APRILIA MSS Mana GT ABS Guide

SERVICE STATION MANUAL
894171
MSS Mana GT ABS

SERVICE STATION
MANUAL
MSS Mana GT ABS
THE VALUE OF SERVICE
Due to the continuous technical updates and specific mechanic training programs for aprilia products,
only aprilia Official Network mechanics know this vehicle fully and have the special tools necessary to
carry out maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical state. Checking the vehicle before riding, its
regular maintenance and using only Original aprilia Spare Parts are essential!
For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or
search directly from the map on our Official Website:
www.aprilia.com
Only by requesting aprilia Original Spare Parts can you be sure of purchasing products that were
developed and tested together with the actual vehicle itself. All aprilia Original Spare Parts undergo
quality control procedures to guarantee reliability and durability.
The descriptions and illustrations given in this publication are not binding; While the basic characteristics
as described and illustrated in this booklet remain unchanged, aprilia reserves the right, at any time and
without being required to 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.
Not all versions/models shown in this publication are available in all Countries. The availability of
individual versions/models should be confirmed with the official aprilia sales network.
© Copyright 2009 aprilia. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. aprilia - After-sales service.
Aprilia trademark is property of Piaggio & C. S.p.A.

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.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sectionsmarkedwiththis symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee

INDEX OF TOPICS
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
BODYWORK BODYW
PRE-DELIVERY PRE DE

INDEX OF TOPICS
CHARACTERISTICS CHAR

Rules
This section describes the vehicle maintenance operations and general safety regulations.
Safety rules
Carbon monoxide
If you need to keep the engine running while working on the vehicle, please ensure that you do so in
an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an
enclosed area, make sure to use a fume extraction system.
CAUTION
EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCANCAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND
MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VA-
POURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES
WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPERSE FUEL IN THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN
Hot components
The engine and the exhaust system components become very hot and remain hot for some time after
the engine has been switched off. When handling these components, wear insulating gloves or wait
until the engine and the exhaust system have cooled down.
Coolant
The coolant contains ethylene glycol which, under certain conditions, can become flammable.
When it burns, ethylene glycol produces an invisible flame which however can cause burns.
CAUTION
TAKE CARE NOT TO POUR COOLANT ONTO HOT ENGINE OR EXHAUST SYSTEM COMPO-
NENTS; THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES. WHEN CARRYING
OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN
Characteristics MSS Mana GT ABS
CHAR - 6

THOUGH IT IS TOXIC, COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRAC-
TIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCES-
SIBLE TO ANIMALS AS THEY MAY DRINK IT.
KEEP OUT OF THE REACH OF CHILDREN
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS
UNDER PRESSURE AND MAY CAUSE BURNS.
Used engine oil and transmission oil
CAUTION
IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE-
HICLE.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
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
Brake and clutch fluid
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.
WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM-
PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING
THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR
EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY
WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN
Battery electrolyte and hydrogen gas
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,
IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY
ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT
OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY
AMOUNTSOFBATTERYACID MAY CAUSEBLINDNESS.IFTHE FLUID GETSINCONTACTWITH
YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE
SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY
FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADE-
QUATE 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, PARTICULARLY ON PLASTIC
COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-
TERY TO BE ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
MSS Mana GT ABS Characteristics
CHAR - 7

When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
BEFORE DISASSEMBLING COMPONENTS
•Beforedismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.
Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
•Donotloosenand/or tighten screws and nuts using pliers or any other tools than the specific
wrench.
•Mark positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with distinctive symbols.
•Each component needs to be clearly marked to enable identification during reassembly.
•Clean and wash the dismantled components carefully using a low-flammability detergent.
•Keep mated parts together since they have "adjusted" to each other due to normal wear.
•Some components must be used together or replaced completely.
•Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.
•Only use ORIGINAL Aprilia SPARE PARTS.
•Comply with lubricant and consumables use guidelines.
•Lubricate parts (whenever possible) before reassembling them.
•Whentightening nutsandscrews, starteitherfrom thecomponentswith thelargestdiameter
or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-
cessive steps before applying the tightening torque.
•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins
and screws with new parts if the thread is damaged.
•When assembling the bearings, make sure to lubricate them well.
•Check that each component is assembled correctly.
•After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on
private grounds or in an area with low traffic.
•Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of
lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand
or batch number facing outward (visible side).
ELECTRICAL CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damage to both the connector and the wiring harness:
Press the relative safety clips, if applicable.
Characteristics MSS Mana GT ABS
CHAR - 8

