimal
water-repellent properties
AGIP CHAIN GREASE SPRAY Recommended CHAIN oil Grease
AGIP BRAKE 4 Brake fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO
4925 - CUNA NC 956 DOT 4 synthetic
fluid
AGIP PERMANENT SPECIAL Ethylene glycol-based antifreeze fluid ASTM D 3306 - ASTM D 4656 - ASTM D
with organic inhibition additives. Red, 4985 - CUNA NC 956-16
ready to use.
CHAR - 24
INDEX OF TOPICS
SPECIFIC TOOLS
Stores code Description
020193Y Gauge for oil pressure check
S-TOOLS - 26
NA 850 Mana Special tools
020357Y 32 x 35 mm adaptor
S-TOOLS - 27
Special tools NA 850 Mana
S-TOOLS - 28
NA 850 Mana Special tools
020414Y 28 mm punch
S-TOOLS - 29
Special tools NA 850 Mana
020456Y 24 mm punch
S-TOOLS - 30
NA 850 Mana Special tools
020483Y 30 mm guide
S-TOOLS - 31
Special tools NA 850 Mana
S-TOOLS - 32
NA 850 Mana Special tools
020662Y 50 mm guide
S-TOOLS - 33
Special tools NA 850 Mana
AP8140146 Weight
S-TOOLS - 34
NA 850 Mana Special tools
S-TOOLS - 35
Special tools NA 850 Mana
S-TOOLS - 36
NA 850 Mana Special tools
S-TOOLS - 37
INDEX OF TOPICS
MAINTENANCE MAIN
NA 850 Mana Maintenance
Maintenance chart
Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum
function and performance.
To this end, Aprilia offers a set of checks and maintenance services (at the owner's expense), that are
summarised in the table shown on the following page. Any minor faults must be reported without delay
to an Authorised Aprilia Dealer or Sub-Dealer without waiting until the next scheduled service to
solve it.
All scheduled services must be carried out at the specified intervals and mileage, as soon as the pre-
determined mileage is reached. Carrying out scheduled services on time is essential for the validity of
your warranty. For further information regarding Warranty procedures and ''Scheduled Maintenance'',
please refer to the ''Warranty Booklet''.
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE-
HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK
USE.
NOTE
THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED
TO MANAGEMENT ACTIVITIES.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
(1) Replace every 2 years
(2) Replace every 4 years
(3) Check every 2,000 km (1250 mi)
MAIN - 39
Maintenance NA 850 Mana
km x 1,000 1 10 20 30 40 50 60 70 80
Engine oil R R R R R R R R
Fork oil seals I I I I I I I I I
Brake pads (3) I I I I I I I I I
Variator sliders R R R R
Parking brake calliper I I I I I I I I I
Tyres I I I I I I I I I
Tyre pressure I I I I I I I I I
Wheels and transmission cush drive I I I I I I I I I
Transmission screws and bolts torque tightening I I I I I I I I
Tightening bolts, nuts and screws I I I I I I I I I
Suspension and setting I I I I I I I I I
Final drive unit (chain, crown and pinion) I I R I I R I I
Fuel lines (2) I I
Labour time (minutes) 100 120 140 290 140 120 270 120 200
Spark plug
At regular intervals, remove the spark plug and clean off any carbon deposits or replace as required.
CAUTION
ALWAYS REPLACE BOTH SPARK PLUGS EVEN IF ONLY ONE NEEDS REPLACING.
In order to reach the spark plugs:
CAUTION
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS,
LEAVE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE.
• Working from both sides, remove the
two spark plug tubes.
• With the specific supplied wrench, un-
screw and remove the spark plugs (two
per cylinder).
MAIN - 40
NA 850 Mana Maintenance
Installation:
Engine oil
Check
MAIN - 41
Maintenance NA 850 Mana
Replacement
CHANGING ENGINE OIL AND ENGINE OIL FILTER CAN PROVE DIFFICULT IF YOUR ARE INEX-
PERIENCED.
CONTACT AN OFFICIAL APRILIA DEALER IF REQUIRED.
IF YOU WISH TO PERFORM THESE OPERATIONS YOURSELF, FOLLOW THESE INSTRUC-
TIONS.
Check the engine oil level frequently.
To change the oil:
CAUTION
HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE
EASILY AND COMPLETELY; IDEAL TEMPERATURE IS
REACHED AFTER THE ENGINE HAS RUN FOR ABOUT
TWENTY MINUTES.
MAIN - 42
NA 850 Mana Maintenance
MAIN - 43
Maintenance NA 850 Mana
Air filter
MAIN - 44
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
Troubleshooting NA 850 Mana
Engine
YES, go to 3; NO, go to 7.
TROUBL - 46
NA 850 Mana Troubleshooting
TROUBL - 47
Troubleshooting NA 850 Mana
TROUBL - 48
NA 850 Mana Troubleshooting
• 46 - CHECK CONTINUITY BETWEEN PIN 1 AND PIN 2 OF THE RELAY AND CONTINU-
ITY AND GROUND INSULATION OF THE YELLOW/GREEN CABLE AND THE PINK/
BROWN CABLE - END
• 47 - RESTORE THE CABLE HARNESS(PINK/BROWN CABLE) - END
• 48 - RESTORE THE CABLE HARNESS(YELLOW/RED CABLE) - END
• 49 - IS THERE CONTINUITY BETWEEN THE STARTER BUTTON BLUE CABLE AND THE
GROUND LEAD?
• 50 - CHECK THE RIGHT LIGHT SWITCH CONNECTOR, THE CABLES FROM THE CON-
NECTOR TO THE LIGHT SWITCH AND THE LIGHT SWITCH - END
• 51 - RESTORE THE CABLE HARNESS (BLUE CABLE) - END
• 52 - DOES THE START-UP CONTROL RELAY WORK CORRECTLY?
• YES, go to 53; NO, go to 54
• 53 - PROBABLE MALFUNCTION OF THE INJECTION ECU - END
• 54 - REPLACE THE RELAY - END 55 - DISCONNECT THE START-UP REMOTE CON-
TROL CONNECTOR, WHEN TRYING TO START UP THE ENGINE (BY PRESSING THE
STARTER BUTTON AND OPERATING THE BRAKES), IS VOLTAGE PRESENT ON THE
ORANGE/YELLOW CABLE?
• 56 - IS THERE CONTINUITY WITH THE GROUND OF THE BLUE CABLE OF THE START-
UP REMOTE CONTROL?
TROUBL - 49
Troubleshooting NA 850 Mana
YES, go to 3; NO, go to 4.
YES, go to 8; NO, go to 5.
YES, go to 7; NO, go to 6.
• 9 - SLIDE OFF THE AUXILIARY 15A FUSE: IS THERE VOLTAGE IN THE RED/BLACK
CABLE?
TROUBL - 50
NA 850 Mana Troubleshooting
Service
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 - "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.
YES, go to 7; NO, go to 8.
• 12 - STORE ALL THE KEYS THE FIRST TIME THE INSTRUMENT PANEL IS SWITCHED
ON - END
• 13 - DELETE THE ERROR WITH THE "ERROR CLEARING" FUNCTION IN THE "DIAG-
NOSIS" FUNCTION OF THE INSTRUMENT PANEL - END
Belt
CAUTION
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 - WORD "BELT" SHOWN ON THE DISPLAY
TROUBL - 51
Troubleshooting NA 850 Mana
YES, go to 4; NO, go to 3.
• 3 - NOW THE CURRENT BELT CAN BE USED UNTIL THE "EFI" WARNING LIGHT
COMES ON AND THERE IS A FORCED SETTING OF THE GEARSHIFT IN "AUTOMATIC
-RAIN" MODE
• 7 - HOWEVER, DO YOU WANT TO REPLACE THE BELT? YES, go to 5; NO, END
• 4 - CONNECT TO AXONE BY SELECTING "AUTOMATIC GEARSHIFT", THE "BELT
WEAR" ERROR, CODE 9011 CURR. (CURRENT) IS PRESENT.
• 5 - REPLACE THE BELT AND BEFORE STARTING THE ENGINE, REPLACE THE BELT
WITH AXONE (SEE ELECTRICAL SYSTEM/CHECKS AND CONTROLS/TRANSMISSION
ECU/ADJUSTABLE PARAMETERS).
• 6 - DELETE THE ERROR WITH THE "ERROR CLEARING" FUNCTION - END
GEAR
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
CAUTION
BEFORE ANY TROUBLESHOOTING, MAKE SURE THAT:
1) BATTERY VOLTAGE IS ABOVE 12V;
2) THE MAIN 30A FUSE IS NOT DAMAGED AND IS ADEQUATELY FITTED;
3) SECONDARY FUSES ARE NOT DAMAGED AND ARE ADEQUATELY FITTED.
1 - "EFI" WARNING LIGHT IS ON AND THE WORD "GEAR" IS SHOWN ON THE DISPLAY
2 - CONNECT TO AXONE BY SELECTING "AUTOMATIC GEARSHIFT" AND CHECK WHICH ER-
ROR IS PRESENT: FOR FURTHER INFORMATION ABOUT THE ERROR AND ITS POSSIBLE
CAUSES, PUSH BUTTON "?". THE AMBIENT PARAMETERS RELATED TO THE ERROR CAN ALSO
BE CONSULTED BY SELECTING THE "ACTIVATIONS" SCREEN AND THEN (INJECTOR ICON)/
ERROR AMBIENT PARAMETER READING
3 - FIND THE MALFUNCTION (SEE THE "ELECTRICAL SYSTEM/CHECKS AND CONTROLS"
CHAPTER) AND RESTORE THE CORRECT OPERATION
4 - TO SOLVE THE MALFUNCTION, IS IT NECESSARY TO REPLACE OR REMOVE THE DRIVING
PULLEY POSITION POTENTIOMETER?
YES, go to 5; NO, go to 7.
5 - ONCE THE POTENTIOMETER HAS BEEN REFITTED (SEE "ELECTRICAL SYSTEM/CHECKS
AND CONTROLS/POSITION SENSOR/DRIVING PULLEY/FITTING) AND BEFORE STARTING THE
ENGINE, CARRY OUT THE "POTENTIOMETER RESET" OPERATION WITH AXONE (SEE "ELEC-
TRICAL SYSTEM/CHECKS AND CONTROLS/DRIVING PULLEY POSITION SENSOR/ADJUSTA-
BLE PARAMETERS)
TROUBL - 52
NA 850 Mana Troubleshooting
H-F-M
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 - LETTERS "H"; "F" OR "M" ARE SHOWN ON THE DISPLAY
• 2 - "H" DISPLAYED?
YES, go to 3; NO, go to 4.
YES, go to 4; NO, go to 7.
TROUBL - 53
Troubleshooting NA 850 Mana
YES, go to 3; NO, go to 4.
OIL BULB
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 - EFI WARNING LIGHT IS ON AND THE BULB ICON IS SHOWN IN THE DISPLAY
• 2 - OPEN THE "DIAGNOSIS" FUNCTION OF THE INSTRUMENT PANEL AND SELECT
"INSTRUMENT PANEL ERRORS"
• 3 - FIND THE MALFUNCTION (SEE THE "ELECTRICAL SYSTEM/CHECKS AND CON-
TROLS/INSTRUMENT PANEL/DIAGNOSIS" CHAPTER AND RESTORE THE CORRECT
OPERATION
• 4 - HAS THE INSTRUMENT PANEL BEEN REPLACED?
YES, go to 5; NO, go to 6.
• 5 - STORE ALL THE KEYS THE FIRST TIME THE INSTRUMENT PANEL IS SWITCHED
ON - END
• 6 - DELETE THE ERROR WITH THE "ERROR CLEARING" FUNCTION IN THE "DIAG-
NOSIS" FUNCTION OF THE INSTRUMENT PANEL - END
TROUBL - 54
INDEX OF TOPICS
Components arrangement
CAUTION
A RELAY CANNOT BE IDENTIFIED BASED ONLY ON THE FOLLOWING INDICATIONS: THIS
SHOULD BE DONE ALSO IDENTIFYING THE COLOUR OF THE RELAY CABLES.
RELAY LAYOUT ON THE WIRING DIAGRAM AND ON THE VEHICLE
START-UP CONTROL RELAY
START-UP RELAY
RETENTION RELAY
RESISTANCE MODULE
ELE SYS - 56
NA 850 Mana Electrical system
INTRODUCTION
Scope and applicability
The aim of this document is to define the way the cable harnesses are laid and fixed to the motorbike
and any possible critical situations (Special checks on connections and laying), in order meet the ob-
jectives of vehicle reliability.
Materials used and corresponding quantities
The electrical system consists of the following cable harnesses and parts:
Motorcycle division
The wiring timing is subdivided in three essential sections, as indicated in the figure.
1. Front section
2. Central section
3. Rear section
• Check the connector block for connections and correct tightening in the following connec-
tors.
ELE SYS - 57
Electrical system NA 850 Mana
Front side
1. Small clamp
ELE SYS - 58
NA 850 Mana Electrical system
TABLE B
2. Small clamps
3. Reference red tape between the two clamps
TABLE C
TABLE E
4. Clamp code 8104606
ELE SYS - 59
Electrical system NA 850 Mana
TABLE F
5. Medium clamp
Central part
TABLE A - COILS
1. Part for fitting ground terminals, on coil assembly.
2. Cable guide
ELE SYS - 60
NA 850 Mana Electrical system
TABLE D
3. Fan connector
4. Middle clamp
5. Coil "A" connector
6. Clamp to chassis
TABLE F
8. Cable harness laying through the cable guide
ELE SYS - 61
Electrical system NA 850 Mana
TABLE H
9. Medium clamp
TABLE I
10. Gearshift motor connection
11. Regulator connection
TABLE L
12. Clamp to chassis that holds three cables
13. Small clamps
ELE SYS - 62
NA 850 Mana Electrical system
TABLE O
16. Clamp to chassis
ELE SYS - 63
Electrical system NA 850 Mana
TABLE P
TABLE Q
17. Big clamp
18. Clamp to chassis
TABLE R
19. The connections of the light switch should be
above the chassis pipe
20. The flywheel cable passes under the main ca-
ble harness
ELE SYS - 64
NA 850 Mana Electrical system
TABLE Z
22. Clamp to chassis that locks the fuel pipe and
the pulley sensor
ELE SYS - 65
Electrical system NA 850 Mana
TABLE ZA
23. Medium clamp
TABLE ZB
TABLE ZC
ELE SYS - 66
NA 850 Mana Electrical system
Back side
TABLE A
1. Clamp to chassis
ELE SYS - 67
Electrical system NA 850 Mana
KEY
1. MULTIPLE CONNECTORS
2. PULLEY POSITION SENSOR
3. START-UP RELAY
4. PULLEY SPEED SENSOR
ELE SYS - 68
NA 850 Mana Electrical system
ELE SYS - 69
Electrical system NA 850 Mana
ELE SYS - 70
NA 850 Mana Electrical system
THE DIFFERENCES ARE HIGHLIGHTED ON THE DIAGRAM BY TWO TYPES OF LINES, DIFFER-
ENT AND ALTERNATE BETWEEN THEM:
• IF THERE IS A WHITE/RED CABLE ON THE VEHICLE, REFER TO THE PATH MARKED
WITH long/short dashes
• IF THERE IS A GREEN CABLE ON THE VEHICLE, REFER TO THE PATH MARKED WITH
A UNIFORM DOTTED LINE.
3. Pulling the cables slightly from the back of the connector in order to check the correct position of
terminals on the connector and of the cable on the terminal.
CONTINUITY check
Check goal: this control is to check that there are not any circuit interruptions nor excessive resistance,
for instance caused by rust, on the two terminals being inspected.
ELE SYS - 71
Electrical system NA 850 Mana
Tester: set the tester on the "continuity" symbol and place the tester probes on the two circuit ends:
the tester emits a sound signal only if there is continuity; the tester can also be set to the Ohm symbol
to check that the circuit resistance is null or a few tenths of an Ohm.
CAUTION: THE CIRCUIT SHOULD NOT BE ENERGISED, OTHERWISE THE TEST IS IRRELE-
VANT.
