APRILIA MSS Mana GT ABS Service Station Manual
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APRILIA MSS Mana GT ABS Service Station Manual

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Table Of Contents
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Table of Contents

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SERVICE STATION MANUAL
894171
MSS Mana GT ABS

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Summary of Contents for APRILIA MSS Mana GT ABS

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

  • Page 2: The Value Of Service

    The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this booklet remain unchanged, aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 SERVICE STATION MANUAL MSS Mana GT ABS NOTE Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
  • Page 4 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE DELIVERY...

  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 6: Safety Rules

    MSS Mana GT ABS Characteristics 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.

  • Page 7: Maintenance Rules

    MSS Mana GT ABS Characteristics THOUGH IT IS TOXIC, COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRAC- TIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCES- SIBLE TO ANIMALS AS THEY MAY DRINK IT.
  • Page 8 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.
  • Page 9 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.

  • Page 10: Vehicle Identification

    MSS Mana GT ABS Characteristics Vehicle identification Write down the chassis and engine number in the specific space in this booklet. The chassis number is handy when purchasing spare parts. CAUTION THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISHABLE CRIME.

  • Page 11: Oil Pump

    Air filter With dry cartridge filter Cooling Forced-circulation coolant system. EARBOX 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)

  • Page 12: Drive Chain

    MSS Mana GT ABS Characteristics HEAD LUBRICATION CONTROL JET Specification Desc./Quantity Diameter Ø 1 ± 0.05 mm * * Tightening torque 5÷7 N·m PISTON COOLING NOZZLE Specification Desc./Quantity Diameter Ø 0.95 - 1.05 mm (0.037 - 0.041 in) CRANKCASE VENTILATION CHECK Specification Desc./Quantity...
  • Page 13 MSS Mana GT ABS Characteristics Specification Desc./Quantity Ignition Electronic, inductive, high-efficiency, integrated with the injec- tion system, with variable advance separate HV coil. Ignition advance Three-dimensional map managed by control unit Pick-up air gap front: 0.1 - 3.17 mm (0.004 - 0.124 in) rear: 0.1 - 2.0 mm (0.004 - 0.078 in)

  • Page 14: Wheels And Tyres

    MSS Mana GT ABS Characteristics Specification Desc./Quantity 702.6 ± 0.5 mm (27.66 ± 0.02 in) 225.5 ± 0.6 mm (8.88 ± 0.02 in) 187.2 ± 0.6 mm (7.37 ± 0.02 in) USPENSIONS Specification Desc./Quantity Front Upside-down hydraulic action telescopic fork, Ø 43 mm (1.69...
  • Page 15 MSS Mana GT ABS Characteristics Tightening Torques LUBRICATION Name Torque in Nm Engine oil drainage plug 21 - 29 Oil pump compartment cover bulkhead screws 3 - 4 Engine oil filter 12 - 16 Chain tensioner slider - oil pump...
  • Page 16 MSS Mana GT ABS Characteristics RAME 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)
  • Page 17 MSS Mana GT ABS Characteristics EAR WHEEL UNIT Name Torque in Nm Brake disc fixing screw on wheel M8x20 (5) 30 Nm (22.13 lbf ft) - Loct. 243 Screw for fixing the cush drive mounting on the wheel - M10x30 50 Nm (36.88 lbf ft) - Loctite 2701...
  • Page 18 MSS Mana GT ABS Characteristics Name Torque in Nm Screw fixing ABS sensor plate (2) - M5x12 6 Nm (4.42 lbf ft) EAR 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...
  • Page 19 MSS Mana GT ABS Characteristics ADDLE Name Torque in Nm hex headflanged screw fixing saddle rotation bracket - M6x20 10 Nm (7.38 lbf ft) 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)
  • Page 20 MSS Mana GT ABS Characteristics EAR 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)
  • Page 21 MSS Mana GT ABS Characteristics THE REAR CYLINDER PISTON, UNLIKE THE FRONT ONE, MUST BE FITTED WITH THE ARROW TURNED TOWARDS THE EXHAUST. THE PISTON RINGS MUST BE FITTED WITH THE "TOP" REFERENCE OR THE TRADEMARK FACING UP. Rod small end - pin - piston...

  • Page 22: Piston Rings

    MSS Mana GT ABS Characteristics 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.
  • Page 23 MSS Mana GT ABS Characteristics CRANKSHAFT Specification Desc./Quantity Cat. 1 Standard diameter: 45.010 ÷ 45.016 Cat. 2 Standard diameter: 45.016 ÷ 45.022 CRANKSHAFT / CONNECTING ROD AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half shaft, transmission 29.9 +0.05 D = 0.20 ÷ 0.60...
  • Page 24 MSS Mana GT ABS Characteristics Name Description Dimensions Initials Quantity Connecting rod 22 -0.10 -0.15 D = 0.20 ÷ 0.60 Complete crankshaft 104 +0.1 -0.05 Characteristic Crankshaft-crankcase axial clearance (H) 0.1 ÷ 0.45 mm (when cold) - Measure the inside diameter of the connecting rod small end using a bore meter.
  • Page 25 MSS Mana GT ABS Characteristics X = Crankshaft category Y = Crankcase half-shells category A = Red B = Blue C = Yellow Recommended products chart ECOMMENDED PRODUCTS Product Description Specifications ENI i-RIDE Aprilia Racing 5W-40 Engine oil Use top-branded oils that meet or exceed...

  • Page 26: Index Of Topics

    INDEX OF TOPICS S-TOOLS PECIAL TOOLS...

  • Page 27: Specific Tools

    MSS Mana GT ABS Special tools SPECIFIC TOOLS Stores code Description 020193Y Gauge for oil pressure check 020262Y Crankcase splitting strip 020306Y Punch for fitting the valve seal rings 020330Y Stroboscopic light for timing checking 020331Y Digital multimeter S-TOOLS - 27...
  • Page 28 MSS Mana GT ABS Special tools Stores code Description 020335Y Dial gauge magnetic support 020357Y 32 x 35 mm adaptor 020358Y 37 x 40-mm adaptor 020359Y 42 x 47-mm adaptor 020360Y 52 x 55-mm adaptor 020362Y 12 mm guide for oil seal in kick start pedal...
  • Page 29 MSS Mana GT ABS Special tools Stores code Description 020363Y 20 mm guide for oil seal 020364Y 25-mm Guide 020365Y 22 mm (0.87 in) guide 020375Y 28x30 mm punch 020376Y Adapter handle 020408Y 72x75-mm (2.83x2.95 in) adaptor S-TOOLS - 29...
  • Page 30 MSS Mana GT ABS Special tools Stores code Description 020412Y 15-mm Oil seal guide 020414Y 28 mm punch 020424Y Punch for fitting driven pulley roller casing 020434Y Fitting for oil pressure check 020439Y 17-mm guide for oil seal 020431Y Valve oil seal extractor...
  • Page 31 MSS Mana GT ABS Special tools Stores code Description 020441Y Oil seal punch 020455Y 10-mm guide for oil seal on water pump shaft 020456Y 24 mm punch 020470Y Pin snap ring fitting tool 020477Y 37-mm Adaptor 020478Y Punch for roller casing...
  • Page 32 MSS Mana GT ABS Special tools Stores code Description 020480Y Fuel pressure check set 020481Y Adaptor cable harness 020481Y004 Adaptor cable 020483Y 30 mm guide 020527Y Engine support base 020621Y HV cable extraction adaptor S-TOOLS - 32...
  • Page 33 MSS Mana GT ABS Special tools Stores code Description 020629Y 8 mm (0.31 in) guide 020648Y Single battery charger 020654Y 35-mm Guide 020655Y 62x68 mm Adaptor 020658Y Engine plate 020659Y Tool to remove clutch and repl. belt S-TOOLS - 33...
  • Page 34 MSS Mana GT ABS Special tools Stores code Description 020660Y Driving pulley check ring 020661Y Water pump overall seal replacement kit 020662Y 50 mm guide 020663Y Water pump shaft oil seal punch 020664Y Flywheel side crankshaft fitting tip 020665Y Transmission side crankshaft fitting tip...
  • Page 35 MSS Mana GT ABS Special tools Stores code Description 020713Y Flywheel extractor 020714Y Dial gauge mounting 020716Y Connecting rod locking AP0276474 Valve spring compressor adaptor AP8140146 Weight AP8140147 Spacer tool AP8140148 Spacer-piston separating plate S-TOOLS - 35...
  • Page 36 MSS Mana GT ABS Special tools Stores code Description AP8140149 Protection for fitting operations AP8140150 Perforated rod for piston air bleed AP8140179 Support for valve fitting/removal AP8140180 Extractor for bushings AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in)
  • Page 37 MSS Mana GT ABS Special tools Stores code Description AP8140595 Axone + battery charger (230V 50Hz) AP8140187 Engine support stand AP8106702 Flywheel lock calliper spanner AP8202311 Axone + battery charger (110V 60Hz) AP8140199 Tool panel 8140426 Hooks for panel S-TOOLS - 37...
  • Page 38 MSS Mana GT ABS Special tools Stores code Description 020881Y Panel graphics S-TOOLS - 38...

  • Page 39: Index Of Topics

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 40: 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.

  • Page 41: Spark Plug

    MSS Mana GT ABS Maintenance km x 1,000 Engine oil Fork oil seals Brake pads (3) Variator sliders Parking brake calliper Tyres Tyre pressure Wheels and transmission cush drive Transmission screws and bolts torque tightening Tightening bolts, nuts and screws...

  • Page 42: Engine Oil

    MSS Mana GT ABS Maintenance The gap between the electrodes should be be- tween 0.7 - 0.8 mm (0.027 - 0.031 in). Otherwise, replace the spark plug (2). • Make sure the washer is in good con- ditions. Installation: •...
  • Page 43 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.
  • Page 44 MSS Mana GT ABS Maintenance • Use a cloth to wipe off any mud deposit on the area next to the filler plug (1). • Place a container with + 4000 cm³ (244 cu.in) capacity under the drainage plug (2).

  • Page 45: Engine Oil Filter Replacement

    MSS Mana GT ABS Maintenance Engine oil filter ENGINE OIL FILTER REPLACEMENT • Replace the engine oil filter (1) at the intervals specified in the routine main- tenance table. • Remove the engine oil filter (1). Never reuse an old filter.

  • Page 46: Troubleshooting

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 47 MSS Mana GT ABS Troubleshooting Engine The engine does not start CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
  • Page 48 MSS Mana GT ABS Troubleshooting • 9 - RESTORE THE CABLE HARNESS - END • 10 - CHECK THE ELECTRICAL SPECIFICATIONS OF THE FUEL PUMP - END • 11 - RESTORE THE CABLE HARNESS - END • 12 - CONNECT TO AXONE BY SELECTING "PETROL INJECTION": WHAT DOES THE "IGNITION"...
  • Page 49 MSS Mana GT ABS Troubleshooting • 23 - IS THE STARTER MOTOR CORRECTLY CONNECTED TO THE VEHICLE GROUND CONNECTION? YES, go to 24; NO, go to 60. • 24 - PROBABLE ELECTRIC MOTOR MALFUNCTION: CHECK ITS SPECIFICATIONS - • 25 - WHAT DOES THE FALL SENSOR STATUS INDICATE? NORMAL, go to 26;...

  • Page 50: Ground Lead

    MSS Mana GT ABS Troubleshooting • YES, go to 40; NO, go to 41 • 40 - REPLACE THE REAR BRAKE SWITCH - END • 41 - RESTORE THE CABLE HARNESS (GREEN CABLE) - END • 42 - RESTORE THE CABLE HARNESS (YELLOW/GREEN CABLE) - END •...