•Grip the two connectors and disconnect them by pulling them in opposite directions.
•If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully
with a jet of compressed air.
•Ensure that the cables are correctly fastened to the internal connector terminals.
•Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you
will hear them "click" into place).
CAUTION
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.
NOTE
THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM
THE RIGHT WAY ROUND.
TIGHTENING TORQUES
CAUTION
REMEMBERTHATTHETIGHTENING TORQUES FORALLFASTENINGELEMENTS ON WHEELS,
BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE
IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE
TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE
A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH
THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR
EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS
MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.
Running-in
Runningtheengineincorrectlyisessentialfor ensuring engine longevity and functionality. Twisty roads
and gradients are ideal for running in the engine, brakes and suspension effectively. Vary your riding
speed during the running in period. This ensures that components operate in "loaded" conditions and
then "unloaded" conditions, allowing the engine components to cool.
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT
THE END OF THE RUNNING IN PERIOD.
Follow these guidelines:
•Do not twist the throttle grip abruptly and completely when the engine is working at a low
revs, either during or after run-in.
•During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged
braking. That is to permit the adequate adjustment of the pad friction material to the brake
discs.
AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE
CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE
SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
MSS Mana GT ABS Characteristics
CHAR - 9

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.
HOWEVER, THE LIMITED WARRANTY FOR NEW VEHICLES WILL BE VOID IF THE VEHICLE
IDENTIFICATION NUMBER (VIN) HAS BEEN MODIFIED OR NOT PROMPTLY DETERMINED.
This number consists of numbers and letters, as in the example shown below.
ZD4RCA000YMXXXXXX
KEY:
ZD4: WMI (World manufacturer identifier) code;
RC: model;
A00: version variation;
0: digit free
Yyear of manufacture
M: production plant (M= Mandello del Lario);
XXXXXX: progressive number (6 digits);
CHASSIS NUMBER
The chassis number is stamped on the right side of the headstock.
ENGINE NUMBER
The engine number is printed on the base of the
engine crankcase, left hand side.
Engine No. ....................
CHASSIS NUMBER
The chassis number is stamped on the right side of the headstock.
Chassis No. ....................
Dimensions and mass
DIMENSIONS
Specification Desc./Quantity
Max. length 2180 mm (85.83 in)
Max. width 800 mm (31.50 in)
Characteristics MSS Mana GT ABS
CHAR - 10

Specification Desc./Quantity
Max. height 1350 mm (53.15 in) (with the windscreen adjusted in the top
position)
Saddle height 810 mm (31.89 in)
Wheelbase 1465 mm (57.68 in)
Kerb weight (full fuel tank) 238 kg (524 lb)
Engine
ENGINE
Specification Desc./Quantity
Model M290 Duel
Type 90° longitudinal V-twin, 4-stroke, 4 valves per cylinder, single
overhead camshaft.
No. of cylinders 2
Overall cylinder capacity 839.3 cm³ (51.22 cu.in)
Bore / stroke 88 x 69 mm (3.46 x 2.72 in)
Valve clearance Inlet: 0.15 mm (0.0059 in)
Outlet: 0.15 mm (0.0059 in)
Compression ratio 10 - 10.6 : 1
Electric starter
Engine idle speed 1400 ± 100 rpm
TIMING SYSTEM 4 valves, single overhead camshaft, chain-driven.
MAX. torque 71 Nm at 4,500 rpm
Clutch Automatic
Lubrication system Dry sump system with separate oil tank
Lubrication pressure 3.5 ÷ 4 bar
Minimum lubrication pressure (100 °C - 212 °F) 0.8 bar
Air filter With dry cartridge filter
Cooling Forced-circulation coolant system.
GEARBOX
Specification Desc./Quantity
Type aprilia sport gear with electrically-controlled variator, double
mode: sequential and autodrive
OIL PUMP
Specification Desc./Quantity
Type Trochoidal
Rotor shim washers pressure pump: 12 mm (0.47 in)
scavenge pump: 22 mm (0.87 in)
Fitting clearances Lobe ends: 0.04 - 0.1 mm (0.0016 - 0.0039 in)
External rotor radial clearance 0.05 - 0.12 mm (0.0020 - 0.0047 in)
Flatness 0.015 mm (0.00059 in)
BY-PASS
Specification Desc./Quantity
Type with piston
Piston diameter 13.984 - 13.957 mm (0.5505 - 0.5495 in)
Unloaded spring length 52 mm (2.05 in)
Calibration pressure 4.5 bar (450 kPa) (65 PSI)
OIL FILTER
Specification Desc./Quantity
Type paper filter with pressure relief and anti-drain by-passes
OIL MINIMUM PRESSURE INDICATOR SWITCH
Specification Desc./Quantity
Calibration 0.3 ÷ 0.6 bar
MSS Mana GT ABS Characteristics
CHAR - 11