GROUND CONNECTION check
Check goal: this control is to check if a cable or a circuit is in contact with the vehicle ground (-)
connection.
Tester: set the tester on the "continuity" symbol and place one tester probe on the vehicle ground
connection (or on the battery - terminal) and the other probe on the cable being inspected: the tester
sends out a sound signal only if there is continuity. The tester can also be set to the Ohm symbol to
check that the circuit resistance is null or a few tenths of an Ohm.
CAUTION! IF THERE IS A GROUND CONNECTION COMING FROM THE CONTROL UNIT, MAKE
SURE THAT DURING THE TEST THE CONTROL UNIT IS GROUND CONNECTED TO THE CIR-
CUIT.
VOLTAGE check
Check goal: this control is to check if a cable is energised, i.e. if it receives power supply from the
battery or the control unit.
Tester: set the tester on the direct current symbol and place the tester red probe on the cable being
inspected and the black probe on the vehicle ground connection (or on the battery - terminal).
CAUTION
IN CASE OF TEMPORAL MALFUNCTIONING, CARRY OUT ALL DUE CHECKS LOOKING FOR
FAULT BY MOVING SLIGHTLY THE CABLE HARNESS BEING INSPECTED.
Dashboard
ELE SYS - 72
NA 850 Mana Electrical system
If there is an immobilizer failure at ignition, the instrument panel requests you to enter a user code. If
the code is entered correctly, the instrument panel signals the failure by displaying the SERVICE icon
and the red general warning light comes on.
ELE SYS - 73
Electrical system NA 850 Mana
Alarms - transmission
In case of alarms for gearshift controls and mode
control connected to the transmission control unit,
three kinds of symbols are shown on the display,
according to the nature of the alarm: F, H and M.
F stands for "foot" (foot pedal), H stands for "han-
dlebar" (handlebar control) and M is for
"mode" (gear mode selection).
In case of alarms related to the transmission con-
trol unit, the general alarm warning light is lit and
the display shows the word GEAR.
CAUTION
IN CASE THE HANDLEBAR CONTROLS ARE DISABLED,
THE H SYMBOL WILL BE ALSO SHOWN ON THE DIGITAL
DISPLAY.
ELE SYS - 74
NA 850 Mana Electrical system
ELE SYS - 75
Electrical system NA 850 Mana
Diagnosis
An access code is required to enter this menu which controls the diagnosis function:
• ENTER SERVICE CODE
This is a 5-digit code, fixed for each vehicle. For these vehicles, the code is:
12321
If the code is incorrect, the following message is displayed:
• INCORRECT CODE
and the instrument panel goes back to the main menu. Otherwise, the following menu is displayed:
• EXIT
• ECU DIAGNOSIS
• INSTRUMENT PANEL ERRORS
• ERROR CLEARING
• VEHICLE SERVICING RESET
• UPDATE
• CHANGE KEYS
• KM / MILES
ECU diagnosis
In this mode a chart is displayed showing potential
errors in the control unit.
IT IS NECESSARY TO REFER TO THE ERROR
INDICATIONS GIVEN BY NAVIGATOR FOR
THIS VEHICLE.
The instrument panel does not keep all previous errors stored in its memory.
INSTRUMENT PANEL ERRORS
In this mode, a chart is displayed showing potential
errors in the immobilizer and the sensors connec-
ted to it.
ELE SYS - 76
NA 850 Mana Electrical system
DSB 02 - Immobilizer fault: key code not read (key not present or transponder not working)
DSB 03 - Immobilizer fault: aerial not working (open or short-circuited)
DSB 04 - Internal controller fault
DSB 05 - -
DSB 06 - Ambient air temperature sensor
Error cause
• An oil sensor fault is signalled when it is detected that the sensor circuit is open or shorted
to positive.
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.
UPDATE
This function is used to program the instrument panel again. This screen page shows the software
version currently loaded; the LCD reads:
The instrument panel will restart to work normally after the key is inserted-extracted.
Modify Keys
With this function the instrument panel can update the keys. Up to 4 keys can be stored.
The user code is first requested to be entered:
ELE SYS - 77
Electrical system NA 850 Mana
See also
Diagnosis
ELE SYS - 78
NA 850 Mana Electrical system
• If shorted to positive: excessive voltage has been detected at PIN 1 of connector B (BLUE).
Troubleshooting
• If shorted to positive: the malfunction is detected with an activated brake (12 V voltage de-
tected at PIN 23 of connector B) and the start-up switch is pressed, if the battery voltage is
not reduced (due to the absorption by the drive coil of the start-up control relay No. 3) now
the ECU reads that the pink/brown cable is shorted to battery. Restore the cable harness (if
the short circuit is in the cable harness) or the relay (if the short circuit is inside the relay).
NOTE
IN CASE OF SHORT TO GROUND / OPEN CIRCUIT NO ERROR WILL APPEAR: SEE THE TROU-
BLESHOOTING CHAPTER, THE ENGINE DOES NOT START.
Electrical characteristics:
Pin-out:
• A - 17
• B - 19
• C-9
• D - 18
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
ELE SYS - 79
Electrical system NA 850 Mana
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: FUEL INJECTION SYSTEM
PARAMETERS
Stepper base
Example value: 70 - 50
Steps corresponding to the idle motor reference position: approx. 70 when cold; approx. 50 when hot.
CL Stepper
Example value: 120 - 70
Steps set by the control unit for the idle motor. Steps at idle are so that the engine keeps the target
engine Revs set by the control unit: approx. 90 - 120 steps when cold; approx. 70 - 90 when hot.
Stepper regulator
Difference between current steps of idle motor and those at the reference position.
Virtual throttle angle from Stepper
Example value: 0°
If the engine is not at idle speed, this value indicates the motor air flow by the idle motor in throttle
degrees.
ACTIVATION
Stepper control:
For 4 s, advancement command of 32 steps; for the next 4 s, retrocession command of 32 steps and
so on for 30s
ELECTRICAL ERRORS
Idle check P0505 - shorted to positive / shorted to negative / open circuit
Error cause
• If shorted to positive: excessive voltage has been detected at PINS 17 and 18 or PINS 9
and 19 of connector A (BROWN).
• If shorted to negative: no voltage has been detected.
• If the circuit is open: an interruption has been detected
Troubleshooting
• If shorted to positive: with the key set to key ON disconnect the idle motor connector and
check if there is a voltage different from zero at the ends of one of the PINS on the cable
harness side: if there is voltage, restore the cable harness.
• If shorted to negative: with the key set to key ON disconnect the idle motor connector and
check which pin on the cable harness side is in continuity with the ground connection and
restore the cable harness.
• If the circuit is open: disconnect the idle motor connector and check the continuity towards
the motor between PINS A and D and between PINS B and C: if there is an interruption,
ELE SYS - 80
NA 850 Mana Electrical system
replace the throttle body; if its OK, check the connectors of both idle motor and ECU: if they
are not OK, restore; if OK, check continuity of the 4 cables and once the interrupted cable
is found, restore the cable harness.
Fuses
AUXILIARY FUSES
A - Tail lights, Stop lights, License place light, Horn, Electric lock, Instrument panel power supply,
Transmission ECU power supply, Resistance module (15A).
B - Low-/high-beam lights, Heated hand grips (OPT) (15 A).
C - Fuel pump, Coils, Injectors, Electric fan, Lambda probe, Start-up control relay (20A).
D - Injection load relay, Electric fan relay, Injection control unit power supply, Engine Stop (10A).
E - Injection control unit permanent power supply (3A).
F - Plug socket (15A).
G - Spare fuses (10 - 15 - 20A).
MAIN FUSES
H - Instrument panel, Turn indicators, Glove-box light, Injection main relay (30A).
E - Transmission ECU permanent power supply (40A).
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Electrical system NA 850 Mana
Control unit
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 DEVICES AT THE 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. Potential errors will be shown on the Instrument
Panel Errors screen page, on the DIAGNOSIS section of the instrument panel.
Ignition
Example value: Enabled/Disabled
Indicates whether the control unit will enable start-up when requested: in case the safety measures are
not respected, for example the fall sensor is inverted or if the immobilizer does not send the start-up
consent to the control unit, the status is DISABLED.
ACTIVATIONS
Error clearing
ELECTRICAL ERRORS
P0606 Microprocessor - circuit not operational.
Error cause
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NA 850 Mana Electrical system
• Possible internal control unit error. Also check the control unit supply and ground connec-
tions.
Troubleshooting
• If the power supply and ground connections are connected correctly, replace the injection
control unit.
• After installing a new control unit, it is necessary to carry out the Throttle positioner auto-
detection function using the diagnosis instrument
ELE SYS - 83
Electrical system NA 850 Mana
Speed sensor
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 DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: AUTOMATIC TRANSMISSION system
PARAMETERS
Vehicle speed
Example value:km/h
To make sure that the read value is correct, check its status in the Device Status screen page.
STATUSES
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NA 850 Mana Electrical system
Vehicle speed
Example value:Invalid data / Valid data
If the "Invalid Data" message is displayed, it means that the parameter value in the Engineering pa-
rameters screen page is not correct.
ERRORS
Vehicle speed sensor Code 9003 - no signal/ signal not valid.
Error cause
• If there is no signal: an electric circuit interruption has been detected between PINS B6 and
C3 or a short-circuit has been detected in the battery. If signal is not valid: the vehicle speed
has a value that is not compatible with the engine rpm or the signal is not variable.
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.
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 yellow/blue cable between the
transmission ECU connector and the sensor connector: if it is not OK, restore; if it is OK,
check the continuity of the sensor circuit (PINS 1 and 2 of sensor connector): if it is not OK,
replace the sensor; if it is OK, check the continuity between PIN 2 of the sensor connector
and PIN B6 of the transmission ECU connector: if it is not OK, restore the cable harness; if
it is OK, check with key set to key ON, that PIN B6 of the transmission ECU does not have
continuity with the ground connection, and then replace the transmission ECU (in this case
the Driven pulley revolution sensor error (Code 9004), no signal, should also be present).
• If signal is not valid: check the sensor resistance, from the transmission ECU connector,
between PINS B6 and C3: if it is not OK, replace the sensor; if it is OK, with key set to key
ON, check the voltage at PIN C3: if voltage is other than zero, see Phase 1; if voltage is
equal to zero, carry out the same check with the engine running and by lifting the rear wheel
which should be turning: if the alternating voltage is other than zero, replace the sensor; if
it is approximately 0.8 V in first gear at 50 km/h, check the correct position of the sensor.
Phase 1: check if upon disconnecting the sensor, voltage at PIN C3 reaches zero: if it rea-
ches zero, replace the sensor; if it does not reach zero, restore the cable harness (sensor
pin 1 cable shorted to battery or a cable at 5V).
ELE SYS - 85
Electrical system NA 850 Mana
Electrical specifications:
Pin-out:
1. Negative signal
2. Positive signal
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: FUEL INJECTION SYSTEM
PARAMETERS
Engine rpm
(rpm)
Engine revolutions per minute: the minimum value is set by the control unit and cannot be adjusted.
STATUSES
Synchronisation
Example value:Synchronised / Not synchronised
It indicates if the control unit detects the revolution sensor signal correctly.
ELE SYS - 86
NA 850 Mana Electrical system
ELECTRICAL ERRORS
Engine revolution sensor P0335 - open circuit
Error cause:
• An interruption in the sensor circuit has been detected, from PIN 25 to PIN 35 of connector
A (BROWN).
Troubleshooting:
• Check the sensor connector and the injection control unit connector A (BROWN): if it is not
OK, restore; if it is OK, check continuity of the two cables: if there is no continuity, restore
the cable harness; if there is continuity, check the interruption on the sensor and replace it
CAUTION
IF THE ELECTRIC CIRCUIT IS SHORT-CIRCUITED, NO ERROR IS DISPLAYED. CHECK THE
SENSOR ELECTRICAL SPECIFICATIONS: IF IT IS NOT THE CORRECT ONE, REPLACE THE
SENSOR. IF IT IS THE CORRECT ONE, CHECK INSULATION FROM POWER AND GROUND
CONNECTION OF BOTH CABLES OF PINS 1 AND 2. PERFORM THE TESTS FROM THE SENSOR
CONNECTOR TO THE SENSOR. IF THEY ARE NOT OK, RESTORE THE CABLE HARNESS/RE-
PLACE THE SENSOR. IF OK, PERFORM THE TEST FROM PINS 25 AND 35 OF THE MARELLI
CONTROL UNIT ENGINE CONNECTOR A (BROWN) TO THE CABLE HARNESS AND REPLACE
THE LATTER.
Electrical characteristics:
Pin-out:
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Electrical system NA 850 Mana
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NA 850 Mana Electrical system
same as the engine temperature. Check also that the sensor electrical characteristics are ob-
served: replace the sensor if not OK; if it is OK, check the sensor connector and the Marelli
control unit connector
Electrical characteristics:
Pin-out:
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 DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: FUEL INJECTION SYSTEM
PARAMETERS
Air temperature
Example value: 26° C
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Electrical system NA 850 Mana
Temperature of the air taken in by the engine, measured by the sensor in the throttle body. This is not
the temperature indicated by the instrument panel.
ELECTRICAL ERRORS
air temperature sensor P0110 - open circuit, shorted to positive / shorted to negative.
Error cause
• If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 14 of
connector A (BROWN). If shorted to negative: voltage equal to zero has been detected.
Troubleshooting
• If the circuit is open, shorted to positive: check the sensor connector and the Marelli control
unit connector. If OK, check sensor continuity: replace the sensor if not OK; if it is OK, check
continuity between PIN 14 of connector A (BROWN) and sensor PIN 1: restore cable har-
ness if there is not continuity; if it is OK, reconnect the control unit connector and, with key
set to key ON, check the continuity between the sensor connector PIN 2 and the vehicle
ground connection: if it is OK, it means that the error cause is that the cable is shorted to
positive and it is necessary to restore the cable harness between PIN 14 of the connector
A (BROWN) and sensor PIN 1; check the sensor connector and the Marelli control unit
connector. If they are not OK, restore the cable harness. If they are OK, check continuity
between PIN 20 of the connector A (BROWN) and PIN 2 of the sensor connector: restore
the cable harness if there is not continuity. If there is, it means that the control unit does not
supply the ground connection and therefore should be replaced.
• If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor;
if resistance is correct, it means that the cable has ground connection: restore the cable
harness.
NOTES No error is detected if the sensor does not work correctly or the control unit connector
or sensor terminals are rusty: then check through Navigator if the temperature indicated is
plausible in relation to the ambient temperature. Check also that the sensor electrical charac-
teristics are observed: replace the sensor if not OK; if it is OK, check the sensor connector and
the Marelli control unit connector.
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NA 850 Mana Electrical system
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 difference in oxy-
gen content between the exhaust fumes and the
ambient. It does not require an external supply
source but, in order to work properly, it should
reach a high operating temperature: that is why
there is a heating circuit inside.
Level in wiring diagram:Lambda probe
Location:
Electrical characteristics:
Pin-out:
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 DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: FUEL INJECTION SYSTEM
PARAMETERS
Lambda probe
Example value: 0 - 1000 mV
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Electrical system NA 850 Mana
Signal when energised that the control unit receives from the lambda probe: inversely proportional to
the presence of oxygen.
Lambda integrator
Example value: 0,00 %
In closed loop, the value must be close to 0.00 (values not within the interval from -10.0 % to 10.0 %
indicate a fault): for example, value 25% corresponds to +25% with respect to the reference injection
time; -25% corresponds to -25%. In an open circuit, the lambda probe signal is too low. Therefore, the
control unit takes it as a lean mixture condition and will try to enrich it. The value read will be +25%:
once this correction has been tried, the value shifts to 0.00 fixed and the Lambda probe error is signalled.
STATUSES
Lambda
Example value:Open loop / Closed loop
It indicates if the control unit is using (CLOSED) the lambda probe signal to keep the stoichiometric
combustion. At idle CLOSED only if: Air T >10° and engine T > 18° and engine running for at least 1-2
minutes.
ELECTRICAL ERRORS
Lambda probe P0130 - shorted to positive / open circuit, shorted to negative.
Error cause
• If shorted to positive, excessive voltage has been detected at PIN 22 of connector B (BLUE).
