APRILIA Mana GT ABS 2012 User manual

APRILIA WOULD LIKE TO THANK YOU
for choosing one of its products. We have compiled this booklet to provide a comprehensive overview of your vehicle's quality features. Please read it
carefully before riding the vehicle for the first time. It contains information, tips and precautions for using your vehicle. It also describes features, details
and devices to assure you that you have made the right choice. We believe that if you follow our suggestions, you will soon get to know your new vehicle
well and that it will continue to give you satisfactory service for many years to come. This booklet is an integral part of the vehicle and must be handed
over to the new owner in the event of sale.
Mana GT ABS
Ed. 01_05/2012

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

Personal safety
Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment
Sections marked with this symbol indicate the correct use of the vehicle to prevent dam-
aging the environment.
Vehicle intactness
The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee
The symbols illustrated above are very important. They are used to highlight parts of the
booklet that should be read with particular care. The different symbols are used to make
each topic in the manual simple and quick to locate. Before starting the engine, read this
booklet carefully, particularly the "SAFE RIDING" section. Your safety as well as other's
does not only depend on the quickness of your reflexes and agility, but also on how well
youknow yourvehicle, thestate ofmaintenance ofthe vehicleitself andyour knowledge
of the rules for SAFE RIDING. For your safety, get to know your vehicle well so as to
safely ride and master it given any riding condition. IMPORTANT This booklet is an
integral part of the vehicle, and should the vehicle be sold, it must be transferred to the
new owner.
3

4

INDEX
GENERAL RULES....................................................................... 7
Foreword............................................................................... 8
Carbon monoxide.................................................................. 8
Fuel....................................................................................... 8
Hot components.................................................................... 9
Coolant.................................................................................. 9
Used engine oil and gearbox oil............................................ 10
Brake and clutch fluid............................................................ 11
Battery hydrogen gas and electrolyte.................................... 11
Stand..................................................................................... 12
Reporting of defects that affect safety................................... 12
VEHICLE...................................................................................... 13
Arrangement of the main components...................................... 15
Dashboard................................................................................ 17
Instrument panel....................................................................... 19
Light unit................................................................................... 20
Digital lcd display...................................................................... 21
Alarms................................................................................... 22
Control buttons...................................................................... 27
Advanced functions............................................................... 30
Ignition switch........................................................................ 36
Locking the steering wheel.................................................... 37
Horn button............................................................................... 37
Switch direction indicators........................................................ 38
Passing button.......................................................................... 38
Start-up button.......................................................................... 39
Engine stop switch.................................................................... 39
System ABS.............................................................................. 39
Immobilizer system operation................................................ 43
Helmet compartment................................................................. 44
Power supply socket................................................................. 45
Opening the saddle............................................................... 45
Identification.............................................................................. 46
Adjusting the windscreen.......................................................... 47
Windscreen removal................................................................. 47
Instrument panel removal......................................................... 48
USE.............................................................................................. 49
Checks...................................................................................... 50
Refuelling.................................................................................. 53
Rear shock absorbers adjustment............................................ 54
Front fork adjustment................................................................ 56
Justering af greb til forbremse.................................................. 57
Rear brake pedal adjustment.................................................... 57
Gear pedal adjustment.............................................................. 58
Running in................................................................................. 58
Starting up the engine............................................................... 59
Moving off / riding...................................................................... 63
Stopping the engine.................................................................. 66
Parking...................................................................................... 67
Catalytic silencer....................................................................... 67
Stand......................................................................................... 69
Transmission............................................................................. 70
Suggestion to prevent theft....................................................... 75
Basic safety rules...................................................................... 76
MAINTENANCE........................................................................... 81
Engine oil level check............................................................ 82
Engine oil top-up................................................................... 83
Engine oil change.................................................................. 84
Tyres......................................................................................... 86
Spark plug dismantlement........................................................ 88
Removing the sides.................................................................. 88
Removing the air filter............................................................... 91
Cooling fluid level...................................................................... 92
Checking the brake oil level...................................................... 94
Braking system fluid top up................................................... 95
Battery removal..................................................................... 95
5