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
Device metal reed valve and decantation chamber
Transmission
GEAR RATIO
Specification Desc./Quantity
Primary drive gear ratio Belt primary drive (2.079 - 0.831)
Secondary drive gear ratio Gear secondary drive (23/59)
Final drive gear ratio 18/40
Capacities
CAPACITY
Specification Desc./Quantity
Fuel (reserve included) 16 l (3.52 UKgal; 4.23 USgal)
Fuel reserve 3.3 l (0.73 UKgal; 0.87 USgal)
engine oil 2.5 l (without oil filter change) (0.55 UKgal; 0.66 USgal)
2.6 l (with oil filter change) (0.57 UKgal; 0.69 USgal)
Coolant 2.5 l (0.55 UK gal; 0.66 USgal)
Seats 2
Vehicle max. load (rider + passenger + luggage) 210 kg (463 lb)
Drive chain
DRIVE CHAIN
Specification Desc./Quantity
Type Endless (without master link) and with sealed links. No. of links
100
Model 525 ZRPK
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Battery 12V - 12 Ah
Main fuses 30A - 40A
Secondary fuses 3A, 10A, 15A, 20A
ABS fuses 20 A
Alternator (permanent magnet type) 13.5 V - 450 W at 6000 rpm
Electric starter
Characteristics MSS Mana GT ABS
CHAR - 12

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)
SPARK PLUGS
Specification Desc./Quantity
Standard spark plugs NGK CR7EKB
Spark plug electrode gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Resistance 5 kOhm
BULBS
Specification Desc./Quantity
Low-beam light 12 V - 55 W H11
High-beam light 12 V - 55 W H11
Front daylight running light 12V - 5W
Turn indicator light 12V - 10W
License plate light 12V - 5W
Rear daylight running light / stop light LED
Rpm indicator lighting LED
Multifunction display lighting LED
WARNING LIGHTS
Specification Desc./Quantity
High beam light LED
Right turn indicator LED
Left turn indicator LED
General warning LED
Fuel reserve LED
RPM 1 LED
RPM 2 LED
RPM 3 LED
RPM 4 LED
Frame and suspensions
CHASSIS
Specification Desc./Quantity
Type High strength steel tubular perimeter frame.
Steering inclination angle 24°
Trail 103 mm (4.05 in)
CHASSIS HEIGHTS
Specification Desc./Quantity
A1 386.4 ± 0.5 mm (15.21 ± 0.02 in)
MSS Mana GT ABS Characteristics
CHAR - 13