If the circuit is open, shorted to negative, no voltage has been detected. In both cases, the
recovery function is hardly noticeable for the customer.
Troubleshooting
• if shorted to positive: with key set to ON, disconnect the sensor connector and measure PIN
1 voltage on the cable harness side (grey cable): if there is voltage (5 or 12 V), restore the
cable harness; if there is not, replace the lambda probe.
Lambda probe heater P0130 - shorted to positive / open circuit, shorted to negative.
Error cause
• If shorted to positive: excessive voltage has been detected at PIN 11 of connector B (BLUE).
If the circuit is open, shorted to negative: voltage equal to zero has been detected.
Troubleshooting
• If shorted to positive: disconnect the probe connector and check the sensor correct resist-
ance: replace the sensor if not OK; if it is OK, restore the cable harness.
• If the circuit is open, shorted to negative: check the sensor connector: if it is not OK, restore;
if it is OK, check the continuity towards the sensor from PINS 3 and 4: if it is not OK, replace
the sensor; if it is OK, check the continuity of the white cable between the sensor connector
and PIN 11 of connector B (BLUE) of the control unit: if it is not OK, restore the cable harness;
ELE SYS - 92
NA 850 Mana Electrical system
if it is OK, it means that the white cable is in continuity with the ground cable and it is nec-
essary to restore the cable harness.
Injector
INJECTOR
Function
To supply the correct amount of petrol at the right
timing.
Operation / Operating principle
Injector coil is excited for the petrol passage to
open.
Level in wiring diagram:Coils and injectors
Location:
1. Supply
2. Ground connection
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
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:
FUEL INJECTION SYSTEM
PARAMETERS
Injector
Injection time
ELECTRICAL ERRORS
Front injector P0202 - shorted to positive / shorted to negative / open circuit.
Error cause
ELE SYS - 93
Electrical system NA 850 Mana
Troubleshooting
• if shorted to positive: disconnect the injector connector, set the key to KEY ON and activate
the component with Axone; check if there is voltage at PIN 2 of the injector connector: if
there is, restore the cable harness; if there is not, replace the sensor.
• if shorted to negative: disconnect the injector connector, set the key to KEY ON and check
if there is a ground connection on PIN 2: if there is, restore; if there is not, replace the injector.
• the circuit is open: check the component correct electrical characteristic: if it is not the correct
one, replace the component; if it is correct, check the connector on the component and the
Marelli control unit connector: if they are not OK, restore; if they are OK, check the continuity
of the cable between PIN 37 of connector A (BROWN) and PIN 2 of the component and
restore the cable harness.
Troubleshooting
• if shorted to positive: disconnect the injector connector, set the key to KEY ON and activate
the component with Axone; check if there is voltage at PIN 2 of the injector connector: if
there is, restore the cable harness; if there is not, replace the sensor.
• if shorted to negative: disconnect the injector connector, set the key to KEY ON and check
if there is a ground connection on PIN 2: if there is, restore; if there is not, replace the injector.
• the circuit is open: check the component correct electrical characteristic: if it is not the correct
one, replace the component; if it is correct, check the connector on the component and the
Marelli control unit connector: if they are not OK, restore; if they are OK, check the continuity
of the cable between PIN 28 of the connector A (BROWN) and PIN 2 of the component and
restore the cable harness.
ELE SYS - 94
NA 850 Mana Electrical system
Fuel pump
Electrical characteristics:
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 DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: FUEL INJECTION SYSTEM
ACTIVATION
Fuel pump:
Operation for 30 seconds.
ELECTRICAL ERRORS
Fuel pump relay P0230 - shorted to positive / shorted to negative / open circuit.
Error cause
• If shorted to positive: excessive voltage has been detected at PIN 6 of connector B (BLUE).
• If shorted to negative: no voltage has been detected.
• If the circuit is open: an interruption has been detected.
Troubleshooting
• If shorted to positive: disconnect the injection load relay (No. 29 on the wiring diagram) and
setting the key to KEY ON, measure the voltage read at PIN 1 of the relay connector towards
the cable harness: if voltage is equal to 5 or 12 V, restore the cable harness; if voltage is
equal to zero, replace the relay.
• If shorted to negative: disconnect the injection load relay (No. 29 on the wiring diagram) and
setting the key to KEY ON (wait for a few seconds), check if there is continuity with the
ground cable to PIN 1 of the relay connector towards the cable harness: if there is continuity,
restore the cable harness; if there is not continuity, replace the relay.
• If the circuit is open: check the injection control unit connector and the relay connector: if
they are not OK, restore; if they are OK, check the continuity of the grey/blue cable between
ELE SYS - 95
Electrical system NA 850 Mana
the two connectors: if there is not continuity, restore the cable harness; if there is continuity,
check the continuity of the yellow/grey cable between the relay connector and the auxiliary
D fuse: if there is not continuity, restore the cable harness; if there is continuity, check that
the relay presents no continuity between PINS 1 and 2, and replace the relay.
Coil
Function
It controls the ignition spark plug in order to gen-
erate the fuel ignition spark.
Operation / Operating principle
With inductive discharge: 2 coils with double sec-
ondary circuit (Twin spark)
Level in wiring diagram:Coils and injectors
Location:
Electrical specifications:
Pin-out:
1. Supply + batt V
2. Activation from control unit
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
ELE SYS - 96
NA 850 Mana Electrical system
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: FUEL INJECTION SYSTEM
PARAMETERS
Ignition advance
ACTIVATION
Right coil (rear cylinder):
The auxiliary injection relay (No. 29 in the wiring diagram, placed under helmet compartment, right side)
is energised for 5 seconds and the grey/red cable of the coil is closed to ground for 2 ms per second.
Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation.
The continuity of the wiring is necessary for correct activation: no error indications are displayed in case
of lack of activation.
Left coil (front cylinder):
The auxiliary injection relay (No. 29 in the wiring diagram, placed under helmet compartment, right side)
is energised for 5 seconds and the orange/green cable of the coil is closed to ground for 2 ms per
second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector
activation. The continuity of the wiring is necessary for correct activation: no error indications are dis-
played in case of lack of activation.
ELECTRICAL ERRORS
Right coil (rear cylinder) P0351 - shorted to positive / open circuit, shorted to negative.
Error cause
• If shorted to positive: excessive voltage has been detected at PIN 38 of connector A
(BROWN).
• If the circuit is open, short circuit to negative: voltage equal to zero has been detected
Troubleshooting
• If shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with
Axone and check voltage at connector PIN 1: if there is voltage, restore the cable harness;
if voltage = 0, replace the coil
• if the circuit is open, short circuit to negative: check the coil connector and the Marelli control
unit connector. If they are not OK, restore; if everything is OK, check cable continuity be-
tween the two cable terminals. If there is not continuity, restore the cable harness; if there
is cable continuity, with key set to ON, check the cable earth insulation (from coil connector
or control unit connector). If it is not OK, restore the cable harness; if it is OK, check if there
is voltage in the red/brown cable, with key set to ON or activating with Axone. If there is no
voltage, check continuity and earth isolation of the red/brown cable from the coil connector
to the auxiliary injection relay connector 29. If it is not OK, restore; if everything is OK, dis-
connect the relay and check if there is voltage in the orange/red cable: if there is voltage,
ELE SYS - 97
Electrical system NA 850 Mana
replace the relay; if there is no voltage, check continuity and earth insulation of the orange/
red cable from the relay connector to the auxiliary fuse box and replace the cable harness.
Left coil (front cylinder) P0352 - shorted to positive / open circuit, shorted to negative
Error cause
Troubleshooting
• If shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with
Axone and check voltage at connector PIN 1: if there is voltage, restore the cable harness;
if voltage = 0, replace the coil
• if the circuit is open, short circuit to negative: check the coil connector and the Marelli control
unit connector. If they are not OK, restore; if everything is OK, check cable continuity be-
tween the two cable terminals. If there is not continuity, restore the cable harness; if there
is cable continuity, with key set to ON, check the cable earth insulation (from coil connector
or control unit connector). If it is not OK, restore the cable harness; if it is OK, check if there
is voltage in the red/brown cable, with key set to ON or activating with Axone. If there is no
voltage, check continuity and earth isolation of the red/brown cable from the coil connector
to the auxiliary injection relay connector 29. If it is not OK, restore; if everything is OK, dis-
connect the relay and check if there is voltage in the orange/red cable: if there is voltage,
replace the relay; if there is no voltage, check continuity and earth insulation of the orange/
red cable from the relay connector to the auxiliary fuse box and replace the cable harness.
Throttle body
THROTTLE BODY
• Function
Electrical characteristics:
ELE SYS - 98
NA 850 Mana Electrical system
Pin-out:
• A - Ground connection
• B - Supply voltage + 5V
• C - Potentiometer 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 DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: FUEL INJECTION SYSTEM
PARAMETERS
Throttle
Example value: 4.9°
STATUSES
Throttle position
Example value:Released/Pressed
It indicates if the throttle potentiometer is open or closed in the released position.
ADJUSTABLE PARAMETERS
Throttle positioner autodetection: It allows the control unit to detect the closed throttle position; just
press the Enter key.
Self-adjustable parameters reset: Lambda probe self-adaptability parameters reset: operation to be
carried out after the throttle body is cleaned (every 30,000 km), or in the case a new engine, a new
lambda probe or a new injector is fitted, or the correct operation of the injection system or the valves is
restored
ELECTRICAL ERRORS
Throttle actuator position sensor P0120
Example value:open circuit, shorted to positive / shorted to negative.
Error cause
• If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 3 of
connector A (BROWN).
• If shorted to negative: voltage equal to zero has been detected.
ELE SYS - 99
Electrical system NA 850 Mana
Troubleshooting
• Circuit is open, shorted to positive: check the injection control unit connector and the sensor
connector: if they are not OK, restore; if they are OK, check the continuity between PIN 3 of
the connector A (BROWN) and PIN C (red cable): if there is not continuity, restore the cable
harness; if there is continuity, check continuity of the sensor between PIN A and PIN C: if
there is not continuity, replace the throttle body; if there is continuity, check the resistance:
if below 1.3 kOhm, replace the sensor; if above 1.3 kOhm, there is a short circuit to positive
on the red cable and it is necessary to restore the cable harness.
• If shorted to negative: disconnect the sensor connector and check the ground insulation of
the red cable (from throttle sensor connector or control unit connector): if there is continuity
with the ground connection, restore the cable harness; if isolated from ground connection,
the resistance between PIN A and PIN C is below 1.3 kOhm; therefore, it is necessary to
replace the throttle body.
RESET PROCEDURE
Once the throttle body or the injection control unit is replaced, it is necessary to connect to the diagnosis
instrument selecting FUEL INJECTION and carry out the operation: Throttle position autodetection.
1. Voltage 5V
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.
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
Instrument panel
Error DSB 07
Error cause
• An oil sensor fault is signalled when, with engine off, it is detected that the sensor circuit is
open. The test is performed only once when the key is set to ON. There is an error when
the general warning light turns on.
Troubleshooting
• Check the sensor connector and the instrument panel connector (PIN 17): if they are not
OK, restore. If OK, check continuity of the purple cable between the sensor connector and
the instrument panel connector PIN 17: if not OK, restore the cable harness; if OK, replace
the sensor.
Error DSB 08
Error cause
• An oil sensor fault is signalled when, with engine running, it is detected that the sensor circuit
is closed. There is an error when the general warning light turns on.
Troubleshooting
Location:
Electrical specifications:
Pin-out:
1. Ground connection
2. Voltage 12V
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: FUEL INJECTION SYSTEM
STATUSES
Side stand
Example value:up/down
Troubleshooting
• Indication on Axone always down: check the connector: if not OK, restore; if it is OK, dis-
connect the two terminals from the sensor and check continuity to ground of PIN 1: if there
is no continuity, restore the cable harness; if there is, replace the sensor
• Indication on Axone always up: disconnect the terminals from the sensor and check if there
is continuity between the two PINS, with stand down: if there is continuity, replace the sensor;
if the circuit is open, it means that on the brown/green cable from sensor PIN 2 to PIN 38 of
connector B (BLUE) there is a short circuit to ground: restore the cable harness
Electrical characteristics:
Pin-out:
1. Ground connection
2. Voltage 5V
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
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: FUEL INJECTION SYSTEM
PARAMETERS
Fall sensor
Example value: Normal / Tip over
Troubleshooting
• Indication on Axone always Normal, even when the sensor is inverted: disconnect the con-
nector and, with sensor inverted, check if there is continuity between the two PINS of the
sensor: if there is no continuity, replace the sensor; if there is, check the connector. If not
OK, restore the cable harness; if OK, check continuity to ground of PIN 2: if there is no
continuity, restore the cable harness; if there is, with key set to KEY ON, check if there is
5V voltage at PIN 1. If there is not, check the Marelli control unit connector (PIN 35 of con-
nector B "BLUE")
• Indication on Axone always Tip over: disconnect the connector and check if there is con-
tinuity between the two PINS when the sensor is in vertical position: if there is continuity,
replace the sensor; if there is not, it means that, with key set to KEY ON, there is no 5V
voltage at PIN 1: restore the cable harness whose pink/yellow cable will be shorted to ground
Electrical characteristics:
Pin-out:
1. Voltage 5V
2. Ground connection
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Instrument panel
ERROR DSB 06
Error cause
• An oil sensor failure is signalled when it is detected that the sensor circuit is open or shorted
to positive.
Troubleshooting
• Check the sensor connector and the instrument panel connector (PINS 10 and 30): If not
OK, restore; if OK, check the continuity of the pink cable between the sensor connector and
the instrument panel connector PIN 10: if not OK, restore the cable harness; if OK, check
the correct sensor resistance: if it is not OK, replace the sensor; if it is OK, check the con-
tinuity of the brown/black cable between the sensor connector and PIN 30 of the instrument
panel connector: If not OK, restore the cable harness; if OK, with key set to ON, check if
there is voltage at the sensor connector PIN 1: if there is no voltage, replace the instrument
panel; if there is approximately 12V, restore the cable harness (there is a short circuit in the
battery). If there is 5V voltage, connect a 10 kOhm resistance to PIN 1 of the sensor con-
nector and to the vehicle ground connection: if, with key set to KEY ON, the voltage
measured upstream the resistance decreases, replace the instrument panel. If voltage con-
tinues to be approximately 5V, restore the pink cable (there is a short circuit at + 5V).
Notes
If a short circuit to ground is detected at PIN 10 of the instrument panel connector, the display will show
a temperature full scale indication.
Check the earth insulation of the sensor connector pink cable: if there is a connection, restore the cable
harness; if it is earth insulated, check that sensor resistance is correct: if it is not OK, replace the sensor;
if it is OK, replace the instrument panel.
Electrical specifications:
STATUSES
Fan relay
Example value:on / off.
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: FUEL INJECTION SYSTEM
ELECTRICAL ERRORS
Fan relay P0481 - shorted to positive / open circuit, shorted to negative.
Error cause
• If shorted to positive: excessive voltage has been detected at PIN 14 of connector B (BLUE).
If the circuit is open, shorted to negative: voltage equal to zero has been detected
• If the circuit is open, shorted to negative: voltage equal to zero has been detected.
Troubleshooting
• If shorted to positive: check whether the relay electrical specifications are correct by dis-
connecting it from the cable harness. If they are not correct, replace the relay; if they are
correct, restore the cable harness (blue/brown cable).
• If the circuit is open/shorted to negative: check whether the relay electrical specifications
are correct by disconnecting it from the cable harness. If they are not correct, replace the
relay; if they are correct, restore the cable harness (blue/brown cable).
Electric lock
ELECTRIC LOCK
Function
To open the helmet compartment.
Level in wiring diagram:Services.