  • Page 51: Warning Lights

    MSS Mana GT ABS Troubleshooting • 59 - RESTORE THE CABLE HARNESS - END • 60 - RESTORE THE CABLE HARNESS - END FAILURE INDICATIONS ON INSTRUMENT PANEL DISPLAY WARNING LIGHTS • Instrument panel (hardware) identical to that of the vehicle without ABS system (there is no dedicated warning light).
  • Page 52 MSS Mana GT ABS Troubleshooting • 8 - IS THERE VOLTAGE IN THE WHITE/RED CABLE? YES, go to 9; NO, go to 12. • 9 - SLIDE OFF THE AUXILIARY 15A FUSE: IS THERE VOLTAGE IN THE RED/BLACK CABLE? YES, go to 10; NO, go to 11.
  • Page 53 MSS Mana GT ABS Troubleshooting • 11 - HAS THE INSTRUMENT PANEL BEEN REPLACED? YES, go to 12; NO, go to 13. • 12 - STORE ALL THE KEYS THE FIRST TIME THE INSTRUMENT PANEL IS SWITCHED ON - END •...
  • Page 54 MSS Mana GT ABS Troubleshooting 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;...
  • Page 55 MSS Mana GT ABS Troubleshooting • 5 - FIND THE MALFUNCTION (SEE THE "ELECTRICAL SYSTEM/CHECKS AND CON- TROLS" CHAPTER AND RESTORE THE CORRECT OPERATION • 6 - DELETE THE ERROR WITH THE "ERROR CLEARING" FUNCTION IN THE "DEVICES ACTIVATION" (INJECTOR ICON) SCREEN PAGE - END •...
  • Page 56 MSS Mana GT ABS Troubleshooting • 6 - DELETE THE ERROR WITH THE "ERROR CLEARING" FUNCTION IN THE "DIAG- NOSIS" FUNCTION OF THE INSTRUMENT PANEL - END TROUBL - 56...

  • Page 57: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 58 MSS Mana GT ABS Electrical system 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 •...

  • Page 59: Electrical System Installation

    MSS Mana GT ABS Electrical system Electrical system installation Motorcycle division The wiring timing is subdivided in three essential sections, as indicated in the figure. 1. Front section 2. Central section 3. Rear section SPECIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES Carry out the checks described below once the electrical system is refitted, connectors recon- nected and clamps and retainers restored.

  • Page 60: Front Side

    MSS Mana GT ABS Electrical system Front side TABLE A • Turn signal extension (1) • 3 Black nylon clamps TABLE B • Turn signal extension (1) • 3 Black nylon clamps TABLE C • 4. Clamps TABLE D •...
  • Page 61 MSS Mana GT ABS Electrical system TABLE E • Clamp that fixes the main cable har- ness and antenna cable to the support. TABLE F - Front ABS sensor fitting • 3 Black nylon clamps • White cable guide TABLE F1 •...
  • Page 62 MSS Mana GT ABS Electrical system TABLE H 7. Rear ABS system oil pipes 8. Front ABS system oil pipes Be very careful when placing the rear pump-con- trol unit pipes, insert the two pipes in the respective lower clamps.
  • Page 63 MSS Mana GT ABS Electrical system TABLE K • Clamp that fixes the main cable har- ness, front lamp output, left light switch output and transmission control output. TABLE L 16. 2 clamps that fix the left light switch cable and the transmission control cable to the support.
  • Page 64 MSS Mana GT ABS Electrical system TABLE B - CABLE HARNESS FOR RELAY UNIT The shortest cables must be connected to the three closest relays TABLE C - FLYWHEEL CABLE HARNESS TABLE D 3. Fan connector 4. Middle clamp 5. Coil "A" connector 6.
  • Page 65 MSS Mana GT ABS Electrical system TABLE F 8. Cable harness laying through the cable guide TABLE G - Location of front cylinder injector TABLE H 9. Clamp 178x4 (7x0.16) TABLE I 10a. Gearbox starter motor connection 10b. Pulley sensor connection 11.
  • Page 66 MSS Mana GT ABS Electrical system TABLE L 12. Clamp to chassis fastening the three cables 13. Black clamps 98x2 (3.86x0.08) TABLE M - Locate gear switch on crankcase 14. Switch "D" TABLE N - Starter motor cable 15. Black clamps 98x2 (3.86x0.08)
  • Page 67 MSS Mana GT ABS Electrical system TABLE O 16. Clamp to chassis TABLE P Procedure for the correct insertion of the ABS control unit connector The initial position of the lever that couples the connector must be as shown in the figure.
  • Page 68 MSS Mana GT ABS Electrical system TABLE P3 Fit the housing. TABLE Q - FITTING OPTION WITH PICK-UP DIVIDER CABLE HARNESS 1. Pick-up divider cable harness. 2. Fasten the cable harness with a clamp. 3. Signal regulator exit with WHITE tape.
  • Page 69 MSS Mana GT ABS Electrical system TABLE R 19. The light switch connections must be placed on the chassis pipe 20. The flywheel cable passes under the main ca- ble harness Note: where indicated, fasten with a 290 black clamp on the reference position.
  • Page 70 MSS Mana GT ABS Electrical system TABLE V - Ground to chassis connection TABLE Z 22. Clamp to chassis that locks the fuel pipe and the pulley sensor TABLE ZA 23. Black clamp 178x4 (7.008x0.157) TABLE ZB ELE SYS - 70...
  • Page 71 MSS Mana GT ABS Electrical system TABLE ZC TABLE ZD Red and Blue - Rear cylinder H.V cables laying Yellow - Temperature sensor cable laying TABLE ZE Red - glove-box light cable harness At the centre of the figure, glove-box light connec- Note - fasten the cable harness with a 178x4 (7.008x0.157) black clamp...

  • Page 72: Back Side

    MSS Mana GT ABS Electrical system TABLE ZG The lambda probe and rear stop switch ca- bles must pass BEHIND the braking system pipes Back side TABLE A 1. Clamp to chassis Perform cable taping where indicated by the ar- row.
  • Page 73 MSS Mana GT ABS Electrical system Note - The sensor cable must pass ABOVE the brake pipe. TABLE D 2 black nylon clamps ELE SYS - 73...

  • Page 74: General Wiring Diagram

    MSS Mana GT ABS Electrical system General wiring diagram 1. MULTIPLE CONNECTORS 2. PULLEY POSITION SENSOR 3. START-UP CONTROL RELAY 4. PULLEY SPEED SENSOR ELE SYS - 74...
  • Page 75 MSS Mana GT ABS Electrical system 5. LIGHT LOGIC RELAY 6. RIGHT LIGHT SWITCH 7. HIGH-BEAM BULB 8. HORN 9. LEFT LIGHT SWITCH 10.AMBIENT AIR TEMPERATURE SENSOR 11.Instrument panel 12.INSTRUMENT PANEL DIAGNOSIS 13.KEY SWITCH 14.IMMOBILIZER AERIAL 15.REAR RIGHT TURN INDICATOR 16.REAR LIGHT ASSEMBLY...
  • Page 76 MSS Mana GT ABS Electrical system 43.REAR CYLINDER OUTER SPARK PLUG 44.FRONT CYLINDER DOUBLE COIL 45.REAR CYLINDER DOUBLE COIL 46.FRONT CYLINDER INJECTOR 47.REAR CYLINDER INJECTOR 48.PINION SPEED SENSOR 49.FALL SENSOR 50.PICK-UP 51.PICK-UP WIRE SHIELDING 52.ECU 53.FRONT LEFT TURN INDICATOR 54.TAIL LIGHT BULB 55.LOW-BEAM BULB...

  • Page 77: Checks And Inspections

    MSS Mana GT ABS Electrical system 81.HEATED HANDGRIP UNIT CAUTION THE ELECTRICAL SYSTEM IN THIS VEHICLE CAN BE SLIGHTLY DIFFERENT, DEPENDING ON THE SERIAL NUMBER, SPECIFICALLY IN THE LAYOUT OF THE GLOVE-BOX LIGHT SWITCH CONNECTIONS. THE DIFFERENCES ARE HIGHLIGHTED ON THE DIAGRAM BY TWO TYPES OF LINES, DIFFER- ENT AND ALTERNATE BETWEEN THEM: •...

  • Page 78: Service Alarm

    MSS Mana GT ABS Electrical system 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.
  • Page 79 MSS Mana GT ABS Electrical system Given this, and for some kinds of problems, the engine can be started only if the side stand is up. If there is an immobilizer failure at ignition, the instrument panel requests you to enter a user code. If the code is entered correctly, the instrument panel signals the failure by displaying the SERVICE icon and the red general warning light comes on.
  • Page 80 MSS Mana GT ABS Electrical system Turn indicator malfunction When the instrument panel detects a failing turn indicator, the turn indicator warning light flashes twice as fast and the problem is signalled on the digital display. Alarms - transmission In case of alarms for gearshift controls and mode...
  • Page 81 MSS Mana GT ABS Electrical system Worn belt alarm The alarm for a worn belt indicates excessive wear for that belt. There are two priority levels: • Low-priority alarm: the display shows the word BELT but the alarm warning light is off.
  • Page 82 MSS Mana GT ABS Electrical system 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:...
  • Page 83 MSS Mana GT ABS 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 - -...
  • Page 84 MSS Mana GT ABS Electrical system • ENTER THE CODE After entering the correct code, the following message should be shown on the display: • INSERT THE X KEY • INSERT THE X+1 KEY At least one key must be programmed for the next start-ups. If no other key is inserted within 20 seconds or if there is no power or after the fourth key is programmed, the procedure finishes and all the functions of the vehicle and the instrument panel must be enabled (even if only one key has been programmed).
  • Page 85 MSS Mana GT ABS 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.
  • Page 86 MSS Mana GT ABS 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...

  • Page 87: Auxiliary Fuses

    MSS Mana GT ABS 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.

  • Page 88: Control Unit

    MSS Mana GT ABS Electrical system The hydraulic pump, the solenoid valves and the sensors are activated by a 20A main fuse. Control unit MARELLI CONTROL UNIT Function It manages injection/ignition, the system safety checks and the self-diagnosis function. Location: •...

  • Page 89: Control Unit Removal

    MSS Mana GT ABS Electrical system P0606 Microprocessor - circuit not operational. Error cause • Possible internal control unit error. Also check the control unit supply and ground connec- tions. Troubleshooting • If the power supply and ground connections are connected correctly, replace the injection control unit.

  • Page 90: Speed Sensor

    MSS Mana GT ABS Electrical system Speed sensor VEHICLE FRONT SPEED SENSOR FUNCTION:To indicate the vehicle speed by read- ing the front wheel turning speed. OPERATION / OPERATING PRINCIPLE:Magne- toresistive sensor: a square-wave pulse is gener- ated with voltage approx. between 11.55 V and 11.25 V...
  • Page 91 MSS Mana GT ABS Electrical system Troubleshooting: Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone wheel is dirty, deformed or wrongly fixed. If any of this happens, replace the tone wheel. Otherwise, replace the speed sensor.
  • Page 92 MSS Mana GT ABS Electrical system REMOVAL LOCATION ON THE VEHICLE:on the fork, left side, under the parking brake calliper support. CONNECTOR LOCATION (if available): under the saddle, right side. PINS • PIN 1- Ground connection (yellow) • PIN 2 - Power supply voltage/Output...

  • Page 93: Engine Rpm Sensor

    MSS Mana GT ABS Electrical system Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed.
  • Page 94 MSS Mana GT ABS Electrical system 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"...

  • Page 95: Engine Temperature Sensor

    MSS Mana GT ABS Electrical system Engine temperature sensor ENGINE TEMPERATURE SENSOR Function it tells the engine temperature to the control unit so as to optimise its operation. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature).