Specification Desc./Quantity
A2 702.6 ± 0.5 mm (27.66 ± 0.02 in)
B1 225.5 ± 0.6 mm (8.88 ± 0.02 in)
B2 187.2 ± 0.6 mm (7.37 ± 0.02 in)
SUSPENSIONS
Specification Desc./Quantity
Front Upside-down hydraulic action telescopic fork, Ø 43 mm (1.69
in) stems
Travel 120 mm (4.72 in)
Rear Oscillating swingarm and adjustable hydraulic single shock ab-
sorber
Wheel travel 120 mm (4.72 in)
Brakes
BRAKES
Specification Desc./Quantity
Front Double floating disc, Ø 320 mm (12.60 in), radially-mounted
callipers with four plungers- two of them Ø 27 mm (1.06 in), 2
diam. 32.03 mm (1.26 in) and 4 pads
Rear Ø260mm(10.24in)discbrake,Ø25mm(0.98in)twin-plunger
calliper
Wheels and tyres
WHEEL RIMS
Specification Desc./Quantity
Type Light alloy rims with extractable bolt
Front 3.50 x 17"
Rear 6.00 x 17"
TYRES
Specification Desc./Quantity
Tyre type (standard) DUNLOP SPORTMAX QUALIFIER - PIRELLI SCORPION
SYNC
Front 120/70 ZR17" (58W)
Inflation pressure 1 passenger: 2.3 bar (230 kPa) (33.36 PSI)
2 passengers: 2.5 bar (250 kPa) (36.26 PSI)
Rear 180/55 ZR17" (73W)
Inflation pressure 1 passenger: 2.5 bar (250 kPa) (36.26 PSI)
2 passengers: 2.8 bar (280 kPa) (40.61 PSI)
Supply
FUEL SYSTEM
Specification Desc./Quantity
Type Electronic injection (Multipoint)
Throttle diameter 38 mm (1.50 in)
Fuel Premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)
Characteristics MSS Mana GT ABS
CHAR - 14

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 2 - 3
Oil pump screws 5 - 6
By-pass scavenge pipe fixing screws 11 - 13
Lubrication circuit upper bulkhead 3 - 4
Oil pump sprocket gear screw 10 - 14
Screws fixing oil pump to crankcase 5 - 6
Minimum oil pressure sensor 12 - 14
Water pump gear fixing screws 5 - 6
THERMAL GROUP AND TIMING SYSTEM
Name Torque in Nm
Spark plug 12 - 14
Head fixing stud bolts ***
Head fixing nuts 10 - 12
Exhaust/ intake head fixing nuts 10 - 12
Head lubrication control jet 5 - 7
Tensioner slider fixing screw 10 - 14
injector fixing screw 3 - 4
Inlet manifold fixing screws 11 - 13
Tappet cover fixing screws 7 - 9
Throttle body fixing screws 11 - 13
Camshaft retaining bracket fixing screws 4 - 6
Head fixing screws 10 - 12
Coolant temperature sensor 21 - 23
Rpm-timing sensor fixing screw 7.5 - 8.5
Timing system chain tensioner screw 11 - 13
Timing system crown screw on camshaft 12 - 14
*** First, apply a preliminary torque of 10 Nm in a criss-crossed sequence. - tighten to a torque of 13 Nm + 90° in a criss-crossed
sequence. - tighten again by 90° in a criss-crossed sequence.
TRANSMISSION COVER
Name Torque in Nm
Driving pulley screw 175 - 195
Driven pulley nut 153 - 187
Driving pulley ring nut 65 - 75
External driving pulley ring nut 80 - 90
External transmission cover screws 5 - 7
Internal transmission cover screws 11 - 13
Air deflector screws 3 - 4
Air outlet grid screws 3 - 4
FLYWHEEL COVER
Name Torque in Nm
Flywheel fixing nut 116 - 128
Stator clamps 8 - 10
Screws fixing freewheel to flywheel 13 - 15
Flywheel cover screws 11 - 13
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Starting ring gear retaining plate 3 - 4
Crankcase-engine coupling screws (M6) 11 - 13
Crankcase-engine coupling screws (M8) 25 - 28
MSS Mana GT ABS Characteristics
CHAR - 15