Location:
Electrical characteristics:
Pin-out:
1. Ground.
2. Supply.
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
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
Electrical characteristics:
Pin-out:
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 DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE: FUEL INJECTION SYSTEM
STATUSES
Run / stop switch
Example value:Run/Stop
Troubleshooting
• Indication on Axone always STOP: disconnect the connector and, with the switch set to
RUN, check if there is continuity towards the switch of the two cables- yellow/grey and green/
orange: if there is not continuity, replace the sensor; if there is, check the connector. If it is
not OK, restore the cable harness; if it is OK, with key set to KEY ON, check if there is voltage
on the yellow/grey cable: if there is no voltage, restore the cable harness; if there is, check
the yellow/grey cable earth insulation: if there is continuity to ground, restore the cable har-
ness; if it is OK, take the key to KEY OFF and check the control unit connector and the
continuity of the yellow/grey cable between the connector in question and PIN 27 of the
control unit connector B "BLUE": if not OK, restore the cable harness; if OK, replace the
Marelli control unit.
• Indication on Axone always RUN: disconnect the connector and, with the switch set to
STOP, check if there is continuity between the two cables of the switch: if there is continuity,
replace the switch; if there is not, it means that, with key set to KEY ON, the green/orange
cable is shorted to positive: restore the cable harness.
Function
It controls the TRANSMISSION system.
is consider normal that the error is displayed before the Potentiometer reset function, Phase
2, or the Belt replacement, Phase 2: it will no longer be displayed even after this second
phase has been carried out correctly.
• If there is an EEPROM access error: replace the transmission ECU (see New control unit
activation procedure) and the belt.
Troubleshooting
• It is necessary to replace the worn belt and in the future, before starting the engine, select
the Belt replacement or Belt replacement, Phase 1, and Belt replacement, Phase 2, function
(next, see Adjustable parameters).
ADJUSTABLE PARAMETERS
CAUTION
DURING THIS PROCEDURE, THE REAR WHEEL SHOULD NOT TOUCH THE GROUND.
Potentiometer reset: Follow the procedure step by step as indicated in the various screen pages (OBD
2006 module).
Belt replacement: Follow the procedure step by step as indicated in the various screen pages (OBD
2006 module).
Potentiometer reset, Phase 1: Follow the procedure step by step as indicated in the various screen
pages (yellow or black label OBD module without 2006 legend).
Potentiometer reset, Phase 2: Follow the procedure step by step as indicated in the various screen
pages (yellow or black label OBD module without 2006 legend).
Belt replacement, Phase 1: Follow the procedure step by step as indicated in the various screen pages
(yellow or black label OBD module without 2006 legend).
Belt replacement, Phase 2: Follow the procedure step by step as indicated in the various screen pages
(yellow or black label OBD module without 2006 legend).
Entering the gearshift stroke category: Allows you to enter the gearshift stroke category in case of
a new control unit (display of the category in the parameters screen page, see also Driving pulley
position sensor).
Gearshift stroke default value setting: Allows you to enter the default value for the gearshift stroke
category in the event of replacement of the variator components that affect the gearshift stroke. The
components are:
spacer
slider support
bearing support bushing
bearing support
THIS PROCEDURE IS ALSO VALID IN THE EVENT OF REPLACING THE TRANSMISSION ECU.
• Perform the gearshift stroke category operations from the "settings" menu of the diagnosis
instrument.
CAUTION
AFTER ENTERING THE GEARSHIFT STROKE CATEGORY FROM THE "SETTINGS" MENU OF
THE DIAGNOSIS INSTRUMENT, YOU MUST PERFORM A KEY OFF/ON TO STORE THE DATA
ON THE CONTROL UNIT.
• Check that the gearshift stroke category has been stored correctly from the "parameters"
menu of the diagnosis instrument.
• Perform the belt replacement operation from the "parameters" menu of the diagnosis in-
strument.
• To determine the gearshift class category, see the procedure in chapter "Motor - Automatic
transmission - Driving pulley fitting"
See also
Refitting the driving pulley
SENSOR FITTING
Reset procedure
It is necessary to use Axone in case the variator unit is removed and the potentiometer is replaced or
removed: Potentiometer reset
CAUTION
FOR VEHICLES INCLUDED IN THE FOLLOWING RANGE
ZD4RC000_7S000002 - ZD4RC000_7S000737
IN ORDER TO FIT THE DRIVING PULLEY POSITION SENSOR CORRECTLY, SEE THE "Engine"
CHAPTER, "Transmission Cover Fitting" SECTION.
See also
Refitting the
transmission cover
Function
It tells the position of the driving half-pulley to the
transmission ECU.
Operation / Operating principle
It is a double track potentiometer, with inversely
proportional voltage variation.
Level in wiring diagram:transmission manage-
ment
Location:
Electrical characteristics:
Pin-out:
Example value:4.97 V
Voltage supplied by the transmission ECU.
Driving pulley target position
Example value:2.09 mm
Target gap, compared to the lower mechanical stop position, supplied by the control unit based on
conveyed commands.
Driving pulley lower stop position
Example value:0 mm
It is the reference position for all the other positions indicated by the driving pulley position sensor.
Driving pulley saved position in first gear
Example value:2.06 mm
It should be a value between 0.5 and 2.5 mm.
Movement of the first gear in relation to the saved position (wear)
Example value:0.03 mm
Even if the belt is worn, the first gear position is modified in relation to the initial position in order to keep
the pre-set ratio
Gearshift stroke
It is the maximum complete stroke of the driving half-pulley useful in case of compensation for belt wear
(used in seventh gear).
Gearshift stroke category
It is the category the gearshift stroke belongs to: from 1 to 8 or 64 (corresponding to the default value,
a shorter stroke corresponds to a stroke lower than category 1)
When the ECU is replaced, the gearshift stroke category can be entered in the ECU.
AXONE: AUTOMATIC TRANSMISSION system
STATUSES
Driving pulley position potentiometer:track 1
Example value:Invalid data / Valid data
If the "Invalid Data" message is displayed, it means that the parameter value in the Engineering pa-
rameters screen page is not correct.
Driving pulley position potentiometer:track 2
Example value:Invalid data / Valid data
If the "Invalid Data" message is displayed, it means that the parameter value in the Engineering pa-
rameters screen page is not correct.
NOTE When troubleshooting, use the interface, code 020481Y, with the adaptor, code 020481Y004.
The correspondence between the control unit PIN and the interface PIN is the following: control unit
PIN A1….A8 and interface PIN interface 11….18, control unit PIN B1….B8 and interface PIN interface
21….28, control unit PIN C1….C8 and interface PIN interface 31….38
ERRORS
Track 1 potentiometer - Code 9001 - above maximum threshold/ below minimum threshold/ signal
not valid.
Error cause
• If above the maximum threshold: excessive voltage has been detected at PIN A2. If below
the minimum threshold: voltage equal to zero has been detected at PIN A2. If signal is not
valid: excessive deviation of the potentiometer track value in relation to the other track.
Troubleshooting
• If above the maximum threshold: with key set to KEY ON, disconnect the sensor and ob-
serve, with the diagnosis instrument, if the voltage value of the "Driving pulley position
potentiometer: track 1" parameter drops to zero: if it drops to zero, replace the sensor; if it
does not, restore the purple/red cable.
• If below the minimum threshold: check the transmission ECU connector and the sensor
connector: if they are not OK, restore; if they are OK, check continuity on the purple/red
cable: if it is not OK, restore the cable; if it is OK, replace the sensor.
• If signal is not valid: check the transmission ECU connector and the sensor connector: if
they are not OK, restore; if they are OK, replace the sensor.
Track 2 potentiometer - Code 9002 - above maximum threshold/ below minimum threshold/ signal
not valid.
Error cause
• If above the maximum threshold: excessive voltage has been detected at PIN C2. If below
the minimum threshold: voltage equal to zero has been detected at PIN C2. If signal is not
valid: excessive deviation of the potentiometer track value in relation to the other track.
Troubleshooting
• If above the maximum threshold: with key set to KEY ON, disconnect the sensor and ob-
serve, with the diagnosis instrument, if the voltage value of the "Driving pulley position
potentiometer: track 2" parameters drops to zero: if it drops to zero, replace the sensor; if it
does not, restore the green/pink cable.
• If below the minimum threshold: check the transmission ECU connector and the sensor
connector: if it they are not OK, restore; if they are OK, check continuity on green/pink cable:
if it is not OK, restore the cable; if it is OK, replace the sensor.
• If signal is not valid: check the transmission ECU connector and the sensor connector: if
they are not OK, restore; if they are OK, replace the sensor.
Driving pulley potentiometer supply voltage: track 1 - Code 900B - signal not valid.
Error cause
Troubleshooting
• With key set to KEY ON, read the value of the "Driving pulley potentiometer supply voltage:
track 1" parameter: if it is equal to the battery voltage, there is a short circuit on the battery
and it is necessary to restore the cable harness; if it is equal to zero, disconnect the sensor:
if voltage goes up to approximately 5 V, replace the sensor; if the voltage remains at zero,
check the transmission ECU connector: if it is not OK, restore; if it is OK, check if there is
continuity between PIN C6 and the ground connection: if there is continuity restore the cable
harness; if there is not continuity, replace the transmission ECU.
Driving pulley potentiometer supply voltage: track 2 - Code 900C - signal not valid.
Error cause
Troubleshooting
• With key set to KEY ON, read the value of the "Driving pulley potentiometer supply voltage:
track 2" parameter: if it is equal to the battery voltage, there is a short circuit on the battery
and it is necessary to restore the cable harness; if it is equal to zero, disconnect the sensor:
if voltage goes up to approximately 5 V, replace the sensor; if the voltage remains at zero,
check the transmission ECU connector: if it is not OK, restore; if it is OK, check if there is
continuity between PIN A4 and the ground connection: if there is continuity, restore the cable
harness; if there is not continuity, replace the transmission ECU.
ADJUSTABLE PARAMETERS
CAUTION
DURING THIS PROCEDURE, THE REAR WHEEL SHOULD NOT TOUCH THE GROUND.
Potentiometer reset
Follow the procedure step by step as indicated in the various screen pages (black label module OBD,
2006).
Potentiometer reset, Phase 1
Follow the procedure step by step as indicated in the various screen pages (yellow or black label OBD
module without 2006 legend).
Potentiometer reset, Phase 2
Follow the procedure step by step as indicated in the different screen pages (yellow or black label OBD
module without 2006 legend).
Entering the gearshift stroke category
If the ECU is replaced, the gearshift stroke category can be entered in the new ECU (reading the
category in the old ECU). The categories range from 1 to 8.
Gearshift stroke default value setting:
Setting to be used if a component of the variator that affects the gearshift stroke has been replaced.
See also
Refitting the driving pulley
STATUSES
Driven pulley rotation
Example values: Invalid data / Valid data
If the "Invalid Data" message is displayed, it means that the parameter value in the Engineering pa-
rameters screen page is not correct.
ERRORS
Driven pulley rotation sensor Code 9004 - no signal/ signal not valid/ below minimum threshold.
Error cause
• If there is no signal: detects an interruption of the electrical circuit to PINs B3 and B6. If signal
is not valid: variable signal with excess speed or non variable if below minimum threshold:
voltage equal to zero has been detected at PIN B3.
Troubleshooting
• If there is no signal: check the transmission ECU connector and the sensor connector: if it
is not OK, restore; if it is OK, check the continuity of the PIN 1 cable between the transmission
ECU connector and the sensor connector: if it is not OK, restore; if it is OK, check the con-
tinuity of the sensor circuit (PINS 1 and 2 of sensor connector): if it is not OK, replace the
sensor; if it is OK, check the continuity between PIN 2 of the sensor connector and PIN B6
of the transmission ECU connector: if it is not OK, restore the cable harness; if it is OK, check
with key set to key ON, that PIN B6 of the transmission ECU does not have continuity with
the ground connection, and then replace the transmission ECU (in this case the Vehicle
speed sensor error (Code 9003), no signal, should also be present)
• If signal is not valid: check the sensor resistance, from the transmission ECU connector,
between PINS B6 and B6: if it is not OK, replace the sensor; if it is OK, with key set to key
ON, check the voltage at PIN B3: if voltage is other than zero, see Phase 1; if voltage is
equal to zero, check in the same way with running engine: if the non variable voltage is
above zero, replace the sensor; if alternating voltage is excessively below approximately
0.7 V at idle speed, check the correct position of the sensor. Phase 1: check if upon dis-
connecting the sensor, the PIN B3 voltage reaches zero: if it reaches zero, replace the
sensor; if it does not reach zero, restore the cable harness (PIN 1 cable shorted to battery
or a cable at 5V).
• If below the minimum threshold: check if there is continuity between PIN B3 and the ground
connection: if there is continuity, check if upon disconnecting the sensor, the continuity with
the ground connection of PIN B3 is interrupted: if it is interrupted, replace the sensor; if the
continuity with the ground connection remains, restore the cable harness (PIN 1 cable shor-
ted to ground connection).
NOTE
THE SPEED SENSOR FAILURE IS ALSO INDICATED ON THE INSTRUMENT PANEL WITH THE
MESSAGE "GEAR ERROR".
THE "VEHICLE SPEED SENSOR" ERROR WILL APPEAR ON THE DIAGNOSIS INSTRUMENT
Electrical characteristics
Released switch 860 +/- 5% Ohm
Pressed switch 180 +/- 5% Ohm
Pin-out:
1. power supply + 5 V
2. ground connection
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU-
BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
AXONE / AUTOMATIC TRANSMISSION system
PARAMETERS
Gear mode control
Example value: 3.8 V
Voltage detected at PIN B7: if the button is pressed, voltage drops from approximately 3-4 V to ap-
proximately 1 V.
STATUSES
Gear mode control
Example value: Released/Pressed/Invalid data
If the "Invalid Data" message is displayed, it means that a malfunction has been detected
NOTE: When troubleshooting, use the interface, code 020481Y, with the adaptor, code 020481Y004.
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: excessive voltage has been detected at PIN B7. If below
the minimum threshold: voltage equal to zero has been detected at PIN B7.
Troubleshooting
• If above the maximum threshold: check circuit continuity between PIN B7 and C5: if it is not
OK, see Phase 1; if it is OK, check the transmission ECU connector and the gear mode
control connector and restore. Phase 1: check the continuity of the yellow/pink cable; if it is
not OK, restore; if it is OK, check for the interruption in the circuit of the gear mode control
and replace the component.
• If below the minimum threshold: check the gear mode control resistance on its connector:
if the resistance is not within the expected limit values, replace the control; if it is within the
expected values, check the continuity of the yellow/pink cable and the ground connection
and then restore the cable harness.
Gearshift pedal
Electrical characteristics
Gear upshift:
Gear downshift:
Pin-out:
Gear upshift:
Gear downshift:
not OK, restore; if they are OK, check continuity on the blue/yellow cable: if it is not OK,
restore; if it is OK, check, with control activated, that there is not continuity of the gearshift
control from the gearshift control connector (between black cable and yellow cable) and then
replace the control.
• If the control is blocked: check the control mechanically: if it is not OK, restore; if it is OK, it
means that the "Pedal gear upshift control" statues on the diagnosis instrument indicates
"Pressed": the gear upshift control must be replaced.
Pedal gear downshift control - Code 900E - signal not valid for logic reasons/ blocked control.
Error cause
• If the electric signal is not valid due to a logic reason: the control unit detects no voltage or
the same voltage as the other at PIN C4 or PIN A6. If the control is blocked: the control has
been in the pressed position for too long.
Troubleshooting
• If the electric signal is not valid due to a logic reason: CASE 1) if both voltages are below 1
V, with control not activated, it means that a voltage below 1 V, instead of battery, is detected
at PIN C4; disconnect the gearshift control connector and read voltage at PIN C4: if voltage
is equal to 1 V or below, it means that on the blue/purple cable there is a short circuit to
ground; if voltage is above 1 V, replace the gear upshift control sensor. CASE 2) if both
voltages are below 1 V with control activated, it means that at that moment a voltage below
1 V, instead of battery, is detected at PIN A6; disconnect the gearshift control connector and
read voltage at PIN A6: if voltage is below 1 V, it means that on the black/purple cable there
is a short circuit to ground; if the voltage is above 1 V (approximately battery voltage), replace
the gear upshift control sensor. CASE 3) if both voltages are above 1 V (approximately
battery voltage), with control not activated, it means that there is an interruption in the circuit
from PIN A6 to PIN C5 or that PIN C5 does not have a ground connection: check the trans-
mission ECU connector and the gearshift control connector: if they are not OK, restore; if
they are OK, check continuity on the black/purple cable: if it is not OK, restore; if it is OK,
check continuity on the blue/black cable from the gearshift control connector to PIN C5: if it
is not OK, restore; if it is OK, check continuity of the gearshift control from the gearshift
control connector (between red cable and blue cable): if it is not OK, replace the control; if
it is OK, check, with key set to KEY ON, that there is no ground connection in the blue/black
cable and then replace the transmission ECU. CASE 4) if both voltages are above 1 V
(approximately battery voltage), with control activated, it means that there is an interruption
on the circuit from PIN C4 to PIN C5: check the transmission ECU connector and the gear-
shift control connector: if they are not OK, restore; if they are OK, check continuity on the
blue/purple cable: if it is not OK, restore; if it is OK, check, with control activated, that there
is not continuity on the gearshift control from the gearshift control connector (between red
cable and brown cable) and then replace the control.