Use of a new battery............................................................. 96
Checking the electrolyte level................................................ 96
Charging the battery.............................................................. 97
Long periods of inactivity.......................................................... 98
Fuses........................................................................................ 98
Lamps....................................................................................... 102
Headlight adjustment............................................................. 104
Front direction indicators........................................................... 105
Rear optical unit........................................................................ 105
Rear turn indicators................................................................... 106
Number plate light..................................................................... 106
Rear-view mirrors...................................................................... 107
Front and rear disc brake.......................................................... 109
Periods of inactivity................................................................... 110
Cleaning the vehicle.................................................................. 111
Transport................................................................................... 114
Chain backlash check........................................................... 114
Chain backlash adjustment................................................... 115
Checking wear of chain, front and rear sprockets................. 115
Chain lubrication and cleaning.............................................. 116
TECHNICAL DATA...................................................................... 117
Kit equipment............................................................................ 126
PROGRAMMED MAINTENANCE............................................... 127
Scheduled maintenance table................................................... 128
SPECIAL FITTINGS..................................................................... 145
Accessories index..................................................................... 146
6

Mana GT ABS
Chap. 01
General rules
7

Foreword
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECI-
FIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDI-
TIONS, OFF ROAD OR FOR TRACK USE.
Carbon monoxide
If you need to keep the engine running in order to perform a procedure, please ensure
that you do so in an open or very well ventilated area. Never let the engine run in an
enclosed area. If you do work in an enclosed area, make sure to use a smoke-ex-
traction system.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS
WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY
FLAMMABLE AND MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS
THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTE-
NANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED
8
1 General rules

OFF. DO NOT SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR. AVOID
ANY CONTACT WITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES
WHICH MAY CAUSE IGNITION OR EXPLOSION.
DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN.
IF THE VEHICLE FALLS OR IS ON A STEEP INCLINE FUEL CAN LEAK.
Hot components
The engine and the exhaust system components get very hot and remain in this con-
ditionfora certain timeintervalaftertheengine hasbeenswitchedoff.Before handling
these components, make sure that you are wearing insulating gloves or wait until the
engine and the exhaust system have cooled down.
Coolant
The coolant contains ethylene glycol which, under certain conditions, can become
flammable. When ethylene glycol burns, it produces an invisible flame which can nev-
ertheless cause burns.
CAUTION
TAKE CARE NOT TO SPILL COOLANT ONTO HOT ENGINE OR EXHAUST SYS-
TEM COMPONENTS; THE FLUID MAY IGNITE AND BURN WITH AN INVISIBLE
9
1 General rules

FLAME. WHEN CARRYING OUT MAINTENANCE, IT IS ADVISABLE TO WEAR
LATEX GLOVES. EVEN THOUGH IT IS TOXIC, COOLANT HAS A SWEET FLA-
VOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS. NEVER LEAVE THE
COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS
THEY MAY DRINK IT.
KEEP OUT OF THE REACH OF CHILDREN.
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE
COOLANT IS PRESSURISED AND MAY CAUSE SCALDING.
Used engine oil and gearbox oil
CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN
IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BA-
SIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED
OIL RECYCLING COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN.
10
1 General rules

Brake and clutch fluid
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAIN-
TED SURFACES. WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM
PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR
PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS. BRAKE AND
CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT
OFACCIDENTALCONTACTWITHTHEEYES, RINSETHEMIMMEDIATELYWITH
PLENTY OF COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN.
Battery hydrogen gas and electrolyte
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND, AS IT CONTAINS
SULPHURIC ACID, MAY CAUSE BURNING IF IT COMES INTO CONTACT WITH
THE SKIN. WHEN HANDLING BATTERY ELECTROLYTE, WEAR TIGHT-FITTING
GLOVESANDPROTECTIVEAPPAREL.INTHEEVENTOFSKINCONTACTWITH
THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN WATER. IT
IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN
TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IN THE EVENT
OF CONTACT WITH THE EYES, RINSE WITH PLENTY OF WATER FOR FIFTEEN
MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS
ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR
MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETABLE OIL AND SEEK
MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE
GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTH-
11
1 General rules