FRAME
Name Torque in Nm
hex headflanged screw fixing coil support - M6x20 (2) 10 Nm (7.38 lbf ft)
Lower self-locking M4 nut fixing coils (8) 3 Nm (2.21 lbf ft)
Self-locking M10 nut fixing shock absorber (1) 50 Nm (36.88 lbf ft)
DAX M14 nut fixing engine to chassis (2) 80 Nm (59 lbf ft)
TBEI screw fixing rubber rings with groove for saddle - M6x30
(2) 10 Nm (7.38 lbf ft)
TCEI screw fixing tank front rubber rings - M8x20 (2) 25 Nm (18.44 lbf ft)
Screw fixing ABS control unit (1) - M6x25 10 Nm (7.37 lbf ft) - Loctite 243
Nut fixing ABS control unit (2)- M6 10 Nm (7.37 lbf ft)
FOOTPEGS
Name Torque in Nm
Non-slip bolt on driver footrest (2) 25 Nm (18.44 lbf ft)
hex headflanged screw for footrest finish - M6x12 (8) 10 Nm (7.38 lbf ft)
TBEI flanged screw fixing heelrests - M5x16 (4) 6 Nm (4.42 lbf ft)
TCEI screw fixing footrest support to fork pin - M10x63 (2) 50 Nm (36.88 lbf ft)
Lower self-locking flanged M10 nut fixing footrest support to
stand bolt (2) 30 Nm (22.13 lbf ft)
Lower screw fixing rider footrest 25 Nm (18.44 lbf ft)
STAND
Name Torque in Nm
Bolt fixing screwed stand to fork (1) 10 Nm (7.38 lbf ft)
Stand bolt safety lock nut - M10x1.25 (1) 30 Nm (22.13 lbf ft)
Self-locking nut fixing centre stand front bolt (1) 50 Nm (22.13 lbf ft)
TCEI screw fixing switch - M5x25 (2) 6 Nm (4.42 lbf ft)
SWINGARM
Name Torque in Nm
Rear wheel bolt nut fixing fork pin (1) 90 Nm (66.38 lbf ft)
Chain tensioner pad set screw (2) manual
Serpress M8 nut fixing chain tensioner screws (2) manual
M5x15 TBEI screw with washer fixing chain crankcase (4) 6 Nm (4.42 lbf ft)
M5x12 TBEI screw fixing chain slider (2) 3 Nm (2.21 lbf ft) - Loctite 243
Rear brake calliper support lock pin (1) 50 Nm (36.88 lbf ft) - Loctite 243
FRONT WHEEL UNIT
Name Torque in Nm
Brake disc fixing screw on wheel M8x20 (12) 30 Nm (22.13 lbf ft) - Loct. 243
FRONT SUSPENSION
Name Torque in Nm
Stainless steel TCC M8x30 screw fixing stanchions on upper
plate (2) 25 Nm (18.44 lbf ft)
Stainless steel TCC M8x30 screw fixing stanchions on lower
plate (4) 25 Nm (18.44 lbf ft)
Headstock ring nut - M25x1 (1) tighten to 20 Nm (14.75 lbf ft) - unscrew and tighten to 7 Nm
(5.16 lbf ft)
Headstock cap - M22x1 (1) 100 Nm (73.76 lbf ft)
Screw fixing fork feet on wheel pin - M8x40 (4) 25 Nm (18.44 lbf ft)
TCEI screw fixing handlebar U-bolts to upper plates - M10x60
(2) 50 Nm (36.88 lbf ft)
Front 3-way pipe pivot fixing screw on bottom fork plate (1) 10 Nm (7.38 lbf ft)
Nut for fixing sensor on the plate M5 (1) 6 Nm (4.42 lbf ft)
TCB screw for fixing the cable grommet on the RH fork foot
M4x6 (1) 6 Nm (4.42 lbf ft)
Characteristics MSS Mana GT ABS
CHAR - 16