• If the control is blocked: check the control mechanically: if it is not OK, restore; if it is OK, it
means that on the diagnosis instrument the status of "Pedal gear downshift control" indicates
"Pressed": the gear downshift control must be replaced.
Electrical specifications
Gear upshift:
Gear downshift:
Pin-out:
Gear upshift:
Gear downshift:
gearshift control connector and read voltage at PIN 13 of the instrument panel: if voltage is
below 1 V, it means that on the black/purple cable there is a short circuit to ground; if the
voltage is above 1 V (approximately battery voltage), replace the gear upshift control sensor.
CASE 3) if both voltages are equal to battery voltage, with control not activated, it means
that there is an interruption in the circuit from PIN 13 to PIN 30 of the instrument panel or
that PIN 30 does not have a ground connection: check the instrument panel connector and
the gearshift control connector: if they are not OK, restore; if they are OK, check continuity
on the black/purple cable: if it is not OK, restore; if it is OK, check continuity on the brown/
black cable from gearshift control connector to PIN 30 of the instrument panel: if it is not OK,
restore; if it is OK, check continuity of the gearshift control from the gearshift control con-
nector (between black cable and green cable): if it is not OK, replace the control; if it is OK,
check, with key set to key ON, that there is no ground connection in the brown/black cable
and then replace the instrument panel. CASE 4) if both voltages are above 1 V (approxi-
mately battery voltage), with control activated, it means that there is an interruption on the
circuit from PIN 5 to PIN 30 of the instrument panel: check the instrument panel connector
and the gearshift control connector: if they are not OK, restore; if they are OK, check con-
tinuity on the blue/purple cable: if it is not OK, restore; if it is OK, check, with control activated,
that there is not continuity of the gearshift control from the gearshift control connector (be-
tween black cable and yellow cable) and then replace the control.
• If, besides the error, the status of "Handlebar gear upshift control" indicates "Pressed", check
the control mechanically: If it is not OK, restore; if it is OK, the gear upshift control must be
replaced.
ERRORS
Handlebar gear downshift control - Code 9010 - signal not valid
Error cause
• There is a malfunction in the handlebar gear downshift control.
Troubleshooting
• If, besides the error, the status of "Handlebar gear upshift control" indicates "Invalid data":
the instrument panel waits to detect a voltage above approximately 1 V at one of either PINS
and at the same time a voltage below approximately 1 V on the other PIN; if this does not
happen, the instrument panel sends the information to the control unit which signals this
error CASE 1) if the voltage is below 1V on both, with control not activated, it means that a
voltage below 1V, instead of battery, is detected at PIN 18 of the instrument panel; discon-
nect the gearshift control connector and read voltage at PIN 18 of the instrument panel: if
voltage is below 1 V, it means that on the blue/yellow cable there is a short circuit to ground;
if voltage is above 1 V (approximately battery voltage), replace the gear upshift control sen-
sor. CASE 2) if both voltages are below 1 V with control activated, it means that at that
moment a voltage below 1 V, instead of battery, is detected at PIN 19 of the instrument
panel; disconnect the gearshift control connector and read voltage at PIN 19 of the instru-
ment panel: if voltage is below 1 V, it means that on the black/yellow cable there is a short
circuit to ground; if the voltage is above 1 V (approximately battery voltage), replace the gear
upshift control sensor CASE 3) if both voltages are equal to battery voltage, with control not
activated, it means that there is an interruption in the circuit from instrument panel PIN 19
to PIN 30 or that PIN 30 does not have a ground connection: check the instrument panel
connector and the gearshift control connector: if they are not OK, restore; if they are OK,
check continuity on the black/yellow cable: if it is not OK, restore; if it is OK, check continuity
on the brown/black cable from gearshift control connector to PIN 30 of the instrument panel:
if it is not OK, restore; if it is OK, check continuity of the gearshift control from the gearshift
control connector (between brown cable and blue cable): if it is not OK, replace the control;
if it is OK, check, with key set to key ON, that there is no ground connection in the brown/
black cable and then replace the instrument panel. CASE 4) if both voltages are above 1 V
(approximately battery voltage), with control activated, it means that there is an interruption
on the circuit from PIN 18 to PIN 30 of the instrument panel: check the instrument panel
connector and the gearshift control connector: if they are not OK, restore; if they are OK,
check continuity on the blue/yellow cable: if it is not OK, restore; if it is OK, check, with control
activated, that there is not continuity on the gearshift control from the gearshift control con-
nector (between brown cable and red cable) and then replace the control.
• If, besides the error, the status of "Handlebar gear downshift control" indicates "Pressed",
check the control mechanically: if it is not OK, restore; if it is OK, the gear downshift control
must be replaced.
Electrical specifications:
Pin-out:
1. Red
2. Black
ERRORS
Driving pulley electrical motor - Code 900A - excessive actuation time/ excessive current input/ signal
not valid.
Error cause
• If activation time is excessive: the position is not reached within a standard time although
the driving pulley motion control is activated. If input current is excessive: the transmission
ECU detects excessive ampere input for the driving pulley electric motor. If the signal is not
valid: a short-circuit to ground has been detected at battery PIN A8 or PIN B8.
Troubleshooting
• If activation time is excessive: check circuit continuity between PIN A8 and B8: if it is not
OK, continue with Phase 1; if it is OK, check the gears which receive the movement from
the electrical motor and set the position of the driving half-pulley. Phase 1: check continuity
of the red cable and the black cable between the electrical motor connector and the control
unit connector: if they are not OK, restore the cable harness; if they are OK, check that there
is not continuity on the circuit of the electrical motor and replace it.
• If input current is excessive: check the driving half-pulley movement system mechanically
(excessive friction material).
• If the signal is not valid: set the key to key ON and check the voltage value at PIN A8 and
B8 which should be approximately 3 V at both PINS; if there is voltage similar to battery
voltage or there is continuity with the ground in one of the two PINS, restore the cable har-
ness; otherwise, replace the transmission ECU.
• Check through the diagnosis instrument for any errors in the transmission ECU from the
"errors display" menu. Erase them if necessary.
• Take the measurement of the gearshift stroke to identify the category to which it belongs.
NOTE
AFTER ENTERING THE GEARSHIFT STROKE CATEGORY FROM THE "SETTINGS" MENU OF
THE DIAGNOSIS INSTRUMENT, YOU MUST PERFORM A KEY OFF/ON TO STORE THE DATA
ON THE CONTROL UNIT.
• Check that the gearshift stroke category has been stored correctly from the "parameters"
menu of the diagnosis instrument.
• Perform the belt replacement operation from the "parameters" menu of the diagnosis in-
strument.
• To determine the gearshift class category, see the procedure in chapter "Motor - Automatic
transmission - Driving pulley fitting"
See also
Refitting the driving pulley
Connectors
ECU
1. -
2. -
3. Throttle position sensor input
4. -
5. -
6. -
7. -
8. -
9. Idle motor D
10.Front coil control output
11.-
12.-
13.-
14.Air temperature sensor input
15.-
16.-
17.Idle motor A
18.Idle motor B
19.Idle motor C
20.Reference voltage output + 5 V temperature sensors
21.-
22.-
23.-
24.-
25.Revolution sensor input ( + )
26.-
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.-
19.-
20.CAN H Line (high speed)
21.-
22.Lambda sensor input (+)
23."Stop switches" input
24.-
25.-
26.-
27.-
28."Start engine" switch input
29.CAN L Line (high speed)
30.-
31.-
32.Lambda sensor input (-)
33.-
34.-
35.Fall sensor input
36.-
37.-
38.Side stand input
Dashboard
INSTRUMENT PANEL
GREY CONNECTOR PIN OUT
PIN 1 - + Key
PIN 2 - Right indicator control
PIN 3 - *
PIN 4 - High-beam input
PIN 5 - gear UP normally open input
PIN 6 - Select 3 (Set)
PIN 7 - Select 2 (Down)
PIN 8 - Select 1 (Up)
PIN 9 - Fuel reserve sensor
PIN 10 - Ambient temperature sensor
PIN 11 - + Battery
PIN 12 - Left indicator control
PIN 13 - gear UP normally closed input
PIN 14 - heated handgrips warning light
PIN 15 - *
PIN 16 - Indicators reset
PIN 17 - Oil sensor input
PIN 18 - gear DOWN normally open input
PIN 19 - gear DOWN normally closed input
PIN 20 - K Line
BLACK CONNECTOR
PIN 21 - + Battery
PIN 22 - Front left turn indicator activation
PIN 23 - Front right turn indicator activation
PIN 24 - Aerial 2
PIN 25 - *
PIN 26 - CAN H
PIN 27 - CAN L
PIN 28 - ABS warning light input
PIN 29 - *
PIN 30 - Sensor ground
PIN 31 - + Battery
PIN 32 - Rear left turn indicator activation
PIN 33 - Rear right turn indicator activation
PIN 34 - Aerial 1
PIN 35 - Light relay activation
PIN 36 - *
PIN 37 - *
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
Troubleshooting
• Replace transmission ECU.
Troubleshooting
• Check the connector of the instrument panel: if it is not OK, restore; if it is OK, check the
continuity of the two lines from the instrument panel connector to the transmission ECU
connector: if not OK, restore the cable harness; if OK, replace the instrument panel.
Troubleshooting
• Check the transmission ECU connector and the Marelli control unit connector: if they are
not OK, restore; if they are OK, check the continuity of the two lines from the transmission
ECU connector and from the Marelli control unit connector: if it is not OK, restore the cable
harness; if it is OK, replace the Marelli control unit.
• The control unit cannot send CAN signals; it receives signals from the instrument panel and
the transmission ECU: the control unit may need replacing.
Troubleshooting
• No communication on CAN line (PIN B4 and/or PIN B5): problem on the whole network (for
example, battery cut-off or short circuited or shorted to ground).
Troubleshooting
• Check the Marelli control unit connector: if not OK, restore; if OK, check the earth insulation
of the two CAN lines from PIN 20 and PIN 51 of the VEHICLE connector: If not OK, restore
the cable harness; if OK, check continuity of the two CAN lines from the Marelli control unit
VEHICLE connector to the filter casing large connector and to the instrument panel con-
nector: if not OK, restore the cable harness; if OK, check that the two lines are not short
circuited to positive testing each of the 3 connectors (Marelli control unit connector, filter
casing large connector and instrument panel connector) with 1 connector disconnected at
a time and by setting the key to ON: If not OK, restore; if OK, replace the Marelli control unit.
• No signal arrives to the instrument panel from either CAN line cables.
Troubleshooting
• Check the connector of the instrument panel: if it is not OK, restore; if it is OK, check the
continuity of the two lines from the instrument panel connector to the injection ECU con-
nector: if not OK, restore the cable harness; if OK, replace the instrument panel.
• No signal arrives from the transmission ECU from either CAN line cables.
Troubleshooting
• Check the transmission ECU connector and the Marelli control unit connector: if they are
not OK, restore; if they are OK, check the continuity of the two lines from the transmission
ECU connector and from the Marelli control unit connector: if it is not OK, restore the cable
harness; if it is OK, replace the transmission ECU.
Vehicle preparation
ENG VE - 139
Engine from vehicle NA 850 Mana
ENG VE - 140
NA 850 Mana Engine from vehicle
ENG VE - 141
Engine from vehicle NA 850 Mana
ENG VE - 142
NA 850 Mana Engine from vehicle
ENG VE - 143
Engine from vehicle NA 850 Mana
ENG VE - 144
NA 850 Mana Engine from vehicle
ENG VE - 145
Engine from vehicle NA 850 Mana
ENG VE - 146
NA 850 Mana Engine from vehicle
ENG VE - 147
Engine from vehicle NA 850 Mana
ENG VE - 148
NA 850 Mana Engine from vehicle
ENG VE - 149
Engine from vehicle NA 850 Mana
ENG VE - 150
NA 850 Mana Engine from vehicle
ENG VE - 151
Engine from vehicle NA 850 Mana
ENG VE - 152
NA 850 Mana Engine from vehicle
ENG VE - 153
INDEX OF TOPICS
ENGINE ENG
NA 850 Mana Engine
This section describes the operations to be carried out on the engine and the tools required.
Starter motor
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 shaft.
The torque limiter is calibrated at 100 Nm (73.76 lbf ft); this component protects the structure of the
engine and the start-up kinematic mechanism in the event of incorrect start-up procedure, resulting in
inverse rotation.
The freewheel is used for a sufficiently silent start-up.
The start-up control (energised remote control) is slaved to enabling signals by the side stand and the
emergency OFF/RUN switch, which does not allow starting given dangerous conditions.
The start-up control circuit is not controlled by the immobiliser system; therefore, before insisting on the
starter system in an abnormal way, check the immobiliser enabling switch.
ENG - 155
Engine NA 850 Mana
To check the enabling switch circuit, see the "Electrical system" chapter; to check the crankshaft control
transmission, follow what is described in the «Flywheel and start-up system» chapter.
Characteristic
Gear bearing diameter
12 (0; - 0.011) mm (0.47000 (0; -0.00043) in)
ENG - 156
NA 850 Mana Engine
Characteristic
Diameter of bearing on the flywheel cover
12 (+0.034; - 0.016) mm (0.47000 (+0.0013;
-0.0006) in)
Characteristic
Diameter of bearing on the engine crankcase
12 (+0.034; - 0.016) mm (0.47000 (+0.0013;
-0.0006) in)
NOTE
THE TORQUE LIMITER IS EQUIPPED WITH 4 GEARS THAT FUNCTION AS CLUTCH DRIVING
PLATES.
Driven plates consist of 4 Belleville springs with
grooved profiles; this assembly allows transmitting
torques below 100 Nm (73.75 lbf ft).
In case of incorrect start-up procedures, the torque
limiter prevents any kicks, resulting in inversion of
rotation direction of the crankshaft which would
impair the engine structure.
The limiter assembly cannot be overhauled. In case of clearly visible irregularities on the toothed discs,
replace the assembly.
ENG - 157
Engine NA 850 Mana
Characteristic
Hub outside diameter
45.665 mm (+0.008; +0.005) mm (1.79 in
(+0.0003; + 0.0002) in)
Characteristic
Bushing inside diameter
27 mm (+0.020; +0.041) mm (1.0629 in (+0.0008;
0.0016) in)
NOTE
IF THE FAULTS FOUND AFFECT THE HUB, IT IS EXPEDIENT TO REPLACE THE STARTING RING
GEAR AND THE FREEWHEEL.
ENG - 158
NA 850 Mana Engine
IF ONLY THE BUSHING IS WORN, REPLACE ONLY THE COMPLETE STARTING RING GEAR.
ALSO CHECK THE DIAMETER AND THE SURFACE OF THE BEARING ON THE CRANKSHAFT.
IN CASE OF IRREGULARITIES, REPLACE THE CRANKSHAFT.
ENG - 159
Engine NA 850 Mana
Generator side
ENG - 160
NA 850 Mana Engine
Specific tooling
020713Y Flywheel extractor
Specific tooling
020713Y Flywheel extractor
ENG - 161
Engine NA 850 Mana
ENG - 162
NA 850 Mana Engine
Electric characteristic
Resistance:
0.2 ÷ 1 Ω
ENG - 163
Engine NA 850 Mana
Recommended products
Loctite 243 Medium strength threadlock
-
ENG - 164
NA 850 Mana Engine
Stator 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
Diagram
ENG - 165
Engine NA 850 Mana
ENG - 166
NA 850 Mana Engine
ENG - 167
Engine NA 850 Mana
Specific tooling
AP8106702 Flywheel lock calliper spanner
- Repeat the operations for the front cylinder timing system gear.