ER HEAT SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING
OR RECHARGING THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICU-
LARLY ON PLASTIC COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID
IS COMPATIBLE WITH THE BATTERY BEING ACTIVATED.
Stand
BEFORE SETTING OFF, MAKE SURE THE STAND HAS BEEN COMPLETELY
RETRACTED TO ITS POSITION.
DO NOT REST THE RIDER OR PASSENGER WEIGHT ON THE SIDE STAND.
Reporting of defects that affect safety
Unless otherwise specified in this Use and Maintenance Booklet, do not remove any
mechanical or electrical component.
12
1 General rules

Mana GT ABS
Chap. 02
Vehicle
13

02_01
14
2 Vehicle

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

12. Passenger saddle lock
13. Rear left turn indicator
14. Rear shock absorber
15. Left passenger footrest (snap-on, closed / open)
16. Rear fork
17. Rear tone wheel
18. REAR BRAKE DISC
19. Rear ABS sensor
20. Left rider footrest
21. Transmission air filters
22. Side stand
23. Pedal control lever
24. Parking brake lever
25. Air filter
26. Horn
27. Front left brake disc
28. Fuel tank cap
29. Fuel tank
30. Transmission control unit
31. Auxiliary fuses
32. ABS control unit
33. Right rear-view mirror
34. Front brake fluid reservoir
35. Expansion tank cap
36. adjustable windscreen
37. Front right turn indicator
38. Front headlamp
39. Right side fairing
40. Expansion tank
41. Front right brake disc
42. Front tone wheel
43. Front ABS sensor
44. Engine control unit
45. Engine oil filter
46. Engine oil max level
47. Engine oil plug
48. Rear brake control lever
49. Right rider footrest
16
2 Vehicle

50. Rear brake pump
51. Drive chain
52. Right passenger footrest (snap-on, closed / open)
53. Rear brake fluid reservoir
54. License plate holder light
55. Rear right turn indicator
02_03
Dashboard (02_03)
Instrument panel / controls location key
1. Ignition switch /steering lock
17
2 Vehicle

2. Instrument panel
3. Throttle grip
4. Front brake lever
5. Flash switch and high-beam activation
6. GEAR DOWN control
7. Helmet compartment opening control
8. Instrument panel MODE control
9. Turn indicator control
10. Horn button
11. GEAR UP control
12. Starter button / engine stop switch
13. GEAR MODE control
02_04
18
2 Vehicle

Instrument panel (02_04)
key:
1. Speedometer
2. Multifunctional digital display
3. Warning lights
The instrument panel has an immobilizer system which prevents start-up in case the
system does not identify a key which has been stored before.
The vehicle is supplied with two keys already programmed. The instrument panel ac-
cepts a maximum of four keys at the same time: contact an Official Aprilia Dealer to
enable these keys or to disable a key that has been lost. When the vehicle is delivered
and approximately ten seconds after the key is set to ON, the instrument panel re-
quests a personal five-digit code to be entered. This request is no longer displayed
once the personal code is entered. For code entering procedure, see the CODE
MODIFICATION section
It is important to remember the personal code because:
•the vehicle can be started if the immobilizer system is faulty
•the instrument panel need not be replaced should the ignition switch
be changed
•new keys can be programmed
19
2 Vehicle

02_05
Light unit (02_05)
key:
1. High-beam warning light, blue
2. Left turn indicator warning light, green
3. RPM 4 warning light, red (active only when in SPORT GEAR mode)
4. RPM3warninglight,amberyellow(activeonlywheninSPORTGEARmode)
5. RPM2warninglight,amberyellow(activeonlywheninSPORTGEARmode)
6. RPM1warninglight,amberyellow(activeonlywheninSPORTGEARmode)
7. Right turn indicator warning light, green
8. General alarm warning light, red
9. Low fuel warning light, amber yellow
20
2 Vehicle