REAR WHEEL UNIT
Name Torque in Nm
Brake disc fixing screw on wheel M8x20 (5) 30 Nm (22.13 lbf ft) - Loct. 243
Screwfor fixing thecush drive mountingon the wheel- M10x30
(5) 50 Nm (36.88 lbf ft) - Loctite 2701
Nut for fixing the crown on sprocket carrier M10 (5) 50 Nm (36.88 lbf ft)
Wheel pin fixing nut (1) 120 Nm (88.51lbf ft)
Screw fixing the pinion cover on the engine M5x25 (3) 6 Nm (4.42 lbf ft)
Pinion nut (1) 170 Nm (125.38 lbf ft)
REAR SUSPENSION
Name Torque in Nm
Self-locking M10 nut fixing shock absorber to fork (1) 50 Nm (36.88 lbf ft)
Mounting plate adjustment knob fixing screw - M6x40 (2) 10 Nm (7.38 lbf ft)
Screw fixing the mounting plate to the engine crankcase -
M6x40 (2) 10 Nm (7.38 lbf ft)
ENGINE
Name Torque in Nm
TEF screw fixing gear control unit - M6x16 (4) 10 Nm (7.37 lbf ft)
TBEI screw with washer fixing micro-switch bracket - M5x9 (1) 6 Nm (4.42 lbf ft)
TCEI screw fixing pin lever to gearshift lever - M6x16 (1) 10 Nm (7.38 lbf ft)
TCEI screw fixing gearshift lever to engine pin - M6x16 (1) 10 Nm (7.38 lbf ft) - knurled washer
Self-tapping screw fixing air deflector cover on air deflector (4) 1 Nm (0.74 lbf ft)
Self-tapping screw fixing mesh filter on air deflector (2) 1 Nm (0.74 lbf ft)
Self-tapping screw fixing filter cover to air deflector (1) 1 Nm (0.74 lbf ft)
TCCIC screw with shank fixing air deflector to engine (4) 7 Nm (5.16 lbf ft)
hex headflanged screw fixing voltage regulator on bracket -
M6x30 (2) 10 Nm (7.38 lbf ft)
FILTER BOX
Name Torque in Nm
SWP screw assembling filter support to filter box - M5x19 (6) 2 Nm (1.47 lbf ft)
SWP screw fixing filter box cover - M5x19 (3) 2 Nm (1.47 lbf ft)
hex headflanged screw fixing filter box to chassis - M6x25 (2) 10 Nm (7.37 lbf ft)
EXHAUST SYSTEM
Name Torque in Nm
Self-locking flanged nut tightening exhaust manifolds to heads
(4) 25 Nm (18.44 lbf ft)
TBEI flanged screw fixing exhaust front protection (4) 8 Nm (5.9 lbf ft)
M8 flanged self-locking nut fixing silencer (1) 25 Nm (18.44 lbf ft)
M10 screw fixing compensator on footrest support (2) 30 Nm (22.13 lbf ft)
Manifolds fixing clamp (2) 18 Nm (13.28 lbf ft)
COOLING SYSTEM
Name Torque in Nm
Radiator TCEI fixing screw - M6x35 (2) 10 Nm (7.38 lbf ft)
Heat protection fixing screw - M5x10 (1) 6 Nm (4.42 lbf ft)
Heat protection fixing screw - M6x16 (3) 10 Nm (7.38 lbf ft)
Expansion tank TCEI fixing screw - M6x25 (1) 10 Nm (7.38 lbf ft)
Electric fan fixing screw (3) 0.3 Nm (0.22 lbf ft)
Radiator cover TBEI fixing screw - M5x12 (4) 6 Nm (4.42 lbf ft)
FRONT BRAKE
Name Torque in Nm
hex headflanged screw fixing calliper - M10x1.25x55 (4) 50 Nm (36.88 lbf ft)
Union with breather fixing pipe to callipers - M10x1 (2) 25 Nm (18.44 lbf ft)
Union fixing pipe to pump - M10x1 (1) 25 Nm (18.44 lbf ft)
TEF screw fixing braking system to lower plate - M6x16 (1) 10 Nm (7.38 lbf ft)
Screw tightening ABS sensor (1) - M5 6 Nm (4.42 lbf ft)
MSS Mana GT ABS Characteristics
CHAR - 17