  • Page 96: Intake Air Temperature Sensor

    MSS Mana GT ABS Electrical system • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 5 of connector A (BROWN). If shorted to negative: voltage equal to zero has been detected. In both cases, recovery function.
  • Page 97 MSS Mana GT ABS Electrical system • on the vehicle: on throttle body • on connector sensor: on throttle body Electrical characteristics: • Resistance at 0°: 5.9 kΩ ± 5% • Resistance at 10°: 3.8 kΩ ± 5% • Resistance at 20°: 2.5 kΩ ± 5% •...

  • Page 98: Lambda Sensor

    MSS Mana GT ABS Electrical system 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.
  • Page 99 MSS Mana GT ABS Electrical system 3. Heater ground connection (white) 4. Heater power supply (white) 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"...
  • Page 100 MSS Mana GT ABS Electrical system • 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;...
  • Page 101 MSS Mana GT ABS Electrical system 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.

  • Page 102: Fuel Pump

    MSS Mana GT ABS Electrical system • 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;...
  • Page 103 MSS Mana GT ABS Electrical system 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;...
  • Page 104 MSS Mana GT ABS Electrical system 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"...
  • Page 105 MSS Mana GT ABS Electrical system • 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;...

  • Page 106: Throttle Body

    MSS Mana GT ABS Electrical system Throttle body THROTTLE BODY • Function To tell the position of the throttle to the throttle control unit. Operation / Operating principle The throttle position sensor works as a variable resistance according to the throttle rotation.

  • Page 107: Reset Procedure

    MSS Mana GT ABS Electrical system 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...
  • Page 108 MSS Mana GT ABS Electrical system Connector location: on the sensor Pin-out: 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.
  • Page 109 MSS Mana GT ABS Electrical system Side stand sensor SIDE STAND SENSOR Function It tells the side stand position to the control unit. Operation / Operating principle If vehicle speed is equal to zero and with the stand down, start-up is attempted, a restriction to engine revolutions is activated.

  • Page 110: Bank Angle Sensor

    MSS Mana GT ABS Electrical system • 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;...
  • Page 111 MSS Mana GT ABS Electrical system 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...
  • Page 112 MSS Mana GT ABS Electrical system 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"...
  • Page 113 MSS Mana GT ABS Electrical system Function Radiator fan and coolant - Operation. Operation / Operating principle When the control unit detects a temperature above 100 °C, it closes the fan control relay pickup circuit to ground until the temperature falls to 97 °C.

  • Page 114: Electric Lock

    MSS Mana GT ABS Electrical system Electric lock ELECTRIC LOCK Function To open the helmet compartment. Level in wiring diagram:Services. Location: • on the vehicle: under key block, left side • connector: on electric lock Electrical characteristics: • 150 Ohm +/- 20 % Pin-out: 1.
  • Page 115 MSS Mana GT ABS Electrical system • connector: right side, under helmet compartment, along upper frame. Electrical characteristics: • STOP position: the circuit is open • RUN position: closed circuit (continui- Pin-out: 1. Green/orange cable: ground connection 2. Yellow/grey cable: voltage 12V THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS;...
  • Page 116 MSS Mana GT ABS Electrical system Transmission control unit Function It controls the TRANSMISSION system. Operation / Operating principle It receives information from the sensors connected to it and, via CAN line communication with the instrument panel and the injection control unit, it controls the predetermined operating strategies for the position of the driving pulley in order to obtain the gear ratio requested by the user (manual transmission) or expected according to the kind of calibration of the selected gear (automatic transmission).
  • Page 117 MSS Mana GT ABS Electrical system Example value: °C There is a sensor inside the control unit. AXONE: STATUSES AXONE / AUTOMATIC TRANSMISSION system - ECU operation status Example value:automatic/manual/from manual to automatic/from automatic to manual/semiautomatic/ start-up/power latch/error General ECU operation status.
  • Page 118 MSS Mana GT ABS Electrical system EEPROM error - Code 9009 - transmission reset not carried out/ EEPROM access error Error cause • If the transmission has not been reset: the potentiometer reset or belt reset procedures have not been successful or a new transmission ECU has been fitted without resetting the trans- mission.
  • Page 119 MSS Mana GT ABS Electrical system 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).
  • Page 120 MSS Mana GT ABS Electrical system 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"...
  • Page 121 MSS Mana GT ABS Electrical system • Track resistance (pin 1-5 or 2-3): 1.5 kΩ. • Signal resistance (pin 4-5 or 3-6): Min 1.0 kΩ (released sensor) - Max. 2.5 kΩ (rotated sensor) Pin-out: 1. Track 1 ground (Green/Grey - Digitek Pin 2.
  • Page 122 MSS Mana GT ABS Electrical system Example value:2.09 mm Current gap, compared to the lower mechanical stop position, based on the potentiometer track 2: to make sure that the read value is correct, check the status of the driving pulley position Potentiometer: track 2.
  • Page 123 MSS Mana GT ABS Electrical system 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"...
  • Page 124 MSS Mana GT ABS Electrical system 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;...
  • Page 125 MSS Mana GT ABS Electrical system 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).
  • Page 126 MSS Mana GT ABS Electrical system 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"...
  • Page 127 MSS Mana GT ABS Electrical system 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).
  • Page 128 MSS Mana GT ABS Electrical system 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"...

  • Page 129: Gearshift Pedal

    MSS Mana GT ABS Electrical system expected values, check the continuity of the yellow/pink cable and the ground connection and then restore the cable harness. Gearshift pedal PEDAL GEARSHIFT CONTROL Function To tell the transmission ECU that the driver wishes to change the variator transmission ratio (gear shift in manual gear mode).
  • Page 130 MSS Mana GT ABS Electrical system • 4 - supply + 12 V (green - black/yellow) • 8 - supply + 12 V (yellow - blue/yellow) 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"...
  • Page 131 MSS Mana GT ABS Electrical system A7: if voltage is below 1 V, it means that on the black/yellow cable there is a short circuit to ground; if the voltage is above 1 V (approximately battery voltage), replace the gear upshift...
  • Page 132 MSS Mana GT ABS Electrical system 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;...
  • Page 133 MSS Mana GT ABS Electrical system Electrical specifications Gear upshift: • 0 Ohm, between PIN 2 and PIN 1 • infinite resistance between PIN 2 and PIN 5 Gear downshift: • 0 Ohm between PIN 3 and PIN 8 •...
  • Page 134 MSS Mana GT ABS Electrical system • There is a malfunction in the handlebar gear upshift control. Troubleshooting • If, besides the error, the status of "Handlebar gear upshift control" indicates "Invalid data": the instrument panel waits to detect a voltage above approximately 1 V at one of either PINS and at the same time a voltage below approximately 1 V on the other PIN;...
  • Page 135 MSS Mana GT ABS Electrical system • 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;...
  • Page 136 MSS Mana GT ABS Electrical system Function By means of a transmission gear, it allows the rotation of the driving pulley control bushing which in turn moves the driving half-pulley axially. Operation / Operating principle DC motor with pulse activation (duty cycle). The rotation in both directions is controlled by the control unit by inverting the power supply polarity.
  • Page 137 MSS Mana GT ABS Electrical system 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.
  • Page 138 MSS Mana GT ABS Electrical system By means of a transmission gear, it allows the rotation of the driving pulley control bushing which in turn moves the driving half-pulley axially. Operation / Operating principle DC motor with pulse activation (duty cycle). The rotation in both directions is controlled by the control unit by inverting the power supply polarity.
  • Page 139 MSS Mana GT ABS Electrical system 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.
  • Page 140 MSS Mana GT ABS Electrical system 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...
  • Page 141 MSS Mana GT ABS Electrical system BLUE "B" CONNECTOR 1. Start-up control output 2. - 3. - 4. Control unit direct power supply 5. Water temperature sensor input 6. Auxiliary injection relay control output 7. - 8. - 9. - 10.-...
  • Page 142 MSS Mana GT ABS Electrical system 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...
  • Page 143 MSS Mana GT ABS Electrical system Transmission control unit TRANSMISSION ECU PIN OUT A1 - / A2 - Track 1 driving pulley position sensor input A3 - Gear UP pedal sensor normally open input A4 - Track 2 driving pulley position sensor voltage output...
  • Page 144 MSS Mana GT ABS Electrical system Dashboard INSTRUMENT PANEL PIN OUT GREY CONNECTOR PIN 1 - + Key PIN 2 - Right indicator control PIN 3 - * PIN 4 - High-beam input PIN 5 - gear UP normally open input...

  • Page 145: Abs Modulator

    MSS Mana GT ABS Electrical system PIN 26 - CAN H PIN 27 - CAN L PIN 28 - ABS Warning light input PIN 29 - * PIN 30 - Sensors ground PIN 31 - + Battery PIN 32 - Rear left turn indicator activation...
  • Page 146 MSS Mana GT ABS Electrical system • If the initial position of the connector and the driving lever is not that shown in fig. 1, the connector will not be prop- erly coupled and the distance meas- ured will be greater (12 mm approx.
  • Page 147 MSS Mana GT ABS Electrical system • The transmission ECU cannot send CAN signals; it receives signals from the instrument panel and the injection control unit: the control unit may need replacing. Troubleshooting • Replace transmission ECU. CAN line to instrument panel Code 9007 - no signal Error cause •...
  • Page 148 MSS Mana GT ABS Electrical system 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;...

  • Page 149: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...

  • Page 150: Vehicle Preparation

    MSS Mana GT ABS Engine from vehicle Vehicle preparation • Rest the vehicle on its rear centre stand. • Remove the helmet compartment. • Remove the radiator. • Remove the expansion tank. • Disconnect the lambda probe connec- tor. •...
  • Page 151 MSS Mana GT ABS Engine from vehicle • Disconnect the two sensors. • Remove the clamp. • Undo and remove the four upper fixing screws. ENG VE - 151...
  • Page 152 MSS Mana GT ABS Engine from vehicle • Remove the upper cover of the trans- mission cooling housing. • Undo and remove the two lower fixing screws. • Undo and remove the internal fixing screw. • Undo and remove the screw fixing the gearshift lever.
  • Page 153 MSS Mana GT ABS Engine from vehicle • Undo and remove the lower screw. • Remove the left passenger footrest support. • Remove the transmission cooling cov- • Undo and remove the starter motor supply cable fixing nut. • Slide off the starter motor power supply cable.
  • Page 154 MSS Mana GT ABS Engine from vehicle • Undo and remove the screw fixing the speed sensor. • Remove the speed sensor. • Undo and remove the two screws fixing the stand sensor. • Remove the stand sensor. • Undo and remove the gear sensor fix- ing screw.
  • Page 155 MSS Mana GT ABS Engine from vehicle • Remove the variator motor cover. • Undo and remove the two fixing screws. • Remove the variator motor. • Disconnect the horn connectors. ENG VE - 155...
  • Page 156 MSS Mana GT ABS Engine from vehicle • Disconnect the yellow cable connec- tor. • Remove the connector of the voltage regulator cable harness. • Remove the ground lead. • Disconnect the intake air sensor from the throttle body. ENG VE - 156...
  • Page 157 MSS Mana GT ABS Engine from vehicle • Disconnect the temperature sensor from the throttle body. • Remove the two retaining straps. • Disconnect the timing sensor. • Working on the left side, slide off the spark plug tube. •...
  • Page 158 MSS Mana GT ABS Engine from vehicle • Disconnect the front coil connector. • Release the coil ground lead. • Disconnect the rear coil connector. • Slide off the six relays from their seats. ENG VE - 158...
  • Page 159 MSS Mana GT ABS Engine from vehicle • Release the water bulb. • Undo and remove the fixing screw and collect the washer. • Release the two quick-release joints for fuel delivery and return. • Remove the injector connectors. ENG VE - 159...
  • Page 160 MSS Mana GT ABS Engine from vehicle • Disconnect the ignition connectors. • Remove the oil pressure sensor and release it from the seal clamp. • Remove the exhaust. • Slide off the rubber protection. • Undo and remove the cable holder sheath fixing nut.