- The head removal operation is carried out in two separate stages, first on the rear cylinder, then on
the front one.
- If the heads are removed together with the valves and the camshaft, follow the recommendations.
NOTE
THE HEADS MUST BE CORRECTLY REMOVED WITH THE PISTONS AT TDC AND THE VALVES
CLOSED.
- Remove the engine revolution sensor and the
water temperature sensor, fitted only on the rear
cylinder head.
ENG - 168
NA 850 Mana Engine
ENG - 169
Engine NA 850 Mana
Cylinder head
ENG - 170
NA 850 Mana Engine
- Using the appropriate tool fitted with an adapter, remove the cotter pins, plates, springs and valves.
Specific tooling
AP0276474 Valve spring compressor adaptor
AP8140179 Support for valve fitting/removal
CAUTION
ARRANGE THE VALVES SO AS TO RECOGNISE THEIR
ORIGINAL POSITION ON THE HEAD (FLYWHEEL-SIDE
AND TRANSMISSION-SIDE).
Specific tooling
020431Y Valve oil seal extractor
ENG - 171
Engine NA 850 Mana
STANDARD DIAMETER
Specification Desc./Quantity
Bearing A Ø: 42- 0.060 -0.085 mm
Bearing B Ø: 20- 0.020 -0.041 mm
ENG - 172
NA 850 Mana Engine
LIMITS ALLOWED
Specification Desc./Quantity
Inlet: 33.740 mm
Outlet: 33.170 mm
Standard axial clearance: 0 ÷ 0.22 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 also
Assembly clearances
ENG - 173
Engine NA 850 Mana
Characteristic
Standard diameter:
Ø 13 + 0.026 +0.015 mm
Valve check
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.
- Measure the diameter of the valve stem at the three positions indicated in the diagram.
ENG - 174
NA 850 Mana Engine
STANDARD DIAMETER
Specification Desc./Quantity
Inlet: 4.987 ÷ 4.972 mm
Outlet: 4.975 ÷ 4.960 mm
Characteristic
Limit value allowed:
0.1 mm
Characteristic
Limit allowed:
0.03 mm
ENG - 175
Engine NA 850 Mana
See also
Installing the
cylinder head
See also
Installing the
cylinder head
ENG - 176
NA 850 Mana Engine
Characteristic
Standard length:
44.4 mm
Limit allowed after use:
42.4 mm
See also
Installing the
cylinder head
Characteristic
Valve guide:
5+0.012 mm
ENG - 177
Engine NA 850 Mana
EXHAUST
Specification Desc./Quantity
Standard clearance: 0.025 - 0.052 mm
Limit allowed: 0.09 mm
INTAKE
Specification Desc./Quantity
Standard clearance: 0.013 ÷ 0.04 mm
Limit allowed: 0.08 mm
See also
Installing the
cylinder head
Clean all the coupling surfaces thoroughly before servicing the head. Pay attention to the position of
the springs and valves so as not to change the original position upon refitting them
Characteristic
Maximum run-out allowed:
0.1 mm
ENG - 178
NA 850 Mana Engine
HEAD BEARINGS
Specification Desc./Quantity
Bearing "A" 42 +0.025
Bearing "B" 19.5 -0.2
Bearing "C" 13 +0.018
Specific tooling
020306Y Punch for fitting the valve seal rings
ENG - 179
Engine NA 850 Mana
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).
ENG - 180
NA 850 Mana Engine
Timing
ENG - 181
Engine NA 850 Mana
Cam timing
The ignition advance is determined electronically on the basis of parameters known by the control unit.
For this reason it is not possible to state the reference values based on the engine revs.
The ignition advance value can be measured at any time with the Axone.
It is possible to check whether the ignition advance determined by the injection system does in fact
correspond with the value actually activated on the engine, by means of the stroboscopic light.
Specific tooling
AP8140595 Axone + battery charger (230V 50Hz)
AP8202311 Axone + battery charger (110V 60Hz)
020330Y Stroboscopic light for timing checking
ENG - 182
NA 850 Mana Engine
Specific tooling
AP8140595 Axone + battery charger (230V 50Hz)
AP8202311 Axone + battery charger (110V 60Hz)
Timing
ENG - 183
Engine NA 850 Mana
Characteristic
Valve clearance
Inlet: 0.15 mm
Outlet: 0.15 mm
ENG - 184
NA 850 Mana Engine
Cylinder-piston assembly
ENG - 185
Engine NA 850 Mana
See also
Removing the
cylinder head
ENG - 186
NA 850 Mana Engine
CYLINDER CHECK
Specification Desc./Quantity
B 43 mm (1.69 in)
Cylinder Ø C 88 mm (+0.018; -0.01) mm (3.4645 in (+0.0007; -0.00039) in)
Characteristic
Maximum run-out allowed:
0.05 mm
ENG - 187
Engine NA 850 Mana
PISTON CHECK
Specification Desc./Quantity
Piston Ø P (aluminium cylinder) 87.968 mm (+/- 0.014 mm) (3.4632 in (+/- 0.0005)in)
A 10 mm (0.393 in)
Piston Ø P (iron cast cylinder) 87.947 mm (+/- 0.014 mm) (3.4625 in (+/- 0.0005)in)
A 10.5 mm (0.413 in)
- Fit the piston and wrist pin onto the connecting rod, aligning the piston arrow towards the engine
direction of rotation.
NOTE
THE PISTON MUST BE INSTALLED WITH THE ARROW
POINTING IN THE DIRECTION OF ROTATION OF THE EN-
GINE, WHILE THE PISTON RINGS MUST BE INSTALLED
WITH THE «TOP» REFERENCE MARKING OR THE BRAND
FACING UPWARD.
ENG - 188
NA 850 Mana Engine
- Fit the pin snap ring in the specific tool, with the
opening in the position indicated on the tool.
S = left
D = right
- Set the snap ring into its position with the punch.
- Fit the pin snap ring with the pin as shown in the
figure.
Specific tooling
020470Y Pin snap ring fitting tool
NOTE
THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY.
CAUTION
USING A HAMMER MAY DAMAGE THE RINGS HOUSINGS.
ENG - 189
Engine NA 850 Mana
Specific tooling
AP8140302 tool for sealing ring fitting
020716Y Connecting rod locking
- Remove the specific tool.
ENG - 190
NA 850 Mana Engine
- First fit the piston into the cylinder, without any base gasket.
- Fit a dial gauge on the specific tool with the short union, as shown in the figure.
Specific tooling
020714Y Dial gauge mounting
ENG - 191
Engine NA 850 Mana
- By means of the chart, identify the thickness of the cylinder base gasket to be used upon refitting. By
correctly identifying the cylinder base gasket thickness, an adequate compression ratio can be main-
tained
- Remove the specific tool and the cylinder.
NOTE
IF DEVIATIONS (PROTRUSIONS OR RECESSES) CLOSE TO THE CHANGE OF CATEGORY ARE
MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSITE SIDE. TO DO SO, REPEAT THE
TOOL FITTING OPERATION, INVERTING ITS POSITION.
MEASUREMENT «A» IS A PROTRUSION OR RECESS VAL-
UE OF THE PISTON CROWN COMPARED WITH THE CYL-
INDER PLANE.
MEASUREMENT «A» ALLOWS TO DETERMINE THE
THICKNESS OF THE GASKET «B» THAT HAS TO BE FIT-
TED INTO THE CYLINDER BASE IN ORDER TO RESTORE
THE COMPRESSION RATIO. THE MORE THE PLANE
FORMED BY THE PISTON CROWN PROTRUDES BEYOND
THE PLANE FORMED BY THE CYLINDER UPPER END,
THE THICKER THE GASKET TO BE USED AT THE CYLIN-
DER BASE «B» SHOULD BE. ON THE OTHER HAND, THE
MORE THE PISTON CROWN IS RECESSED INTO THE CYL-
INDER TOP PLANE, THE SMALLER THE GASKET THICK-
NESS.
Characteristic
Compression ratio
10.5 ± 0.5 : 1
ENG - 192
NA 850 Mana Engine
NOTE
THE FIGURE SHOWS THE FITTING POSITION OF THE TWO CENTRING DOWELS BETWEEN
HEAD AND CYLINDER. THE DIRECTION OF FITTING FOR THE GASKET IS FORCED BY THESE
DOWELS.
- Fit the head gasket
- The head gasket is made of steel and has a
standard thickness.
- Tighten the 4 fixing stud bolts in a criss-crossed sequence to the prescribed torque as shown in the
figure.
ENG - 193
Engine NA 850 Mana
ENG - 194
NA 850 Mana Engine
- Fit the spark plugs and tighten them to the prescribed torque.
Recommended products
Loctite 243 Medium strength threadlock
-
ENG - 195
Engine NA 850 Mana
- Remove any LOCTITE left on the screws fixing the camshaft retaining bracket using a brush.
- Apply the recommended product to the fixing screws and tighten them to the prescribed torque.
Recommended products
Loctite 243 Medium strength threadlock
-
- Finish closing the flywheel side crankcase with the components following the instructions described
in the specific sections.
- Time following the instructions in the specific section.
ENG - 196
NA 850 Mana Engine
ENG - 197
Engine NA 850 Mana
ENG - 198
NA 850 Mana Engine
Crankcase - crankshaft
- Remove the transmission cover, the driving and the driven pulleys, as described in the «Automatic
transmission» chapter.
- Remove the flywheel cover as described in the «Flywheel cover removal» chapter.
- Remove the magneto flywheel with the start-up control as described in the «Magneto flywheel re-
moval» chapter.
- Remove the thermal parts (cylinders, heads, pistons) as described in the «Thermal group and Timing
system» chapter.
- Before opening the engine crankcase, it is advisable to check the axial clearance of the crankshaft.
Specific tooling
020262Y Crankcase splitting strip
020335Y Dial gauge magnetic support
Characteristic
Standard clearance:
0.10 ÷ 0.50 mm
Increased limit after use:
0.60 mm
- Higher clearances are signs of wear on the supporting surfaces of the crankshaft on the crankcase.
- To carry out an accurate measurement, measure the clearance in both directions between crankcase
and crankshaft.
ENG - 199
Engine NA 850 Mana
Specific tooling
020664Y Flywheel side crankshaft fitting tip
- Lubricate the external surface of the tip with petroleum jelly grease.
ENG - 200
NA 850 Mana Engine
ENG - 201
Engine NA 850 Mana
Specific tooling
020664Y Flywheel side crankshaft fitting tip
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.
ENG - 202
NA 850 Mana Engine
- Hold the tip with one hand and the crankshaft with
the other, pull the crankshaft upwards.
- Once the crankshaft has been removed it is possible to remove the timing chain on the transmission
side.
- Before checking the crankcase halves, thoroughly clean all the surfaces and oil pipes.
- Clean the jets and contacts carefully.
NOTE
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT
IMPROVES PISTON CROWN COOLING. CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO
DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAKAGE CAN CONSIDERABLY
CAUSE A DROP IN LUBRICATION PRESSURE FOR THE MAIN BUSHINGS AND CONNECTING
ROD.
NOTE
AS ALREADY DESCRIBED IN THE LUBRICATION CHAPTER, IT IS ESPECIALLY IMPORTANT
THAT THE BY-PASS VALVE HOUSING SHOWS NO WEAR THAT MAY IMPAIR THE PROPER
SEALING OF THE LUBRICATION PRESSURE ADJUSTMENT PISTON. THE HEAD LUBRICATION
ENG - 203
Engine NA 850 Mana
CHANNEL IS FITTED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRI-
CATION. THIS CHOICE HAS BEEN MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP.
Jet clogging impairs head lubrication and the timing mechanisms.
A jet failure causes a drop in lubrication pressure for the main bushings and connecting rod.
- Check the coupling surfaces for scratches or deformation, paying special attention to the cylinder -
crankcase surfaces and the crankcase halves coupling surfaces.
- Defects in the crankcase coupling gasket or the surfaces can cause a drop in the oil pressure and
affect the lubricating pressure.
- Check that the surfaces limiting the crankshaft axial clearance show no signs of wear. To measure
and check sizes follow the procedure described previously for checking crankshaft axial clearance and
dimensions
Crankshaft alignment
Specific tooling
020335Y Dial gauge magnetic support
ENG - 204
NA 850 Mana Engine
- The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason, it is
arranged opposed to the cylinder.
- So as not to obstruct the oil supply channels, the coupling surface of the two half-bearings must be
perpendicular to the cylinder axis as shown in the figure.
- The oil supplying channel section is also influenced by the depth to which the bushings are driven
compared with the crankshaft axial clearance of the limiting surface.
NOTE
TO KEEP THIS POSITION OF THE BUSHINGS ON THE CRANKCASE, FITTING IS FORCED ON
CAST IRON RINGS INSERTED IN THE CASTING OF CRANKCASE HALVES.
- Measure the bushings diameter at the 3 positions
indicated in the figure.
- Repeat the measurements for the other half of
the bushing. See figure.
NOTE
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-
SHELLS COUPLING SURFACE SINCE THE ENDS ARE RE-
LIEVED TO ALLOW BENDING DURING THE DRIVING
OPERATION.
Before fitting, check that the clearance between the engine crankcase bushing and the crankshaft is
within the predetermined limits.
Characteristic
Crankshaft-bushing maximum clearance allowed:
0.08 mm
- The standard bushing diameter after driving varies according to a coupling selection.
- The bushing seats in the crankcase are classified into 2 categories - Cat 1 and Cat 2 - just like those
for the crankshaft
ENG - 205
Engine NA 850 Mana
- Bushings are subdivided into 3 categories according to their thickness. (See chart on the "Specifica-
tions" chapter)
Specific tooling
020665Y Transmission side crankshaft fitting
tip
- Lubricate the external surface of the tip with petroleum jelly grease.
NOTE
LUBRICATE THE BUSHINGS WITH ENGINE OIL BEFORE FITTING THE CRANKSHAFT.
CAUTION
FIT THE TRANSMISSION SIDE TIMING CHAIN.
FIT THE DRIVE CHAIN BEFORE THE CRANKSHAFT.
ENG - 206
NA 850 Mana Engine
Specific tooling
020665Y Transmission side crankshaft fitting
tip
ENG - 207
Engine NA 850 Mana
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.
ENG - 208
NA 850 Mana Engine
Specific tooling
020664Y Flywheel side crankshaft fitting tip
ENG - 209
Engine NA 850 Mana
Lubrication
ENG - 210
NA 850 Mana Engine
Conceptual diagrams
LUBRICATION CIRCUIT
Specification Desc./Quantity
1 FRONT HEAD CAMSHAFTS
2 REAR HEAD CAMSHAFTS
3 CONNECTING ROD BUSHINGS
4 FRONT PISTON LUBRICATION JET
5 REAR PISTON LUBRICATION JET
6 STARTING RING GEAR BUSHING LUBRICATION
7 CRANKSHAFT BUSHINGS
8 WATER PUMP CONTROL TRANSMISSION GEAR SHAFT
LUBRICATION
9 WATER PUMP SHAFT LUBRICATION
10 MINIMUM OIL PRESSURE SENSOR
11 NON-RETURN VALVE
12 OIL CARTRIDGE FILTER
14 BY-PASS VALVE
13 OIL DELIVERY PUMP
16 RECOVERY OIL PUMP
15 FILLER NECK OIL
17 SUCTION ROSE
18 OIL DRAINAGE PLUG
19 OIL TANK
20 OIL TANK FILTER
21 OIL PASSAGE FROM THE HUB TO THE TANK
The RED arrows indicate the oil delivery circuit.
The BLUE arrows indicate the oil recovery circuit.
General characteristics
ENG - 211
Engine NA 850 Mana
- low pressure
The high pressure section includes all components located on the engine crankcase; while the low
pressure section only refers to the thermal group.
The trochoidal pump is fitted into the sump and controlled through the chain.
To guarantee the integrity of the pump, a pre-filter is fitted.