Name Torque in Nm
Screw fixing ABS sensor plate (2) - M5x12 6 Nm (4.42 lbf ft)
REAR BRAKE
Name Torque in Nm
Screw fixing pin on brake lever - M6x16 (1) 10 Nm (7.38 lbf ft)
Screw fixing lever on footrest support (1) 25 Nm (18.44 lbf ft) - Loctite 243
Brake pipe union on pump and calliper - M10x1 (1) 25 Nm (18.44 lbf ft)
Hydraulic stop switch (1) 25 Nm (18.44 lbf ft)
M6 Lock nut for fork (1) 10 Nm (7.38 lbf ft)
Parking brake calliper retainer - M8x21 (2) 25 Nm (18.44 lbf ft) - Loctite 243
Hydraulic calliper retainer - M8x29 (2) 25 Nm (18.44 lbf ft) - Loctite 243
hex headscrew fixing pump on footrest plate - M6x25 (2) 10 Nm (7.38 lbf ft) - Loctite 243
Oil tank hex head fixing screw - M6x15 (1) 10 Nm (7.38 lbf ft)
Upper TCEI screw fixing parking lever unit - M6x30 (2) 10 Nm (7.38 lbf ft)
Lower TCEI screw fixing parking lever unit - M6x20 (1) 10 Nm (7.38 lbf ft)
Brake pipe support bracket fixing screw (2) 25 Nm (18.44 lbf ft)
Parking brake cable guide fixing screw (1) 10 Nm (7.38 lbf ft)
Screw tightening ABS sensor (1) - M5 6 Nm (4.42 lbf ft)
HANDLEBAR / CONTROLS / TRANSMISSION
Name Torque in Nm
Anti-vibration weights fixing screw - M6x40 (2) 10 Nm (7.38 lbf ft)
Anti-vibration weight terminal - M8x1 (2) 35 Nm (25.81 lbf ft)
Front brake pump screw (2) 10 Nm (7.38 lbf ft)
Mirror support screw (2) 10 Nm (7.38 lbf ft)
Rear-view mirrors manual
Light switch (2) 1.5 Nm (1.11 lbf ft)
TCC stainless steel screw fixing upper U-bolt on lower U-bolt -
M8x25 (4) 25 Nm (18.44 lbf ft)
Screw fixing gearshift switch on handlebar- M4x10 (1) 2 Nm (1.47 lbf ft)
ELECTRICAL COMPONENTS
Name Torque in Nm
Hex head flanged screw fixing horn - M8x16 (1) 25 Nm (18.44 lbf ft)
TBEI flanged screw fixing multiple relay support - M6x16 (2) 10 Nm (7.38 lbf ft)
Self-locking M5 nut fixing single relay support (1) 6 Nm (4.42 lbf ft)
Voltage regulator hex head flanged fixing screw - M6x30 (2) 10 Nm (7.38 lbf ft)
Shear head screw fixing ignition lock - M8x40 (2) up to the breaking point
TCEI screw fixing ignition lock - M8x40 (1) 25 Nm (18.44 lbf ft)
LIGHTS / INSTRUMENT PANEL
Name Torque in Nm
Self-tapping screw 3.9x14 (4) 1 Nm (0.74 lbf ft)
Self-locking nut fixing light to light support - M6 (1) 10 Nm (7.38 lbf ft)
TCEI screw fixing light support to upper plate - M6x10(2) 10 Nm (7.38 lbf ft)
Self-locking M6 nut fixing light support to upper plate (2) 10 Nm (7.38 lbf ft)
TBC screw fixing instrument panel clamp - M5x20 (2) 1.5 Nm (1.11 lbf ft)
hex headscrew fixing instrument panel clamp - M5x15 (1) 1.5 Nm (1.11 lbf ft)
Self-tapping screw fixing front light to cover - 3.9x14 (4) 1 Nm (0.74 lbf ft)
TEF screw fixing light support to lower plate - M6x16 (2) 10 Nm (7.38 lbf ft)
Rear light self-tapping fixing screw - 5x14 (4) 1.5 Nm (1.11 lbf ft)
Self-locking flanged M5 nut fixing licence plate lamp retainer
(1) 6 Nm (4.42 lbf ft)
Turn indicator TCEI fixing screw - M6x20 (4) 1.5 Nm (1.11 lbf ft)
Light rim self-tapping fixing screw - 3.9x14 (4) 1 Nm (0.74 lbf ft)
TANK
Name Torque in Nm
Fuel pump fixing ring nut (1) 20 Nm (14.75 lbf ft)
Characteristics MSS Mana GT ABS
CHAR - 18