  • Page 161: Removing The Engine From The Vehicle

    MSS Mana GT ABS Engine from vehicle Removing the engine from the vehicle • Carry out the operations described un- der Vehicle preparation. • Support the vehicle by means of belts and a hoist. • Remove the saddle. • Remove the passenger grab handle.
  • Page 162 MSS Mana GT ABS Engine from vehicle • Unscrew and remove the lower nut. • Undo and remove both brake plate fix- ing screws. • Unscrew and remove the fixing nut. • Collect the washer. • Working on the right side, hold the fork and with a rubber hammer, collect the fork pin.
  • Page 163 MSS Mana GT ABS Engine from vehicle • From behind, slide off the fork unit to- gether with gear and chain. • Working on the left side, unscrew and remove the fixing nuts of the engine bolts. • Working on the right side, slide off the engine bolts.
  • Page 164 MSS Mana GT ABS Engine from vehicle ENG VE - 164...

  • Page 165: Index Of Topics

    INDEX OF TOPICS NGINE...

  • Page 166: Starter Motor

    MSS Mana GT ABS Engine This section describes the operations to be carried out on the engine and the tools required. Starter motor The starter motor is sold as a complete part. Before deciding on its replacement, it is necessary...

  • Page 167: Removing The Starter Motor

    MSS Mana GT ABS Engine 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. Removing the starter motor - Disconnect the electric terminals.
  • Page 168 MSS Mana GT ABS Engine Also check the diameter of the bearings on the fly- wheel cover and on the engine crankcase. 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;...
  • Page 169 MSS Mana GT ABS Engine Fitting the idle gear - Grease the gear housing on the engine crank- case. - Fit the intermediate gear with torque limiter. Removing the starter gear - Check that there is no wear or abnormal marks on the «rollers»...
  • Page 170 MSS Mana GT ABS 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. Installing the starter gear - Lubricate the internal bushing and the starter ring gear hub surface.

  • Page 171: Generator Side

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

  • Page 172: Magneto Flywheel Removal

    MSS Mana GT ABS Engine Magneto flywheel removal - Lock the flywheel and tighten the nut fixing it to the shaft with the specific tool. Specific tooling 020713Y Flywheel extractor - Fit the specific extractor, and unlock the flywheel operating the tool.

  • Page 173: Removing The Stator

    MSS Mana GT ABS Engine - Remove the starting ring gear. - Undo the five fixing screws and remove the oil pump compartment closing bulkhead. - Remove the intermediate gear. Removing the stator - Undo the 3 fixing screws and remove the stator with the cable harness.
  • Page 174 MSS Mana GT ABS Engine Inspecting the cover components - Check the condition of the stator and of the rele- vant cable harness. - Check the continuity between the 3 phases. NOTE THE VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERA- TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.

  • Page 175: Checking The Starter Clutch

    MSS Mana GT ABS Engine Flywheel components check - Check that the magnets are in good conditions. - Check that the magnet support cage is not de- formed or broken. Checking the starter clutch - Make sure the freewheel faying surfaces are in good condition.

  • Page 176: Stator Installation

    MSS Mana GT ABS Engine Stator installation - Fit the stator together with the cable harness, fix- ing the 3 screws to the prescribed torque. NOTE INSERT THE SEALING GASKET OF THE RUBBER WIRING INTO THE SPECIFIC SEAT ON THE CRANKCASE.

  • Page 177: Removing The Intake Manifold

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

  • Page 178: Removing The Head Cover

    MSS Mana GT ABS Engine - Remove the inlet manifold. Removing the head cover - Undo the 6 special screws with stop and the rel- evant rubber gaskets. - Remove the tappet cover with the relevant gas- ket. Removing the timing control...

  • Page 179: Removing The Cylinder Head

    MSS Mana GT ABS Engine - Lock the timing system gear with the specific tool, undo the central fixing screw and collect the wash- - Release the chain from the sprocket and be care- ful that it does not fall inside the transmission housing.
  • Page 180 MSS Mana GT ABS Engine - The operations are described only once, but they are valid for both heads. - Remove the spark plugs. - Unscrew the two fixing nuts and collect the wash- ers. - Undo the spark plug side screw.

  • Page 181: Cylinder Head

    MSS Mana GT ABS Engine - Loosen the 4 head-cylinder fixing nuts in two or three stages and in a criss-crossed sequence. - Remove the head, the two centring dowels, the gasket and the lower chain guide slider. Cylinder head...

  • Page 182: Removing The Valves

    MSS Mana GT ABS Engine Removing the valves - 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).
  • Page 183 MSS Mana GT ABS Engine - Remove the spring supports. NOTE BLOW THE SEATS WITH COMPRESSED AIR TO FACILI- TATE REMOVING THE SPRING SUPPORTS. Checking the overhead camshaft - Check the camshaft bearings for signs of abnor- mal wear or scores.
  • Page 184 MSS Mana GT ABS Engine MINIMUM DIAMETER ALLOWED Specification Desc./Quantity Bearing A Ø: 41.910 mm Bearing B Ø: 19.940 mm - Using a gauge, measure the height of the cams. LIMITS ALLOWED Specification Desc./Quantity Inlet: 33.740 mm Outlet: 33.170 mm Standard axial clearance: 0 ÷...

  • Page 185: Checking The Rocker Arms

    MSS Mana GT ABS Engine Checking the rocker arms - Check the inside diameter of each rocking lever. Characteristic Standard diameter: Ø 13 + 0.026 +0.015 mm Valve check - Remove any carbon deposits from the valve seats. - Check the width of the mark on the valve seat «V»...
  • Page 186 MSS Mana GT ABS Engine STANDARD DIAMETER Specification Desc./Quantity Inlet: 4.987 ÷ 4.972 mm Outlet: 4.975 ÷ 4.960 mm MINIMUM DIAMETER ALLOWED Specification Desc./Quantity Inlet: 4.96 mm Outlet: 4.945 mm - Calculate the clearance between the valve and its guide.
  • Page 187 MSS Mana GT ABS Engine - Check that there are no signs of wear on the fay- ing surface with the set screw articulated end and that its surface is smooth and not concave. - If no anomalies are found during the above checks, the same valves can be reused.

  • Page 188: Checking The Valve Guides

    MSS Mana GT ABS Engine Inspecting the springs and half-cones - Check that the upper and lower supporting spring plates, the cotters and the oil seal show no sign of abnormal wear. Otherwise, replace the compo- nent. - Measure the unloaded spring length.

  • Page 189: Checking The Cylinder Head

    MSS Mana GT ABS Engine - After measuring the valve guide diameter and the valve stem diameter, check the clearance be- tween guide and stem. EXHAUST Specification Desc./Quantity Standard clearance: 0.025 - 0.052 mm Limit allowed: 0.09 mm INTAKE Specification Desc./Quantity...

  • Page 190: Installing The Valves

    MSS Mana GT ABS Engine Measure the camshaft seat bearings and rocking lever support pins with a bore meter HEAD BEARINGS Specification Desc./Quantity Bearing "A" 42 +0.025 Bearing "B" 19.5 -0.2 Bearing "C" 13 +0.018 Installing the valves - Place the valve spring supporting plates on the head.
  • Page 191 MSS Mana GT ABS Engine - Lubricate the oil seals and the valve guides. - Fit the valves, the springs and the plates. - With the specific tool fitted with the appropriate adaptor, compress the springs and fit the cotters in their seats.

  • Page 192: Checking The Chain

    MSS Mana GT ABS Engine Timing Removing the chain tensioner - Remove the central screw, collect the washer and the spring carefully. Checking the chain tensioner - Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring.

  • Page 193: Checking The Sliders

    MSS Mana GT ABS Engine IF THE CHAIN HAS DAMAGED THE PINION, REPLACE THE CRANKSHAFT. Checking the sliders - Check that the guide slider and the tensioner pad are not excessively worn. - Replace the sliders if they are worn.
  • Page 194 MSS Mana GT ABS Engine AP8140595 Axone + battery charger (230V 50Hz) AP8202311 Axone + battery charger (110V 60Hz) If the values do not correspond, check: - distribution timing - rpm timing sensor - injection control unit Timing - With the TORX wrench, remove the timing check cap.
  • Page 195 MSS Mana GT ABS Engine - Once the reference marks are aligned as indica- ted with the reference marks on the valve cam cap, tighten the screw with the washer to the prescribed torque. Locking torques (N*m) Timing system crown screw on camshaft...

  • Page 196: Removing The Cylinder

    MSS Mana GT ABS Engine - Turn the crankshaft in the normal operating di- rection until the reference mark "A" on the tone wheel is aligned with the rear head reference, so as to take the front piston to the top dead centre.

  • Page 197: Disassembling The Piston

    MSS Mana GT ABS Engine Disassembling the piston - Remove the head. - Remove the 2 piston pin snap rings operating through the specific slots. - Slide off the pin and remove the piston. NOTE USE PAPER OR A CLOTH TO CLOSE THE CYLINDER...

  • Page 198: Cylinder Check

    MSS Mana GT ABS Engine CYLINDER CHECK Specification Desc./Quantity 43 mm (1.69 in) Cylinder Ø C 88 mm (+0.018; -0.01) mm (3.4645 in (+0.0007; -0.00039) in) Characteristic Maximum run-out allowed: 0.05 mm Checking the piston - Measure the piston diameter according to value A and check that the size measured is within the specified range.

  • Page 199: Piston Check

    MSS Mana GT ABS Engine PISTON CHECK Specification Desc./Quantity Piston Ø P (aluminium cylinder) 87.968 mm (+/- 0.014 mm) (3.4632 in (+/- 0.0005)in) 10 mm (0.393 in) Piston Ø P (iron cast cylinder) 87.947 mm (+/- 0.014 mm) (3.4625 in (+/- 0.0005)in) 10.5 mm (0.413 in)
  • Page 200 MSS Mana GT ABS 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.

  • Page 201: Installing The Cylinder

    MSS Mana GT ABS Engine any case, the tapered side of the ring must be fac- ing opposite the piston crown. - Fit the top compression ring in the direction forced by the housing. - It is advisable to use a fitter to help fitting the rings.
  • Page 202 MSS Mana GT ABS Engine - Check that the centring dowel is correctly fitted and push the cylinder until it stops. Selecting the base gasket - First fit the piston into the cylinder, without any base gasket. - Fit a dial gauge on the specific tool with the short union, as shown in the figure.

  • Page 203: Installing The Cylinder Head

    MSS Mana GT ABS Engine - 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.
  • Page 204 MSS Mana GT ABS Engine - Fit the chain guide slider. - Fit the two centring dowels between head and cylinder. NOTE THE FIGURE SHOWS THE FITTING POSITION OF THE TWO CENTRING DOWELS BETWEEN HEAD AND CYLINDER. THE DIRECTION OF FITTING FOR THE GASKET IS FORCED BY THESE DOWELS.
  • Page 205 MSS Mana GT ABS Engine *** First, apply a preliminary torque of 10 Nm in a criss-crossed sequence. - tighten to a torque of 13 Nm + 90° in a criss- crossed sequence. - tighten again at 90° in a criss-crossed sequence.
  • Page 206 MSS Mana GT ABS Engine - Tighten the two internal screws on the head, tim- ing system side, to the prescribed torque. Locking torques (N*m) Exhaust/ intake head fixing nuts 10 - 12 - Fit the coolant temperature sensor with the wash- er and tighten it to the prescribed torque.
  • Page 207 MSS Mana GT ABS Engine - Fit the pins and the rocking levers operating on the transmission side. - Lubricate the 2 rocking levers through the holes at the top. - Clean the camshaft by blowing short blasts of compressed air, especially the groove that holds the retaining plate.
  • Page 208 MSS Mana GT ABS Engine - Fitting the head and the components of the front cylinder timing system vary if the spacer is fitted instead of the tone wheel and id the reference "A" instead of "P" is in the timing system gear.