Pump delivery is controlled by means of a piston by-pass calibrated to 4.5 bar. This piston is located
upline the cartridge filter.
The by-pass located upline the cartridge filter improves the operating conditions for the filter, particularly
with cold oil.
The filter is equipped with an anti-drain valve and a pressure relief valve; the latter intervenes when the
filtering element causes a pressure drop exceeding 1 ± 0.2 bar.
These conditions naturally occur only with cold oil and at high running engine or if the filter is dirty.
The filtered oil is used to lubricate the water pump shaft and the transmission shaft, to lubricate the
main bearings, the connecting rod head and the piston cooling nozzle, located on the transmission side
bearing.
The main bearing on the transmission side is fitted with an oil seal and the respective drain line.
The supply line for the timing system comes from the flywheel-side bearing; delivery to the head is
controlled by the respective jet screwed in the engine crankcase, in the same way the supply line of the
timing system to the rear cylinder comes from the transmission.
The components of the timing system work with low-pressure oil.
The camshaft bearings are marked directly on the aluminium of the head; the camshaft axial clearance
is partially compensated by the oil supplied to the smaller diameter bearing.
The camshaft supplies the lubricant to the rocking levers via the bores provided; these are installed in
a position so as to ensure that the lubrication is maintained even after the vehicle has stopped. This is
achieved when the camshaft reaches its most usual and likely position when the engine is switched off.
The oil used to lubricate the head returns to the sump via the chain casing channel and therefore it also
provides lubrication for the chain.
In order to avoid that the gas collected from the crankcase carries oil, a one-way valve and a decantation
chamber are used. The one-way valve is a metal reed valve; the decantation chamber has a drainage
hole. A failure in these components implies oil getting into the line supplying air to the engine.
Excessive oil vapours may result in the clogging of ducts on the throttle body.
In order to signal low oil pressure in the system, a pressure switch is used, located immediately after
the oil filter outlet.
The lubrication circuit does not include the piston or the pin, also in this case the cooling nozzle is
particularly important.
Diagnosis guide
1 - Minimum oil pressure warning light on with hot engine.
ENG - 212
NA 850 Mana Engine
CONTINUE - point 2
2 - Remove the electric connector of the minimum pressure switch.
Check that the warning light turns off.
YES - point 3 NO point 11
3 - Check the actual oil pressure.
CONTINUE - point 4
4 - Remove the switch and fit the specific tool with the relevant gasket.
Specific tooling
020193Y Gauge for oil pressure check
020434Y Fitting for oil pressure check
- Remove the dipstick with the oil filler plug and insert a plug with the temperature probe supplied with
the specific tool. Insert the probe to feel contact with the crankcase bottom and pull back a few milli-
metres.
Specific tooling
020331Y Digital multimeter
CONTINUE - point 5
STANDARD VALUES
Specification Desc./Quantity
20°C Temperature
1400 rpm
~ 4.5 bar
STANDARD VALUES
Specification Desc./Quantity
80°C Temperature
1400 rpm
~ 1.5 bar
ENG - 213
Engine NA 850 Mana
Specific tooling
020193Y Gauge for oil pressure check
020434Y Fitting for oil pressure check
CONTINUE - go to point 3
ENG - 214
NA 850 Mana Engine
3 - Check the system pressure with cold engine and medium - high speed.
Standard pressure < 6 bar
YES go to point 4 NO go to point 5
4 - Replace the damaged components.
5 - Check the adjustment by-pass efficiency and restore the proper sliding.
NOTE
STANDARD PRESSURES ARE OBTAINED USING OIL WITH THE PRESCRIBED VISCOSITY. A
HIGHER VISCOSITY CAUSES AN INCREASE OF THE SYSTEM PRESSURE.
1 - If oil consumption is higher than 250 gr/1000 km on run-in engine, proceed as follows.
CONTINUE go to point 2
2 - Check the presence of oil at the recovery duct on the filter housing.
YES - go to point 3 NO go to point 4
3 - Check the efficiency of the one-way reed valve and the decantation chamber drainage hole.
YES - go to point 5 NO go to point 4
4 - Check the thermal group seals (piston rings, valve guides and oil seals), see the "Thermal group
and Timing system" chapter.
5 - Restore the valve or the drainage hole efficiency.
Oil pump
KEY:
A. Delivery pump
B. Recovery pump
ENG - 215
Engine NA 850 Mana
C. By-pass
Removing
Specific tooling
AP8106702 Flywheel lock calliper spanner
ENG - 216
NA 850 Mana Engine
ENG - 217
Engine NA 850 Mana
Inspection
- The procedure is described only once but it is valid for both pumps.
ENG - 218
NA 850 Mana Engine
ENG - 219
Engine NA 850 Mana
NOTE
VISUALLY INSPECT THAT ALL THE COMPONENTS ARE
IN GOOD CONDITIONS. THERE MUST BE NO SIGNS OF
WEAR OR SLIPPAGE. IN CASE OF THERE ARE EVIDENT
TRACES OF WEAR, REPLACE THE COMPONENTS.
ENG - 220
NA 850 Mana Engine
CAUTION
ONCE THE ROTORS ARE FITTED INSIDE THE PUMP
BODY, THE REFERENCE MARKS ON THEM MUST NOT BE
VISIBLE.
Characteristic
Standard clearance:
0.04 - 0.1 mm
Characteristic
Standard clearance:
0.05 - 0.12 mm
ENG - 221
Engine NA 850 Mana
Characteristic
Limit value allowed:
0.1 mm
Installing
ENG - 222
NA 850 Mana Engine
ENG - 223
Engine NA 850 Mana
Specific tooling
AP8106702 Flywheel lock calliper spanner
ENG - 224
NA 850 Mana Engine
Automatic transmission
Transmission cover
ENG - 225
Engine NA 850 Mana
CAUTION
REPLACE THE TWO CONTROL BUSHING O-RINGS EACH
TIME THE COVER IS REMOVED.
ENG - 226
NA 850 Mana Engine
Specific tooling
AP8140180 Extractor for bushings
020376Y Adapter handle
020357Y 32 x 35 mm adaptor
020363Y 20-mm Oil seal guide
- 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
ENG - 227
Engine NA 850 Mana
Specific tooling
AP8140180 Extractor for bushings
ENG - 228
NA 850 Mana Engine
Specific tooling
020376Y Adapter handle
020441Y Oil seal punch
020455Y 10-mm guide for oil seal on water
pump shaft
See also
ENG - 229
Engine NA 850 Mana
Characteristic
Max. value:
175.5 mm
Standard value:
175+0+0.2 mm
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
ENG - 230
NA 850 Mana Engine
Characteristic
Minimum thickness allowed:
1 mm
- The masses must not show traces of lubricants. If they do, check the driven pulley unit seals.
NOTE
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST
NOT BE DIFFERENT FROM ONE ANOTHER. DIFFERENT CONDITIONS MAY CAUSE CLUTCH
TEARING.
- To avoid variation in the return spring load, do not
use any tool to open the masses.
ENG - 231
Engine NA 850 Mana
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
ENG - 232
NA 850 Mana Engine
Specific tooling
020376Y Adapter handle
020375Y 28 x30 mm Punch
020483Y 30-mm guide
AP8140180 Extractor for bushings
Characteristic
Minimum diameter allowed:
54.91 mm
Standard diameter:
55.00-0.015 -0.035 mm
Characteristic
Maximum diameter allowed:
55.05 mm
Standard diameter:
55.00 +0.035 0.00 mm
ENG - 233
Engine NA 850 Mana
Specific tooling
020478Y Punch for roller casing
AP8140180 Extractor for bushings
Specific tooling
020376Y Adapter handle
020477Y 37-mm Adaptor
020364Y 25-mm Guide
ENG - 234
NA 850 Mana Engine
- Using a curved-spout grease gun, lubricate the driven pulley assembly with approximately 10 grams
of grease. Apply the grease through one of the holes in the bushing until grease comes out through the
hole on the opposite side. This procedure is necessary to prevent the presence of grease beyond the
O-rings.
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 resistance.
Characteristic
Standard length:
190.2 mm
Limit allowed after use:
182 mm
ENG - 235
Engine NA 850 Mana
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.
ENG - 236
NA 850 Mana Engine
ENG - 237
Engine NA 850 Mana
See also
Refitting the
clutch
Drive-belt
- Make sure the driving belt is not damaged and does not show signs of abnormal wear.
- Replace according to the scheduled maintenance table.
Specific tooling
020660Y Driving pulley check ring
ENG - 238
NA 850 Mana Engine
ENG - 239
Engine NA 850 Mana
ENG - 240
NA 850 Mana Engine
ENG - 241
Engine NA 850 Mana
Characteristic
Max. diameter admitted
40.050 mm
Standard diameter
40.000 +0.034 -0.009 mm
Characteristic
Max. diameter admitted
35.050 mm
Standard diameter
35.000 +0.034 -0.009 mm
Characteristic
Minimum outside diameter admitted
34.055 mm
Standard diameter
35.000 -0.015 -0.040 mm
Characteristic
Minimum outside diameter admitted
39.055 mm
Standard diameter
40.000 -0.015 -0.040 mm
ENG - 242
NA 850 Mana Engine
Characteristic
Maximum clearance allowed
0.4 mm
Characteristic
Max. diameter admitted
10.040 mm
Standard diameter
10.000 +0.005 -0.030 mm
ENG - 243
Engine NA 850 Mana
- Fit the stop washer and tighten the ring nut with
the level surface facing upwards.
CAUTION
ENG - 244
NA 850 Mana Engine
Specific tooling
020659Y Tool to remove clutch and repl. belt
- Fit the unit following the removal steps but in reverse order with the specific tool being careful to tighten
to the prescribed torques.
ENG - 245
Engine NA 850 Mana
CAUTION
IN THE EVENT OF REPLACEMENT OF ONE OR MORE OF THE FOLLOWING COMPONENTS:
• SPACER (DIAM. 40 mm, LENGTH 50.5 mm)
• SLIDER SUPPORT
• BEARING SUPPORT (SLIDING) BUSHING
• BEARING SUPPORT
• FIXED DRIVING HALF-PULLEY
• MOVABLE DRIVING HALF-PULLEY
1) TO PREVENT THE RISK OF THE VARIATOR LOCKING IN SEVENTH GEAR, IN THE TRANS-
MISSION ECU SET THE "DEFAULT" VALUE OF THE GEARSHIFT STROKE AS SHOWN IN THE
CHAPTER "ELECTRICAL SYSTEM/CHECK AND CONTROLS/DRIVE PULLEY POSITION SEN-
SOR/ADJUSTABLE PARAMETERS".
2) NEVER TURN THE KEY TO ON BEFORE COMPLETING THE FITTING OF THE UNIT AND CON-
NECTING WITH THE DIAGNOSIS INSTRUMENT.
3) PERFORM THE POTENTIOMETER RESET PROCEDURE BY CONNECTING THE DIAGNOSIS
INSTRUMENT AND ENTERING INTO MANAGING "AUTOMATIC TRANSMISSION/AUTODIA/PO-
TENTIOMETER RESET/ADJUST".
4) PERFORM THE GEARSHIFT STROKE CATEGORY INSERTION PROCEDURE FROM THE
"SETTINGS" MENU OF THE DIAGNOSIS INSTRUMENT. PERFORM A KEY OFF/ON TO STORE
THE DATA.
5) CHECK THAT THE GEARSHIFT STROKE CATEGORY HAS BEEN STORED CORRECTLY
FROM THE DIAGNOSIS INSTRUMENT MENU.
ENG - 246
NA 850 Mana Engine
ENG - 247
Engine NA 850 Mana
EACH TIME THE ROTATING POSITION SENSOR OR ANY COMPONENT OF THE TRANSMISSION
IS REMOVED OR REPLACED, CARRY OUT THE "POTENTIOMETER RESET" OPERATION AS
INDICATED IN THE WORKSHOP MANUAL, "ELECTRICAL SYSTEM/DRIVING PULLEY POSITION
SENSOR" CHAPTER. UPON RESETTING, MAKE SURE THAT THE POSITION SENSOR LEVER
ROTATES FREELY AND DOES NOT TOUCH THE COVER. THIS RESETTING OPERATION IS
CARRIED OUT BEFORE THE FIRST START-UP.
ENG - 248
NA 850 Mana Engine
End gear
Specific tooling
AP8140180 Extractor for bushings
ENG - 249
Engine NA 850 Mana
Specific tooling
020376Y Adapter handle
020662Y Guide 50 mm
020360Y 52x55 mm Adaptor
- Fit the pinion 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
ENG - 250
NA 850 Mana Engine
- Fit the oil seal until it abuts against the bottom of the seat using the specific tool.
Specific tooling
020376Y Adapter handle
020655Y 62x68 mm Adaptor
020662Y 50 mm guide
Specific tooling
020376Y Adapter handle
020655Y 62x68 mm Adaptor
020662Y 50 mm guide
ENG - 251
Engine NA 850 Mana
ENG - 252
NA 850 Mana Engine
Specific tooling
020376Y Adapter handle
020483Y 30 mm guide
020358Y 37 x 40-mm adaptor
Characteristic
Bearing diameter for shaft driven pulley:
A= Ø30 -0.01 -0.02 mm
B= Ø20 -0.01 -0.02 mm
Diameter for pinion unit shaft:
C= Ø20 -0.01 -0.02 mm
D= Ø30 -0.013 -0.026 mm
ENG - 253
Engine NA 850 Mana
- Insert the driven pulley shaft bearing up to the stop against the bottom of the seat with the specific
tool.
Specific tooling
020376Y Adapter handle
020483Y 30 mm guide
020655Y 62x68 mm Adaptor
ENG - 254
INDEX OF TOPICS
Circuit diagram
In case of problems with the fuel system, the following operations must be carried out:
• Replace the fuel pump with the new model with only one exit.
• Replace the front injector with the new one with a single fuel duct as shown in figure A old
and A new.
• Delete the pipe highlighted in green in figures B, C, D and E.
P SUPP - 256
NA 850 Mana Power supply
P SUPP - 257
Power supply NA 850 Mana
P SUPP - 258
INDEX OF TOPICS
SUSPENSIONS SUSP
Suspensions NA 850 Mana
Front
Key:
SUSP - 260
NA 850 Mana Suspensions
SUSP - 261
Suspensions NA 850 Mana
CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL-
LOWS.
ROTATION CHECK
• Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and
noiseless.
If one or both bearings do not fall within the control parameters:
• Replace both wheel bearings.
RADIAL AND AXIAL CLEARANCE CHECK
• Check the radial and axial clearance.
Axial clearance: a minimum axial clearance is allowed.
Radial clearance: none.
If one or both bearings do not fall within the control parameters:
• Replace both wheel bearings.
SUSP - 262
NA 850 Mana Suspensions
• Check that the gaskets are in good conditions; replace them if they show signs of damage
or excessive wear.
Characteristic
Maximum eccentricity:
0.25 mm (0.0098 in)
Characteristic
Maximum radial and axial eccentricity:
2 mm (0.0079 in)
SUSP - 263
Suspensions NA 850 Mana
Handlebar
Key:
1. Handlebar
2. Anti-vibration weight fix. end
3. Anti-vibration weight v.
4. Screw M6x40
5. Handlebar upper U-bolt
6. TCC screw M8x25
7. Right light switch
8. Left light switch
9. Right hand grip with throttle control
10.Gear left hand grip
11.Mirror support
12.Gear control device
13.Screw M4x10
14.Throttle opening cable
15.Throttle closing cable
16.Right mirror
17.Left mirror
SUSP - 264
NA 850 Mana Suspensions
Front fork
Diagram
Key:
SUSP - 265
Suspensions NA 850 Mana
18.Ring
19.Guide bushing
20.Sliding bushing
21.Special washer
22.Screw M10x1.5
23.TE flanged screw M8x40
24.Spring Centring
SUSP - 266
NA 850 Mana Suspensions
SUSP - 267
Suspensions NA 850 Mana
Draining oil
NOTE
THE FOLLOWING OPERATIONS REFER TO THE SHOWA FORKS.
NOTE
THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS.