  • Page 209: Installing The Intake Manifold

    MSS Mana GT ABS Engine Installing the intake manifold - When refitting always install, on both cylinders between the inlet manifold and the cylinder head, the inlet manifolds gasket to delete the air leak- ages related to the deformation of the rubber mani- fold by aggressive petrol.

  • Page 210: Crankcase - Crankshaft

    MSS Mana GT ABS 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»...
  • Page 211 MSS Mana GT ABS Engine Splitting the crankcase halves - Working from the transmission side, unscrew the six screws «A» and collect the washers. - Turn the support so as to operate on the flywheel side. - Undo the three screws fixing it to the support, collect the washers and remove the three centring bushings.
  • Page 212 MSS Mana GT ABS Engine - Detach the crankcase half keeping the crankshaft connected to crankcase half on the transmission side. - Remove the coupling gasket. ENG - 212...

  • Page 213: Removing The Crankshaft

    MSS Mana GT ABS Engine - Remove the tip. Specific tooling 020664Y Flywheel side crankshaft fitting tip Removing the crankshaft - Fit the specific tool on the transmission side crankshaft, paying special attention that the tool matches the shaft perfectly.
  • Page 214 MSS Mana GT ABS Engine - Hold the tip with one hand and the crankshaft with the other, pull the crankshaft upwards. - Pull out the tip from the bushings, remove the crankshaft. - Once the crankshaft has been removed it is possible to remove the timing chain on the transmission side.
  • Page 215 MSS Mana GT ABS Engine 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.
  • Page 216 MSS Mana GT ABS Engine Inspecting the crankshaft plain bearings - In order to obtain proper bushing lubrication, make sure there are both an outstanding lubrica- tion pressure (4.5 bar) and a good oil flow rate. To that end, the bushings must be correctly posi- tioned so as not to obstruct the oil supply channels.

  • Page 217: Installing The Crankshaft

    MSS Mana GT ABS Engine - Bushings are subdivided into 3 categories according to their thickness. (See chart on the "Specifica- tions" chapter) Installing the crankshaft - Fit the driven pulley shaft and the universal joint axle. - Fit the specific tool on the transmission side crankshaft, paying special attention that the tool matches the shaft perfectly.
  • Page 218 MSS Mana GT ABS Engine - Fit the crankshaft with the driving pulley axle in- side the transmission side crankcase halves. NOTE PLACE THE CONNECTING RODS CORRECTLY. - At the same time, hold with one hand the crank- shaft and with the other the tip until the crankshaft stops on the crankcase half.
  • Page 219 MSS Mana GT ABS Engine - Fit the specific tool on the flywheel side crank- shaft, paying special attention that the tool match- es the shaft perfectly. CAUTION FAILURE TO OBSERVE THIS RULE CAN DAMAGE THE MAIN BUSHINGS. Specific tooling 020664Y Flywheel side crankshaft fitting tip - Lubricate the external surface of the tip with petroleum jelly grease.
  • Page 220 MSS Mana GT ABS Engine - Remove the tip. Specific tooling 020664Y Flywheel side crankshaft fitting tip ENG - 220...
  • Page 221 MSS Mana GT ABS Engine Refitting the crankcase halves - Tighten the seven screws «B» with the copper washers as far as they will go. - Tighten the twelve screws «C» with the washers as far as they will go.

  • Page 222: General Characteristics

    MSS Mana GT ABS Engine Conceptual diagrams LUBRICATION CIRCUIT Specification Desc./Quantity FRONT HEAD CAMSHAFTS REAR HEAD CAMSHAFTS CONNECTING ROD BUSHINGS FRONT PISTON LUBRICATION JET REAR PISTON LUBRICATION JET STARTING RING GEAR BUSHING LUBRICATION CRANKSHAFT BUSHINGS WATER PUMP CONTROL TRANSMISSION GEAR SHAFT...

  • Page 223: Diagnosis Guide

    MSS Mana GT ABS Engine - 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.

  • Page 224: Specific Tooling

    MSS Mana GT ABS 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.

  • Page 225: Oil Pressure Check

    MSS Mana GT ABS Engine 8 - If pressure lower than 1.3 ÷ 1.5 bar is measured. CONTINUE - point 9 9 - Replace the oil filter and repeat the pressure check with oil at 80°C. YES - point 10 NO point 13 10 - The failure is fixed.
  • Page 226 MSS Mana GT ABS 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.
  • Page 227 MSS Mana GT ABS Engine C. By-pass Removing - The lubrication system includes the pressure and scavenge pumps. - To operate the pressure pump, remove the bulkhead of the oil anti-backflow plate under the flywheel. - To operate on the scavenge pump, open the crankcase, and operate inside the crankcase half on the flywheel side.
  • Page 228 MSS Mana GT ABS Engine - Remove the oil pressure pump with the gasket. - Operating from inside: - Lock the oil scavenge pump axle, undo the fixing screw and collect the washer. - Remove the water pump control gear, undo the two indicated screws and collect the washers.
  • Page 229 MSS Mana GT ABS Engine - Remove the oil pump and the relevant gasket. - Undo the four indicated screws. - Remove the by-pass recovery duct with the gas- ket. Inspection - The procedure is described only once but it is valid for both pumps.
  • Page 230 MSS Mana GT ABS Engine - Undo the two screws and remove the oil pump cover. ENG - 230...
  • Page 231 MSS Mana GT ABS Engine - Slide off the shaft with the rotor driving pin. - Remove the two rotors and wash them thorough- NOTE VISUALLY INSPECT THAT ALL THE COMPONENTS ARE IN GOOD CONDITIONS. THERE MUST BE NO SIGNS OF WEAR OR SLIPPAGE.
  • Page 232 MSS Mana GT ABS Engine - Fit the assembled rotors inside the pump body, with the reference marks facing the inside. CAUTION ONCE THE ROTORS ARE FITTED INSIDE THE PUMP BODY, THE REFERENCE MARKS ON THEM MUST NOT BE VISIBLE.
  • Page 233 MSS Mana GT ABS Engine - Check the levelness of the two rotor surfaces and the pump body with a trued bar as an abutment plane as indicated in the figure. CAUTION FAILURE TO OBSERVE THESE RULES CAN CAUSE SE- RIOUS DAMAGE TO THE ENGINE.
  • Page 234 MSS Mana GT ABS Engine - Fit the oil scavenge pump and the bulkhead of the oil anti-backflow plate. - Tighten the two screws indicated to the prescri- bed torque. Locking torques (N*m) Screws fixing oil pump to crankcase 5 - 6 - Fit the water pump control gear on the oil pump shaft.
  • Page 235 MSS Mana GT ABS Engine - Fit the crankcase protecting the oil pump and tighten the two screws to the prescribed torque. Locking torques (N*m) Screws fixing oil pump to crankcase 5 - 6 - Fit the oil pump control crown and the driving chain.

  • Page 236: Automatic Transmission

    MSS Mana GT ABS Engine Automatic transmission Transmission cover - Remove the variator motor, the driven pulley rev- olution sensor and the driving pulley position sen- sor. CAUTION FOR VEHICLES INCLUDED IN THE FOLLOWING RANGE ZD4RC000_7S000002 - ZD4RC000_7S000737 IN ORDER TO FIT THE DRIVING PULLEY POSITION SEN- SOR CORRECTLY, SEE THE "Engine"...
  • Page 237 MSS Mana GT ABS Engine - Undo the thirteen screws fixing it to the engine crankcase. - Remove the nut and collect the washer. - Remove the transmission cover. CAUTION REPLACE THE TWO CONTROL BUSHING O-RINGS EACH TIME THE COVER IS REMOVED.

  • Page 238: Specific Tooling

    MSS Mana GT ABS Engine - Place the transmission cover on a wooden sur- face and use the special tool so that it is adequate- ly supported. - Extract the bearing with the specific tool. NOTE BELL MUST BE PLACED INTO THE TRANSMISSION COV-...
  • Page 239 MSS Mana GT ABS Engine Removing the bearing of the driving pulley control bushing - Undo and remove the three screws, the relevant washers and remove the bearing. Removing the bearings supporting the electric motor driving shafts - Remove the gear.
  • Page 240 MSS Mana GT ABS Engine - Fit the bearings on the specific tools and refit the new bearings. Specific tooling 020376Y Adapter handle 020441Y Oil seal punch 020455Y 10-mm guide for oil seal on water pump shaft Gearshift control shaft removal - Undo the screw and collect the two washers, the plate, the O-ring, the two balls and the spring.

  • Page 241: Removing The Clutch

    MSS Mana GT ABS Engine Removing the driving pulley Inspecting the clutch drum - Make sure that the clutch bell is not worn or dam- aged. - Measure the clutch bell inside diameter. NOTE CHECK THE ECCENTRICITY FOUND; IT SHOULD BE 0.2 MM MAX.
  • Page 242 MSS Mana GT ABS Engine - Screw until the clutch is completely disassem- bled. Inspecting the clutch - Check the thickness of the clutch mass friction material. Characteristic Minimum thickness allowed: 1 mm - The masses must not show traces of lubricants. If they do, check the driven pulley unit seals.
  • Page 243 MSS Mana GT ABS Engine - Remove the 4 guide pins. - Slide off the movable driven half-pulley. Removing the driven half-pulley bearing - Check there are no signs of wear or damage on the bushing; otherwise, replace the fixed driven half-pulley.
  • Page 244 MSS Mana GT ABS Engine - Remove the roller bearing with the specific tool, supporting the fixed half-pulley with the bell. Specific tooling 020376Y Adapter handle 020375Y 28 x30 mm Punch 020483Y 30-mm guide AP8140180 Extractor for bushings Inspecting the driven fixed half-pulley - Check that the belt contact surface is free from wear.
  • Page 245 MSS Mana GT ABS Engine Refitting the driven half-pulley bearing - Fit a new roller bearing with the specific tool. NOTE PLACE THE BEARING WITH THE WORDS AND THE BUILT- IN OIL SEAL FACING OUTWARDS. - Properly support the half-pulley to prevent damaging the threading.
  • Page 246 MSS Mana GT ABS Engine - Fit the half-pulley on the bushing being careful not to damage the top sealing ring. - Make sure the pins and collar are not worn and refit the pins and the collar. - Using a curved-spout grease gun, lubricate the driven pulley assembly with approximately 10 grams of grease.
  • Page 247 MSS Mana GT ABS Engine Refitting the clutch - Prepare the specific tool for the removal phase. - Preassemble the driven pulley unit. - Fit the driven pulley unit, the spring with sheath and clutch into the tool. CAUTION WHILE PERFORMING THESE OPERATIONS, AVOID CON-...
  • Page 248 MSS Mana GT ABS Engine - Screw the tool so as to separate the two half- pulleys. - Position the belt. - Unscrew until the tool frees from the half-pulley and remove it. ENG - 248...

  • Page 249: Removing The Driving Pulley

    MSS Mana GT ABS Engine Refitting the driven pulley - Fit the driving belt in driven pulley with the specific tool. - Fit the assembled unit on the shaft. See also Refitting the clutch Drive-belt - Make sure the driving belt is not damaged and does not show signs of abnormal wear.
  • Page 250 MSS Mana GT ABS Engine - Remove the movable pulley unit. - Remove the driven pulley with the belt. - Remove the clutch bell. - Remove the driving half-pulley. ENG - 250...
  • Page 251 MSS Mana GT ABS Engine - Remove the spacer. NOTE THE SPACER IS CONICAL, UPON REFITTING PAY ATTEN- TION TO INSERT IT WITH THE SMALLER DIAMETER FAC- ING THE INSIDE. - Undo the five fixing screws and remove the air switch.
  • Page 252 MSS Mana GT ABS Engine - Remove the complete advancement bushing. - Undo the four fixing screws and remove the bear- ing support. - Remove the slider support with the relevant slid- ers from the movable driving half-pulley. ENG - 252...
  • Page 253 MSS Mana GT ABS Engine Driving pulley components check - Check that the internal bushings are not abnor- mally worn and measure their inside diameter. CAUTION DO NOT LUBRICATE OR CLEAN BUSHINGS Characteristic Max. diameter admitted 40.050 mm Standard diameter 40.000 +0.034 -0.009 mm...
  • Page 254 MSS Mana GT ABS Engine - Check that the sliders are not worn. - The total clearance between slider and stud bolt should be between 0.01 and 0.1 mm at the place indicated in the figure. DO NOT EXCEED THE MAXIMUM CLEARANCE ALLOWED AS THIS CAN CAUSE NOISE PROBLEMS.
  • Page 255 MSS Mana GT ABS Engine - Fit the bearing support being careful with the dowel pin and tighten the four screws with Loctite 270. - Fit the advancement bushing. - Fit the stop washer and tighten the ring nut with the level surface facing upwards.
  • Page 256 MSS Mana GT ABS Engine - Grease the control bushing with suitable grease, as shown in figure. - Screw the control bushing to the complete mov- able driving half-pulley. Push the bushing and check that the bushing sliding axis and the slider support engage by means of the two teeth.
  • Page 257 MSS Mana GT ABS Engine 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 •...
  • Page 258 MSS Mana GT ABS Engine • Turn over the complete movable driv- ing half-pulley and insert the spacer until it stops. • Using a depth gauge, measure the pro- trusion of the spacer with respect to the upper edge of the movable driving half- pulley.
  • Page 259 MSS Mana GT ABS Engine Refitting the transmission cover - Follow the removal steps but in reverse order, using the specific tool and being careful to tighten to the prescribed torques. Locking torques (N*m) Driven pulley nut Internal transmission 153 - 187...
  • Page 260 MSS Mana GT ABS Engine End gear PINION UNIT AXLE BEARING FITTING - The toothed wheel (pinion unit axle), rotates on two bearings located on the two crankcase halves, for fitting follow these instructions. - Transmission side crankcase half: - Heat up the crankcase using the thermal gun.
  • Page 261 MSS Mana GT ABS Engine - 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 020655Y 62x68 mm Adaptor 020662Y 50 mm guide ENG - 261...
  • Page 262 MSS Mana GT ABS Engine PINION UNIT AXLE BEARING REMOVAL - The toothed wheel (pinion unit axle), rotates on two bearings located on the two crankcase halves, to replace follow these instructions. - Transmission side crankcase half: - Remove the driven pulley shaft axle and the toothed wheel.
  • Page 263 MSS Mana GT ABS Engine - Slide of the driven pulley shaft from one side and remove the oil seal from the other side with a screwdriver. - Remove the Seeger ring. - With the specific tool, remove the bearing.
  • Page 264 MSS Mana GT ABS Engine Inspecting the hub shaft - Check the two shafts for wear or distortions on the toothed surfaces, on the bearing housings and the oil seal positions. - If faults are found, replace the damaged parts.
  • Page 265 MSS Mana GT ABS Engine - Fit the Seeger ring. - From outside the transmission side crankcase half, fit the oil seal. Refitting the hub bearings - Place the two shafts as shown in the figure. ENG - 265...

  • Page 266: Index Of Topics

    INDEX OF TOPICS P SUPP OWER SUPPLY...

  • Page 267: Circuit Diagram

    MSS Mana GT ABS Power supply 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.
  • Page 268 MSS Mana GT ABS Power supply P SUPP - 268...
  • Page 269 MSS Mana GT ABS Power supply P SUPP - 269...
  • Page 270 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 271: Removing The Front Wheel

    MSS Mana GT ABS Suspensions Front Removing the front wheel Key: 1. Front wheel 3.5"x17" 2. Tubeless valve 3. Internal spacer 4. Bearing 5. Sealing ring 30x47x7 6. Seeger ring 7. Front wheel right external spacer 8. Front brake disc 9.
  • Page 272 MSS Mana GT ABS Suspensions • Unscrew the screws fixing the front mudguard and remove it. • Unscrew the screws fixing the front pli- ers and slide them off the disc. • Remove the wheel axle fixing nut. • Retrieve the sealing washer.

  • Page 273: Checking The Front Wheel

    MSS Mana GT ABS Suspensions • Tap the wheel axle slightly with a rub- ber mallet so that the hole on the op- posite side is exposed. • Remove the wheel axle by inserting a screwdriver in the holes on the pin.
  • Page 274 MSS Mana GT ABS Suspensions ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE. GASKETS • Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive wear.
  • Page 275 MSS Mana GT ABS Suspensions 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...

  • Page 276: Front Fork

    MSS Mana GT ABS Suspensions Front fork Diagram Key: 1. Fork right stem 2. Fork left stem 3. Sleeve 4. Spring 5. Preloading pipe 6. Right pumping member assembly 7. Left pumping member assembly 8. Sleeve cap assembly 9. O-ring 10.Rubber ring...
  • Page 277 MSS Mana GT ABS Suspensions 18.Ring 19.Guide bushing 20.Sliding bushing 21.Special washer 22.Screw M10x1.5 23.TE flanged screw M8x40 24.Spring Centring RONT FORK ARZOCCHI pos. Description Type Quantity Torque Notes Screws (fasten onto fork hubs) M8x40 25 Nm (18.44 lb ft)

  • Page 278: Removing The Fork Legs

    MSS Mana GT ABS Suspensions RONT FORK ACHS pos. Description Type Quantity Torque Notes Screws (fasten onto fork hubs) M8x40 25 Nm (18.44 lb ft) Bottom screw 30 Nm (22.13 lb ft) Loctite 242 20 Nm (14.75 lb ft) Nut on pumping member pin 20 Nm (14.75 lb ft)

  • Page 279: Draining Oil

    MSS Mana GT ABS Suspensions Draining oil NOTE THE FOLLOWING OPERATIONS REFER TO THE MARZOCCHI FORKS. NOTE THE STEMS ARE DIFFERENT. RIGHT STEM. • Using the appropriate tool fasten the stem in the vice. • Unscrew the top plug by using a span- ner.

  • Page 280: Specific Tooling

    MSS Mana GT ABS Suspensions • Remove the spring paying attention to drain the oil correctly from the spirals before taking it out. • Drain the oil of the fork by collecting the preload pipe. DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.
  • Page 281 MSS Mana GT ABS Suspensions • Drain the oil into a container of suitable capacity to collect fluids. DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE.
  • Page 282 MSS Mana GT ABS Suspensions • Using the specific tool, fixed to the pre- loading pipe, compress the spring and insert the separating plate on the lock nut of the cover. Specific tooling 020888Y Pliers for pre-fill pipe AP8140148 Spacer-piston separating plate •...
  • Page 283 MSS Mana GT ABS Suspensions • Remove the two washers. • Remove the spring allowing the oil to drip inside the stanchion. • Drain the oil into a container of suitable capacity to collect fluids, pumping out oil a few times.

  • Page 284: Disassembling The Fork

    MSS Mana GT ABS Suspensions • Being careful not to damage the stan- chion when placing it in a vice, in ver- tical position, using the appropriate protection. Specific tooling AP8140149 Protection for fitting operations • Unscrew the sleeve cap.
  • Page 285 MSS Mana GT ABS Suspensions • Drain the fork oil. • Remove the sleeve. • Remove the oil seal. • Remove the retainer ring. • Remove the dust gaiter SUSP - 285...
  • Page 286 MSS Mana GT ABS Suspensions • Remove the spacer bowl. • Remove the lower bushing (1), the spacer pipe (2) and the upper bushing (3). NOTE THE FOLLOWING OPERATIONS REFER TO THE SACHS FORKS. NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS.
  • Page 287 MSS Mana GT ABS Suspensions • Slide off the pumping member unit. • If necessary unscrew and remove the nut of the pumping member pin and re- move the retainer ring, the metal ring and three rubber rings. • Remove the dust guard using a screw- driver as a lever.
  • Page 288 MSS Mana GT ABS Suspensions • If necessary, remove the sliding bush- ing, guide bushing, ring, oil seal, Seeg- er ring and dust guard from the stem. NOTE THE FOLLOWING OPERATIONS REFER TO THE SHOWA FORKS. NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS.
  • Page 289 MSS Mana GT ABS Suspensions With the help of a second operator: • Hold the sleeve cap firmly. • Push the special tool down. • Take out the Seeger ring. With the help of a second operator: • Insert the special tool between the nut and the preloading pipe.
  • Page 290 MSS Mana GT ABS Suspensions • Slide off the preloading pipe together with the spring centring. • Be careful not to damage the stanchion when placing it in a vice, in horizontal position, using the appropriate protec- tions. Specific tooling AP8140149 Protection for fitting operations •...

  • Page 291: Checking The Components

    MSS Mana GT ABS Suspensions • Remove the dust guard using a screw- driver as a lever. • Remove the Seeger ring from inside the sleeve with the aid of a screwdriver. CAUTION DO NOT DAMAGE THE STEM DURING THE OPERATION.
  • Page 292 MSS Mana GT ABS Suspensions These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value.
  • Page 293 MSS Mana GT ABS Suspensions • Insert the upper bushing (3), the spacer pipe (2) and the lower bushing (1) in the sleeve. • Fasten the stem in the vice. • Insert the previous greased oil seal (4), the retainer ring (5), the dust gaiter (6) and the spacer bowl (7).
  • Page 294 MSS Mana GT ABS Suspensions • Remove the external oil seal grip and with specific tools push it to stop. • Refit the grip. 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.
  • Page 295 MSS Mana GT ABS Suspensions • Fit the Seeger ring on the sleeve seat. • Fit the dust gaiter. • If previously removed, insert in the pumping member pin the three rubber rings, the metal ring and the stop ring.

  • Page 296: Recommended Products

    MSS Mana GT ABS Suspensions • Fit the centring plate. • Fit the pumping member together with the centring plate in the sleeve. • Insert the special washer in the screw. • Scatter the screw thread with the spe- cific product.
  • Page 297 MSS Mana GT ABS Suspensions • Push the oil seal fitting special tool hard, applied towards the sleeve with the aid of the specific weight. Specific tooling AP8140146 Weight • Fit the Seeger ring on the sleeve seat. • Fit the dust gaiter.