NOTE
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS GET A CONTAINER WITH SUITABLE
CAPACITY TO COLLECT THE OIL.
• Remove the fork.
Specific tooling
AP8140149 Protection for fitting operations
SUSP - 268
NA 850 Mana Suspensions
See also
Removing the
fork legs
NOTE
THE FOLLOWING OPERATIONS REFER TO THE MARZOCCHI FORKS.
NOTE
THE STEMS ARE DIFFERENT.
RIGHT STEM.
Specific tooling
AP8140149 Protection for fitting operations
SUSP - 269
Suspensions NA 850 Mana
See also
Removing the
fork legs
LEFT STEM.
Specific tooling
AP8140149 Protection for fitting operations
SUSP - 270
NA 850 Mana Suspensions
See also
Removing the
fork legs
NOTE
THE FOLLOWING OPERATIONS 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.
Specific tooling
AP8140149 Protection for fitting operations
See also
Removing the
fork legs
SUSP - 271
Suspensions NA 850 Mana
Specific tooling
020888Y Pliers for pre-fill pipe
AP8140148 Spacer-piston separating plate
SUSP - 272
NA 850 Mana Suspensions
SUSP - 273
Suspensions NA 850 Mana
Specific tooling
AP8140147 Spacer tool
Specific tooling
AP8140148 Spacer-piston separating plate
SUSP - 274
NA 850 Mana Suspensions
Specific tooling
AP8140149 Protection for fitting operations
SUSP - 275
Suspensions NA 850 Mana
SUSP - 276
NA 850 Mana Suspensions
See also
Draining oil
NOTE
THE FOLLOWING OPERATIONS REFER TO THE MARZOCCHI FORKS.
NOTE
THE FOLLOWING OPERATIONS REFER TO BOTH STEMS.
• Drain the fork oil.
• Remove the sleeve.
SUSP - 277
Suspensions NA 850 Mana
NOTE
THE FOLLOWING OPERATIONS REFER TO THE SACHS FORKS.
NOTE
THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS.
SUSP - 278
NA 850 Mana Suspensions
• Be careful not to damage the stanchion when placing it in a vice, in horizontal position, using
the appropriate protections.
See also
Draining oil
SUSP - 279
Suspensions NA 850 Mana
Stem
SUSP - 280
NA 850 Mana Suspensions
Sleeve
Check that there are no damages and/or cracks; otherwise, replace it.
Spring
Check that the spring is in good conditions. Check that the spring length is within the limit value.
Replace the spring if its length does not fall within the limit values.
MINIMUM LENGTH OF FREE SPRING (Showa): 300.8 mm (11.84 in)
MINIMUM LENGTH OF FREE SPRING (Marzocchi): 360 mm (14.17 in)
MINIMUM LENGTH OF FREE SPRING (Sachs): 353 mm (13.90 in)
• sliding bushing;
• guide bushing;
• piston.
If there are signs of excessive wear or damage, replace the affected component.
CAUTION
REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SUR-
FACE.
Replace the following components with new ones:
• dust guard
• oil seal
SUSP - 281
Suspensions NA 850 Mana
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).
Specific tooling
AP8140189 Oil seal fitting tool for Ø 43 mm
(1.69 in) orifices
Specific tooling
AP8140146 Weight
SUSP - 282
NA 850 Mana Suspensions
Specific tooling
AP8140150 Perforated rod for piston air bleed
NOTE
THE FOLLOWING OPERATIONS REFER TO THE MARZOCCHI FORKS.
NOTE
THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS.
SUSP - 283
Suspensions NA 850 Mana
Specific tooling
AP8140189 Oil seal fitting tool for Ø 43 mm
(1.69 in) orifices
AP8140146 Weight
SUSP - 284
NA 850 Mana Suspensions
Specific tooling
AP8140189 Oil seal fitting tool for Ø 43 mm
(1.69 in) orifices
AP8140146 Weight
NOTE
THE FOLLOWING OPERATIONS REFER TO THE SACHS 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).
Specific tooling
AP8140189 Oil seal fitting tool for Ø 43 mm
(1.69 in) orifices
Specific tooling
AP8140146 Weight
SUSP - 285
Suspensions NA 850 Mana
SUSP - 286
NA 850 Mana Suspensions
Recommended products
Loctite 242 Medium strength threadlock
-
Filling oil
NOTE
THE FOLLOWING OPERATIONS REFER TO THE SHOWA 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-
ucts table.
WARNING
MOVE THE PUMPING ELEMENT SEVERAL TIMES UNTIL
AIR BUBBLES ARE SEEN ON THE OIL SURFACE.
Characteristic
Fork oil quantity (for each stem):
535 cm³ (32.65 cu.in)
Oil level (from sleeve rim, without the spring
and with pumping member fully down)
122 mm (4.80 in).
SUSP - 287
Suspensions NA 850 Mana
Specific tooling
AP8140147 Spacer tool
Specific tooling
AP8140148 Spacer-piston separating plate
• Insert the sleeve cap and screw the
nut.
SUSP - 288
NA 850 Mana Suspensions
Specific tooling
AP8140149 Protection for fitting operations
NOTE
THE FOLLOWING OPERATIONS REFER TO THE MARZOCCHI FORKS.
RIGHT STEM
Characteristic
Fork oil quantity (right stem) (Marzocchi)
490 cc (29.90 cu in)
Oil level (from sleeve rim, without the spring
with preload pipe and with stem at end of
stroke)
50 mm (1.97 in)
SUSP - 289
Suspensions NA 850 Mana
SUSP - 290
NA 850 Mana Suspensions
LEFT STEM
Characteristic
Fork oil quantity (left stem) (Marzocchi)
505 cc (30.82 cu in)
SUSP - 291
Suspensions NA 850 Mana
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-
ucts table.
WARNING
MOVE THE PUMPING ELEMENT SEVERAL TIMES UNTIL
AIR BUBBLES ARE SEEN ON THE OIL SURFACE.
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).
SUSP - 292
NA 850 Mana Suspensions
Specific tooling
AP8140150 Perforated rod for piston air bleed
Specific tooling
020888Y Pliers for pre-fill pipe
Specific tooling
AP8140148 Spacer-piston separating plate
SUSP - 293
Suspensions NA 850 Mana
Steering bearing
Key:
SUSP - 294
NA 850 Mana Suspensions
2. Screw M8x30
3. Washer
4. Roller bearing
5. Sealing ring
6. Ring nut
7. Headstock cap washer
8. Headstock cap
9. TCEI screw M10x60
10.Cap
11.Rubber ring
12.Lower U-bolt
13.Fork upper plate
14.Screw M8x30
15.Spacer 10.1x14.1x38
Adjusting play
• Place the vehicle so that the front wheel is off the ground.
• Shake the fork in the riding direction.
• Adjust if clearance is detected.
SUSP - 295
Suspensions NA 850 Mana
SUSP - 296
NA 850 Mana Suspensions
Rear
Key:
SUSP - 297
Suspensions NA 850 Mana
SUSP - 298
NA 850 Mana Suspensions
SUSP - 299
Suspensions NA 850 Mana
CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL-
LOWS.
REAR WHEEL BEARINGS
SUSP - 300
NA 850 Mana Suspensions
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.
• Check that the gaskets are in good conditions; replace them if they show signs of damage
or excessive wear.
Characteristic
Maximum eccentricity:
0.25 mm (0.0098 in)
SUSP - 301
Suspensions NA 850 Mana
Characteristic
Maximum radial and axial eccentricity:
2 mm (0.0079 in)
Shock absorbers
Removing
SUSP - 302
INDEX OF TOPICS
CHASSIS CHAS
Chassis NA 850 Mana
Swinging arm
Key:
1. Swing arm
2. Swing arm pin
3. Nut M20x1.5
4. Rear wheel pin
5. Right chain tensioner
6. Left chain tensioner
7. Rear wheel nut
8. Engine bushing
9. Sealing ring
10.Roller casing 30x37x26
11.Fork right internal spacer
12.Fork left internal spacer
13.Sealing ring
14.Ball bearing 20x37x9
15.Safety ring for holes
16.Nut
17.Chain tensioner set screw
18.Brake calliper support locking pin
CHAS - 304
NA 850 Mana Chassis
Exhaust
Key:
1. Silencer
2. Front manifold
3. Rear manifold
4. Flange
5. Sealant
6. Lambda probe
7. Bushing
CHAS - 305
Chassis NA 850 Mana
8. Clamp
9. TCEI screw M8x40
10.Silencer fixing bushing
11.Washer
12.Rubber ring
13.Spacer
14.Flanged self-locking nut M8
15.Exhaust protection
16.Silencer protection
17.T-shaped bushing
18.Graphite bushing
19.Rubber washer
20.Flanged TBEI screw
21.Rubber ring
22.M10 Compensator fixing screw
23.Washer for shafts D8
24.Flanged metalbloc self-locking nut
CHAS - 306
NA 850 Mana Chassis
CHAS - 307
Chassis NA 850 Mana
CHAS - 308
INDEX OF TOPICS
Key:
Removal
Key:
Removal
PARKING BRAKE
Removal
• 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.
• Fit the two brake pads and fix them with two pins.
Circuit diagram
Key:
1. Water radiator
2. Complete expansion tank
3. Expansion tank cap
4. Radiator right cover - silver crowd v.
5. Radiator left cover - silver crowd v.
6. TBEI screw - M5x12
7. Radiator heat protection
8. 75°C thermostat valve unit
9. H20 pipe union tee
10.Electric fan
11.Fan pin
12.Electric fan spacer
13.Pin fixing screw
14.Washer
15.T-shaped bushing
16.Anti-vibration rubber ring
17.TCEI screw - M6x35
18.TCEI screw - M6x25
19.T-shaped bushing
20.Anti-vibration rubber ring
21.Clip M6
22.T-shaped bushing
23.Screw M6x16
24.Screw M5x10
25.Rear head Y
26.Front head - joint pipe
27.Radiator pipe - joint
28.Joint - thermostatic valve pipe
29.By-pass pipe
30.Radiator - valve pipe
31.Pump pipe
32.Bleed pipe
33.Radiator - expansion tank pipe
34.Clamp clic D35-33
35.Clamp clic D31 white
36.Clamp clic D29x8.9
37.Clamp clic D13.5 white
38.Clamp clic D17.5 white
39.Clamp clic D24.5x8.6
Electric fan
Coolant replacement
TOPPING UP
See also
System bleed
System bleed
• 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.
• Top up the expansion tank fluid level and close the expansion tank closing cap.
• Start the engine and leave it running to warm up until the electric fan triggering temperature
is reached.
• Shut off the engine.
• Wait until the engine cools down.
Water pump
NOTE
OVERALL SEAL REPLACEMENT CAN BE CARRIED OUT WITH ENGINE ASSEMBLED ON THE
VEHICLE.
Specific tooling
020661Y Water pump overall seal replacement kit
- Use two flat blade screwdrivers, and place them as shown in the figure so as to lever on the marked
crankcase edge and disassemble the overall seal, pressure-fitted on the rotor shaft.
CAUTION
USE TEFLON AS SHOWN IN THE FIGURE SO AS NOT TO DAMAGE THE WATER PUMP COVER
SEALING SURFACE.
Small scratches on the seat edge do not present
functional problems.
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
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.
BODYWORK BODYW
NA 850 Mana Bodywork
Seat
BODYW - 333
Bodywork NA 850 Mana
Instrument panel
See also
Headlight assy.
Headlight assy.
BODYW - 334
NA 850 Mana Bodywork
BODYW - 335
Bodywork NA 850 Mana
Taillight assy.
BODYW - 336
NA 850 Mana Bodywork
BODYW - 337
Bodywork NA 850 Mana
Side fairings
NOTE
BODYW - 338
NA 850 Mana Bodywork
THE FOLLOWING OPERATIONS REFER TO ONE SIDE OF THE VEHICLE, BUT APPLY TO BOTH.
• Open the helmet compartment.
• Undo and remove the two fixing screws
for the upper central small fairing (1)
and collect the two washers.
BODYW - 339
Bodywork NA 850 Mana
BODYW - 340
NA 850 Mana Bodywork
BODYW - 341
Bodywork NA 850 Mana
BODYW - 342
NA 850 Mana Bodywork
Air box
BODYW - 343
Bodywork NA 850 Mana
BODYW - 344
NA 850 Mana Bodywork
BODYW - 345
Bodywork NA 850 Mana
Helmet bay
BODYW - 346
NA 850 Mana Bodywork
BODYW - 347
Bodywork NA 850 Mana
BODYW - 348
NA 850 Mana Bodywork
BODYW - 349
Bodywork NA 850 Mana
• Slide off and backwards the fuses and the battery cables.
BODYW - 350
NA 850 Mana Bodywork
BODYW - 351
Bodywork NA 850 Mana
Fuel tank
BODYW - 352
NA 850 Mana Bodywork
BODYW - 353
Bodywork NA 850 Mana
BODYW - 354
NA 850 Mana Bodywork
BODYW - 355
Bodywork NA 850 Mana
Front mudguard
BODYW - 356
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Pre-delivery NA 850 Mana
Aesthetic inspection
- Paintwork
- Fitting of Plastic Parts
- Scratches
- Dirt
- Safety fasteners:
front and rear suspension unit
front and rear brake calliper retainer unit
front and rear wheel unit
engine - chassis retainers
steering assembly
- Plastic parts fixing screws
Electrical system
- Main switch
- Headlamps: high beam lights, low beam lights, tail lights (front and rear) and their warning lights
- Headlight adjustment according to regulations in force
- Front and rear stop light switches and their bulbs
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator (if present)
- Instrument panel warning lights
- Horn
- Electric starter
- Engine stop via emergency stop switch and side stand
- Helmet compartment electrical opening switch (if present)
PRE DE - 358
NA 850 Mana Pre-delivery
- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if
required, program the control unit/s again: consult the technical service website to know about available
upgrades and details regarding the operation.
CAUTION
UPON INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
WARNING
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
- Hydraulic braking system fluid level
- Clutch system fluid level (if present)
- Gearbox oil level (if present)
- Transmission oil level (if present)
- Engine coolant level (if present)
- Engine oil level
- Mixer oil level (if present)
Road test
- Cold start
- Instrument panel operation
PRE DE - 359
Pre-delivery NA 850 Mana
Static test
Functional inspection
PRE DE - 360
A
Air filter: 44
Air temperature sensor: 89, 104
B
Brake: 310, 312, 313
Brake calliper: 310, 312
Bulbs:
C
CAN line: 136
Chain: 12, 181
Chain tensioner: 181
Clutch: 164, 230, 231, 235, 236, 238
Coil: 96
Connectors: 130
coolant: 320
Coolant: 320
Crankcase: 21, 199, 200, 203, 210, 325
Crankshaft: 21, 199, 202, 204–206
Cylinder: 19, 168, 170, 176–178, 185, 186, 190, 192
D
Display: 50
Drive chain: 12
E
ECU: 53, 130
Electric fan: 105, 319
Electrical system: 12, 56, 57, 358
Engine oil: 41
Engine temperature sensor: 87
Exhaust: 305, 307
Exhaust manifold: 307
F
Fairings: 338
Filter box:
Fork: 265, 267, 269–271, 273, 281
Front wheel: 260, 262
Fuel: 95, 352
Fuel pump: 95
Fuses: 81
H
Handlebar: 125, 264
Head cover: 167, 197
Headlight: 334
I
Identification: 10
Instrument panel: 50, 104, 334
L
License plate holder: 340
M
Magneto flywheel: 161
Maintenance: 7, 39
Maintenance Table:
Mudguard: 356
O
Oil filter: 44
Oil pressure sensor: 100
R
Radiator: 328
Rear wheel: 297, 300
Recommended products: 24
Run/Stop switch: 107
S
Saddle:
Shock absorbers: 302
Side fairings: 338
Side stand: 101
Side stand sensor: 101
Spark plug: 40
Spark plugs:
Speed sensor: 84, 118
Stand: 101
Start-up: 78
Starter motor: 155, 156
T
Tank: 331, 352
Throttle body: 98
Transmission: 12, 108, 113, 120, 134, 225, 248
Tyres: 14
W
Warning lights:
Water pump: 321
Wiring diagram: 68