  • Page 298: Filling Oil

    MSS Mana GT ABS Suspensions • Fit the centring plate. • Fit the pumping member together with the centring plate in the sleeve. • Insert the special washer in the screw. • Tighten the screw to the prescribed tor- que.
  • Page 299 MSS Mana GT ABS Suspensions • Fit the spring being careful to check that the tightened part faces upwards. • Compress the spring to be able to screw the cap till the end of the stroke. • Insert a spanner on the nut under the plug the cover allowing to tighten the plug to the tightening torque.
  • Page 300 MSS Mana GT ABS Suspensions • Fill the sleeve with the adequate quality and type of oil indicated on the recommended prod- ucts table. Characteristic Fork oil quantity (left stem) (Marzocchi) 505 cc (30.82 cu in) • Unscrew the plug manually until the stop.
  • Page 301 MSS Mana GT ABS Suspensions WARNING MOVE THE PUMPING ELEMENT SEVERAL TIMES UNTIL AIR BUBBLES ARE SEEN ON THE OIL SURFACE. THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS.
  • Page 302 MSS Mana GT ABS Suspensions Specific tooling AP8140150 Perforated rod for piston air bleed • Fit the special tool. Specific tooling 020888Y Pliers for pre-fill pipe • With the aid of a second operator, hold the pumping member rod firmly, lower...
  • Page 303 MSS Mana GT ABS Suspensions 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.
  • Page 304 MSS Mana GT ABS Suspensions • With the aid of a second operator, hold the pumping member rod firmly, lower the spacer retention tool, insert the stop ring and the plate separating the spacer-pumping member between the ring and the nut.

  • Page 305: Steering Bearing

    MSS Mana GT ABS Suspensions Steering bearing Key: 1. Folk lower plate 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...
  • Page 306 MSS Mana GT ABS Suspensions • Adjust if clearance is detected. • Unscrew and remove the U-bolt four fixing screws. • Remove the U-bolt. • Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out.
  • Page 307 MSS Mana GT ABS Suspensions • Slide off the fork upper plate by moving it towards the instrument panel. • Adjust the steering bearings preload- ing by tightening the ring nut with the specific tool. When refitting the U-bolt, position the two referen- ces facing the front part of the vehicle.

  • Page 308: Removing The Rear Wheel

    MSS Mana GT ABS Suspensions Removing the rear wheel Key: 1. Rear wheel 6"x17" 2. Internal spacer 3. Bearing 4. Seeger ring 5. Sealing ring 30x52x7 6. Tubeless valve 7. Anti-vibration buffer holder 8. 10x20 Pin 9. TCEI screw M10x30 10.Anti-vibration buffer rubber ring...
  • Page 309 MSS Mana GT ABS Suspensions 20.Complete chain 21.Rear cover • Rest the vehicle on its centre stand. • Undo and remove the two fixing screws. • Remove the rear brake calliper. • Undo and remove the two fixing screws. •...
  • Page 310 MSS Mana GT ABS Suspensions • Working from the vehicle right side, un- screw and remove the rear wheel pin fixing nut and collect the washer. • Loosen the right chain set screw. SUSP - 310...

  • Page 311: Checking The Rear Wheel

    MSS Mana GT ABS Suspensions • Remove the spacer. • Slide off the chain. • Slide off the pin with the aid of a plastic hammer, supporting the rear wheel. • Remove the rear tyre. Checking the rear wheel CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS.

  • Page 312: Rear Wheel Gaskets

    MSS Mana GT ABS Suspensions ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE. • Check the radial and axial clearance. Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: •...
  • Page 313 MSS Mana GT ABS Suspensions Removing • Place the vehicle on the service stand under the oil sump carefully. • Undo and remove the front shock ab- sorber fixing screw and collect the col- lar. • Undo and remove the rear fixing screw and collect the collar.

  • Page 314: Index Of Topics

    INDEX OF TOPICS CHAS HASSIS...

  • Page 315: Swinging Arm

    MSS Mana GT ABS Chassis 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...
  • Page 316 MSS Mana GT ABS Chassis 19.Chain lower crankcase 20.Chain guard 21.Chain slider 22.Slider cap 23.TBEI screw 5x12 24.Stand rear bushing 25.TSPEI screw M6x55 26.Washer 20x29x1 27.Rear brake hose guide 28.M5x15 TBEI screw with washer 29.T-shaped bushing Exhaust Key: 1. Silencer 2.
  • Page 317 MSS Mana GT ABS Chassis 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...

  • Page 318: Removing The Exhaust Manifold

    MSS Mana GT ABS Chassis • Operating from both sides, undo and remove the screw on the plate. • Undo and remove the muffler tip fixing screw. • Remove the muffler tip. Removing the exhaust manifold FRONT CYLINDER MANIFOLD •...
  • Page 319 MSS Mana GT ABS Chassis • Remove the exhaust manifold of the front cylinder. CAUTION UPON REFITTING, TIGHTEN THE CLAMP LOCKING NUT TO THE PRESCRIBED TORQUE. Locking torques (N*m) Manifolds fixing clamp (2) 18 Nm (13.28 lbf ft) REAR CYLINDER MANIFOLD •...

  • Page 320: Braking System

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 321 MSS Mana GT ABS Braking system Key: 1. ABS ECU control unit 2. FRONT ABS SENSOR 3. REAR ABS SENSOR 4. Battery 5. Main relay 6. ECU 7. Instrument panel 8. K line (diagnosis) 9. Key 10.CVT ECU control unit 11.fuses...
  • Page 322 MSS Mana GT ABS Braking system • PIN 13 - F_GND - Front ABS sensor ground connection • PIN 14 - F_SIG - Front ABS sensor signal • PIN 15 - PCC2 - Vehicle identification ground connection • PIN 16 - ISO_K - K line (diagnosis) •...

  • Page 323: Operating Diagram

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

  • Page 324: Abs Operation

    MSS Mana GT ABS Braking system 5. Rear brake pump 6. Rear brake pedal control 7. ABS control unit 8. Rear brake calliper 9. Front calliper (2 callipers) 10.Front brake circuit intake solenoid valve (normally open) 11.Humidifier 12.Rear brake circuit intake solenoid valve (normally open) 13.Rear brake exhaust circuit solenoid valve (normally closed)
  • Page 325 MSS Mana GT ABS Braking system D - Pressure restored: by opening the inlet valve (10-12) momentarily, the pressure of the callipers (8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the braking back to the rider.
  • Page 326 MSS Mana GT ABS Braking system Riding with an active ABS system • At engine start-up, the "general warn- ing" warning light (4) and the ABS icon (5) turn on and remain on provided that the vehicle does not exceed 5 km/h (3.1 mph).
  • Page 327 MSS Mana GT ABS Braking system • the ABS warning light flashes (SL 750 Shiver ABS / Dorsoduro 750 ABS) When the 5 km/h (3.11 mph) are exceeded: - if errors are not detected • the EFI warning light turns off and the word ABS on the display disappears (NA 850 Mana ABS).
  • Page 328 MSS Mana GT ABS Braking system 7. CONTACT TECHNICAL SERVICE 8. PERFORM THESE CHECKS: • A. Cable continuity between PIN 8 of the ABS control unit connector and PIN 28 of the instrument panel. • B. Check connectors - refer to the operations described in the chapter If the previous checks are OK, the causes might be: •...
  • Page 329 MSS Mana GT ABS Braking system NOTE: the "X" in the table identifies the con- nector pin is grounded. Parameter reading screen page ENGINE PARAMETER READING This screen page shows the parameters meas- ured by the several sensors (engine revs, engine temperature, etc.) or values set by the control unit...
  • Page 330 MSS Mana GT ABS Braking system Devices activation screen page DEVICES ACTIVATION This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. DEVICES ACTIVATION Characteristic Value/example Unit of...

  • Page 331: Errors Display

    MSS Mana GT ABS Braking system Errors display screen page ERRORS DISPLAY This screen page shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO). ERRORS DISPLAY...

  • Page 332: Adjustable Parameters

    MSS Mana GT ABS Braking system Characteristic Value/example Unit of Notes measure ment hicle identification line - Pins 2-15 of ABS control unit) Control unit F000 Possible control unit fault CAUTION IN CASE OF SPORADIC FLASHING OF THE ABS WARNING LIGHT (Dorsoduro 750 ABS, SL 750...
  • Page 333 MSS Mana GT ABS Braking system Modulator • Remove the rear system pipes from their hooks (5) and the front system pipes from the hose guide (6). MODULATOR REMOVAL • Remove the helmet compartment. • By undoing the nuts, remove and cover the brake oil pipes following this sequence: (4) - (3) - (1) - (2).
  • Page 334 MSS Mana GT ABS Braking system • Undo and remove the radiator lower screw. • Undo and remove the two screws and collect the washers. Pay attention when refitting the screws because they have different sizes. • Move the radiator forward and towards the left, sliding it off from pin (7).

  • Page 335: Component Maintenance

    MSS Mana GT ABS Braking system • Remove the modulator upwards and backwards by disconnecting the connector. Component maintenance ABS control unit The ABS system is fitted with hydraulic system separated from the front and rear brake systems and consists mainly of: 1.
  • Page 336 MSS Mana GT ABS Braking system 1. Rear brake pump 2. Rear brake calliper 3. Rear brake pipe 4. Hydraulic stop switch 5. Copper washer 6. Oil pipe screw 7. Rear brake lever 8. Brake lever pin 9. Brake lever rubber ring 10.TCEI screw M6x20...
  • Page 337 MSS Mana GT ABS Braking system 39.TE flanged screw M6x16 40.Cable guide 41.Cap 42.Brake pump fixing screws Removal REAR BRAKE CALLIPER • Undo and remove both rear brake cal- liper fixing screws. • Remove the rear brake calliper. PARKING BRAKE CALLIPER •...

  • Page 338: Front Brake Calliper

    MSS Mana GT ABS Braking system Front brake calliper Key: 1. Front left brake calliper 2. Front brake calliper oro 3. Front brake pads - pair 4. Pin + calliper spring 5. Bleeding Kit 6. TE flanged screw M10x1.25x55 7. Copper washer Removal •...
  • Page 339 MSS Mana GT ABS Braking system • Remove both pins. • Collect the anti-vibration springs. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
  • Page 340 MSS Mana GT ABS Braking system • Repeat this procedure until the brake fluid is clear and has no air bubbles. (about 10 to 20 times). NOTE: CHECK BRAKE FLUID LEVEL IN THE RESERVOIR AND, IF NECESSARY, TOP UP (CHECKING BRAKE PAD WEAR).
  • Page 341 MSS Mana GT ABS Braking system • So that the brake fluid remains in the ABS control unit, first remove the pro- tective caps of the braking circuit un- ions and connect the respective pipes. Once all the braking circuits have been con-...

  • Page 342: Braking System Bleeding

    MSS Mana GT ABS Braking system • Remove the cap of the reservoir and fill it with the new DOT 4 brake fluid up to the reference "MAX". BRAKING SYSTEM BLEEDING (only the new calliper) CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEED, AS DESCRIBED AT THE BEGINNING OF THE CHAPTER.

  • Page 343: Changing The Brake Fluid

    MSS Mana GT ABS Braking system Changing the brake fluid BRAKE FLUID REPLACEMENT VEHICLE PREPARATION • Connect the bleeding unit to the reser- voir of the braking system. Max. filling pressure to be applied to the sys- tem= 3 bar (300 kPa - 43.51 PSI).
  • Page 344 MSS Mana GT ABS Braking system Removal • Place the vehicle on its side stand. • Loosen the cable adjusting nuts. • Slide off the parking brake cable. • Undo the two screws. • Remove the calliper. • Slide off the two pins and remove the two brake pads.

  • Page 345: Installation And Adjustment

    MSS Mana GT ABS Braking system Installation and adjustment • Release the cable by the lever section. • Fit the calliper and fix it with the two screws. • Fit the two brake pads and fix them with two pins.
  • Page 346 MSS Mana GT ABS Braking system • Adjust the cable. • Once the adjustment is finished, check that the rear wheel turns freely with the lever pulled up to 1/3 of the stroke. BRAK SYS - 346...

  • Page 347: Index Of Topics

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 348 MSS Mana GT ABS Cooling system Circuit diagram Key: 1. Water radiator 2. Complete expansion tank 3. Expansion tank cap 4. Radiator right cover - silver crowd v. 5. Radiator left cover - silver crowd v. 6. TBEI screw - M5x12 7.

  • Page 349: Electric Fan

    MSS Mana GT ABS Cooling system 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...

  • Page 350: Coolant Replacement

    MSS Mana GT ABS Cooling system Coolant replacement • Remove the expansion tank cap. • Place an appropriate container near the water pump. • Remove the clamp and slide off the manifold. • Drain off the system. TOPPING UP •...

  • Page 351: Water Pump

    MSS Mana GT ABS Cooling system • Restore the expansion tank fluid level. Water pump NOTE OVERALL SEAL REPLACEMENT CAN BE CARRIED OUT WITH ENGINE ASSEMBLED ON THE VEHICLE. Specific tooling 020661Y Water pump overall seal replacement kit - With a screw remove the six screws and the wa- ter pump cover and the gasket.
  • Page 352 MSS Mana GT ABS Cooling system - With a 10-mm wrench, unscrew the water pump rotor. CAUTION THE ROTOR THREAD IS ANTICLOCKWISE. THE PUMP SHAFT FACILITATES REMOVING THE ROTOR AS THE GEARED CONTROL CANNOT ROTATE IN REVERSE SENSE. - Use two flat blade screwdrivers, and place them as shown in the figure so as to lever on the marked crankcase edge and disassemble the overall seal, pressure-fitted on the rotor shaft.
  • Page 353 MSS Mana GT ABS Cooling system - Before removal, clean thoroughly all the parts. - Place the extractor complete with pin on the static part of the ceramic seal. - Without modifying the extractor position, make three holes on the static part of the seal using the pin supplied and a hammer.
  • Page 354 MSS Mana GT ABS Cooling system - Complete the tool by fitting the bracket, screw and the nut. - Hold the screw in one position and operate the nut until the static part of the sealing is completely removed. - Remove the extractor with the static part of the entire sealing.
  • Page 355 MSS Mana GT ABS Cooling system - Slide off the water pump control gear together with the shaft. - Undo the two indicated screws and remove the gear protection plate. - Introduce a punch on the water pump shaft seat and remove the oil seal.
  • Page 356 MSS Mana GT ABS Cooling system - Fit the plate in its position and lock it by tightening the two screws to the prescribed torque. Locking torques (N*m) Water pump gear protection plate tightening screws 3 - 4 Nm (2.21 - 2.95 lb ft) - Fit the water pump shaft together with the control gear.
  • Page 357 MSS Mana GT ABS Cooling system - Fit the tie rod screwing it in the rotor shaft. CAUTION THE SHAFT THREAD IS ANTICLOCKWISE, SCREW IT MANUALLY UNTIL IT STOPS. - Place the calibrated punch (with preloading val- ues). - Apply the nut to the tie rod.

  • Page 358: Removing The Radiator

    MSS Mana GT ABS Cooling system - Screw the rotor. (anticlockwise thread). Locking torques (N*m) Water pump rotor 4 - 5 Nm (2.95 - 3.69 lb ft) - Fit the pump cover with a new gasket, previously lubricated with petroleum jelly grease.
  • Page 359 MSS Mana GT ABS Cooling system • Remove the clamp and slide off the manifold. • Drain off the system. • Remove the clamp. • Release the sleeve. • Undo and remove the fixing screw. • Disconnect the electric fan connector.
  • Page 360 MSS Mana GT ABS Cooling system • Undo and remove the radiator lower fixing screw. • Release the sealing clamp of the radi- ator lower pipe. • Release the sealing clamp of the ex- pansion tank upper pipe and release the pipe.

  • Page 361: Removing The Expansion Tank

    MSS Mana GT ABS Cooling system Removing the expansion tank • Right bottom side removal. • Drain off the system. • Undo and remove the fixing screw. • Undo and remove the fixing screw. • Release the clamps and slide off the two sleeves.

  • Page 362: Index Of Topics

    INDEX OF TOPICS BODYW ODYWORK...
  • Page 363 MSS Mana GT ABS Bodywork Seat • Rest the vehicle on its stand. • Turn the key anticlockwise. • Lift the passenger saddle. • Undo and remove the two collar fixing screws. • Undo and remove the two side fixing screws.

  • Page 364: Instrument Panel

    MSS Mana GT ABS Bodywork Instrument panel • Remove the internal screws of the in- strument panel. • Remove the top fairing fixing screws and extract it. • Partially extract the internal instrument panel support • Disconnect the instrument panel con- nector and remove it all.
  • Page 365 MSS Mana GT ABS Bodywork • Remove the front fairing fixing screws (2) and remove the fairing. • Remove the clamp (3). • Remove the front headlight assembly. See also Instrument panel Side fairings Side fairings BODYW - 365...
  • Page 366 MSS Mana GT ABS Bodywork Disassembling the lock • Remove the saddle. • Remove the license plate support. • Slide off the cable. Taillight assy. • Remove the license plate support. • Undo and remove the two fixing screws. •...
  • Page 367 MSS Mana GT ABS Bodywork • Undo and remove the two fixing screws. • Undo and remove the fixing screw. • Slide off the light cover. • Slide off the light. BODYW - 367...
  • Page 368 MSS Mana GT ABS Bodywork Rider footrest plate The following operations also apply to both foot- rest holder plates. • Undo and remove the lower fixing screw and collect the washer. CAUTION UPON REFITTING, THE LOWER M10 FIXING SCREW SHOULD BE TIGHTENED TO THE SPECIFIED LOCKING TORQUE.

  • Page 369: Side Body Panels

    MSS Mana GT ABS Bodywork Side body panels • Remove the side fairing. • Remove the saddle. • Open the helmet compartment. • Working on both sides, unscrew and remove the two top fixing screws. • Working on both sides, release the two bottom fixing snap-in rivets.

  • Page 370: Side Fairings

    MSS Mana GT ABS Bodywork Side fairings Side fairings • Open the helmet compartment. • Undo and remove the two fixing screws for the upper central small fairing (1) and collect the two washers. • Lower the helmet compartment. •...
  • Page 371 MSS Mana GT ABS Bodywork • Remove the internal air deflector. • Disconnect the turn indicator connec- tor. • Remove the side fairing. License plate holder • Remove the saddle. • Undo and remove the two fixing screws. • Undo and remove the two screws fixing the passenger grab handle.
  • Page 372 MSS Mana GT ABS Bodywork • Operating from both sides, undo and remove the side screw. • Undo and remove the two lower fixing screws. • Partially slide off with great care the li- cense plate support. • Remove the locking clamp.
  • Page 373 MSS Mana GT ABS Bodywork • Disconnect the rear light connector. • Disconnect the rear turn indicator con- nector. • Hold the license plate support assem- bly. • Undo and remove the two screws fixing the key lock. • Remove the key lock.
  • Page 374 MSS Mana GT ABS Bodywork • Remove the clamp. • Slide off the entire license plate sup- port. Air box • Remove the mat and rubber cover from the helmet compartment. • Unscrew and remove the two screws and remove the battery cover.
  • Page 375 MSS Mana GT ABS Bodywork • Remove the steering lock protection. • Remove the side fairings. • Undo and remove the two fixing screws. • Remove the plastic radiator protection. • Disconnect the two horn connectors. • Undo the screw on the sleeve clamp through the hole in the helmet com- partment.
  • Page 376 MSS Mana GT ABS Bodywork • Remove the filter box fixing screw in- side the glove-box. • Remove the filter box fixing screw which is on the left of the chassis. • Release the blow by tube from the en- gine crankcase, working on the right of the vehicle.
  • Page 377 MSS Mana GT ABS Bodywork Helmet bay • Remove the saddle. • Open the helmet compartment. • Working on both sides, unscrew and remove the two top fixing screws. • Working on both sides, release the two bottom fixing snap-in rivets.
  • Page 378 MSS Mana GT ABS Bodywork • Close the helmet compartment. • Slide off the cover. • Reopen the helmet compartment. • Remove the side fairings. • Working from both sides, undo and re- move the protection front fixing screw. •...
  • Page 379 MSS Mana GT ABS Bodywork • Working from both sides, undo and re- move the protection rear upper fixing screw. • Remove the lower screw fixing the fair- ing to the chassis. • Disconnect the control unit connectors. • Undo and remove the ground lead fix- ing screw.
  • Page 380 MSS Mana GT ABS Bodywork • Working from both sides, undo and re- move the compartment plastic part fair- ing upper fixing screws. • Working from both sides, undo and re- move the compartment plastic part fair- ing lower fixing screws.
  • Page 381 MSS Mana GT ABS Bodywork • Disconnect the gear control ECU con- nector. • Disconnect the 12V socket connector. • Remove the clamp and disconnect the helmet compartment light connector. • Release the start-up remote control switch from the two tongues.
  • Page 382 MSS Mana GT ABS Bodywork • From both sides undo and remove the three helmet compartment external fix- ing screws. • Undo and remove the helmet compart- ment internal fixing screw. BODYW - 382...

  • Page 383: Fuel Tank

    MSS Mana GT ABS Bodywork • Slide off the fuse box. • Lift the helmet compartment and dis- connect the helmet compartment opening actuator connector. • Remove the helmet compartment. Fuel tank • Remove the saddle. • Remove the license plate support.
  • Page 384 MSS Mana GT ABS Bodywork • Undo and remove the two fixing screws. • Working from both sides, unscrew and remove the luggage fixing pin. • Remove the collar and slide off the breather pipe. • Lift sideways and remove the under- seat cover.
  • Page 385 MSS Mana GT ABS Bodywork • Release the helmet compartment opening cable from its fitting. • Pull up the lever to open the helmet compartment manually and at the same time, lead the cable below; slide off the cable end from the fitting on the opening lever.
  • Page 386 MSS Mana GT ABS Bodywork • To disconnect the quick couplers, push the crown and at the same time pull the coupler up at 90° and slightly rotate it. • Disconnect the fuel pump connector. • Undo and remove the two fixing screws.

  • Page 387: Front Mudguard

    MSS Mana GT ABS Bodywork Front mudguard • Operating from both sides, undo and remove the two screws. • Remove the front mudguard, by sliding it forwards and slightly pressing it so it passes through the forks. Windscreen • Remove the top fairing fixing screws and extract it.
  • Page 388 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 389 MSS Mana GT ABS Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit...

  • Page 390: Road Test

    MSS Mana GT ABS 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.

  • Page 391: Static Test

    MSS Mana GT ABS Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up...
  • Page 392 MSS Mana GT ABS Pre-delivery Specific operations for the vehicle • Fit the rubber elements with groove in the slots on the windshield. • Insert the high T bushes from the inside of the windshield. • Insert the low T bushes in their holes on the bodywork.
  • Page 393 ABS: 145, 321, 328 Air filter: 45 Air temperature sensor: 96, 111 Brake: 335, 338, 343 Brake calliper: 335, 338 Brake fluid: 343 Bulbs: CAN line: 146 Chain: 12, 192 Chain tensioner: 192 Clutch: 175, 241, 242, 246, 247, 249 Coil: 103 Connectors: 139 coolant: 350...
  • Page 394 Identification: 10 Instrument panel: 51, 111, 364, 365 License plate holder: 371 Magneto flywheel: 172 Maintenance: 7, 40, 335 Maintenance Table: Mudguard: 387 Oil filter: 45 Oil pressure sensor: 107 Radiator: 358 Rear wheel: 308, 311 Recommended products: 25 Run/Stop switch: 114 Saddle: Shock absorbers: 312 Side fairings: 370...

Table of Contents