SADDLE
Name Torque in Nm
hex headflanged screw fixing saddle rotation bracket - M6x20
(2) 10 Nm (7.38 lbf ft)
Countersunk head, self-tapping screw fixing saddle hinges to
saddle bottom - 5 (4) 1.5 Nm (1.11 lbf ft)
Driver saddle rear hex headflanged fixing screw - M6x20 (2) 10 Nm (7.38 lbf ft)
Driver saddle lateral TCB fixing screw - 4.2x16 (2) 1 Nm (0.74 lbf ft)
FRONT BODYWORK
Name Torque in Nm
Front mudguard TBEI fixing screw - M5x12 (4) 6 Nm (4.42 lbf ft)
Right/left SWP crosshead flanged screw fixing helmet com-
partment - M5x20 (9) 1.5 Nm (1.11 lbf ft)
Battery cover TBEI fixing screw - M5x12 (2) 6 Nm (4.42 lbf ft)
Screw fixing shock absorber to helmet compartment - M6x20
(1) 10 Nm (7.38 lbf ft)
Self-locking M8 nut fixing shock absorber to helmet compart-
ment (1) 25 Nm (18.44 lbf ft)
Door switch TCB fixing screw - 3.9x14 (1) 1 Nm (0.74 lbf ft)
Lock TBEI fixing screw - M6x16 (2) 10 Nm (7.38 lbf ft)
Self-locking M6 nut fixing injection ECU to support (2) 10 Nm (7.38 lbf ft)
hex headflanged screw fixing cable harness ground cable on
injection ECU - M6x12 (2) 10 Nm (7.38 lbf ft)
Self-tappingscrewfixingECUsupportto compartment - 4.2x12
(2) 1 Nm (0.74 lbf ft)
hex headflanged screw fixing helmet compartment to chassis
- M6x20 (4) 10 Nm (7.38 lbf ft)
Right air deflector TBEI flanged fixing screw - M5x12 (2) 6 Nm (4.42 lbf ft)
TBEI flanged screw fixing right air deflector to expansion tank
- M5x9 (1) 4 Nm (2.95 lbf ft)
Left air deflector TBEI flanged fixing screw - M5x12 (3) 6 Nm (4.42 lbf ft)
Fairing TBEI flanged fixing screw - M5x12 (10) 6 Nm (4.42 lbf ft)
Steering lock housing TBEI fixing screw - M6x30 (2) 6 Nm (4.42 lbf ft)
Latch support TCB fixing screw - 4.2x16 (2) 1 Nm (0.74 lbf ft)
Stainless steel self-tapping screw for plast. fixing helmet com-
partment (14) 1 Nm (0.74 lbf ft)
Rear cover TBEI fixing screw - M5x12 (2) 6 Nm (4.42 lbf ft)
Rear cover TCB fixing screw - 4.2x16 (2) 1 Nm (0.74 lbf ft)
TBEI screw with front washer for fixing the instrument panel to
the side and top fairing elemnts M5x12 (6) 6 Nm (4.42 lbf ft)
Self-tapping screw to fix the instrument panel to the panel -
Diam.5x14 (3) 3 Nm (2.21 lbf ft)
TBEI screw for fixing the steering lock protection to the helmet
compartment - M6x35 (2) 10 Nm (7.38 lbf ft)
Allen screw for fixing the turn indicator to the side fairing -
M6x16 (1) 1.5 Nm (1.11 lbf ft)
TBEI screw with front washer for fixing the air deflector to the
helmet compartment and top fairing elements to the shield -
M5x12 (2)
6 Nm (4.42 lbf ft)
Screw for fixing top fairing element, air deflector and deflector
to the side fairing - Diam.3.9x10 (9) 1 Nm (0.74 lbf ft)
Allen screw for fixing the turn indicator to the side fairing -
M6x16 (1) 1.5 Nm (1.11 lbf ft)
TBEI screw for fixing the air deflector to the helmet compart-
ment and top fairing elements to the shield - M5x12 (2) 6 Nm (4.42 lbf ft)
Screw for fixing top faring element air deflector and deflector to
the side fairing - Diam.3.9x10 (9) 1 Nm (0.74 lbf ft)
TBEI screw with front washer for fixing the shield to the side
fairings - M6x25 (2) 10 Nm (7.37 lbf ft)
Screwfor fixingthe shieldand lampmounting tothe frontframe
- M6x25 (2) 10 Nm (7.37 lbf ft)
Screw to fix the front cover to the shield - Diam.5x14 (2) 3 Nm (2.21 lbf ft)
Screw to fix the lamp to the lamp mounting - 3.9x14 (4) 1 Nm (0.74 lbf ft)
MSS Mana GT ABS Characteristics
CHAR - 19

REAR BODYWORK
Name Torque in Nm
Grab handle hex headflanged fixing screw - M8x45 (2) 25 Nm (18.44 lbf ft)
Left tail section self-tapping fixing screw - 3.8 (3) 1 Nm (0.74 lbf ft)
hex headflanged screw fixing license plate holder frame -
M6x20 (2) 10 Nm (7.38 lbf ft)
License plate holder TBEI fixing screw - M5x12 (4) 6 Nm (4.42 lbf ft)
License plate holder TBEI fixing screw - M5x9 (2) 6 Nm (4.42 lbf ft)
License plate holder self-tapping fixing screw - 5 (2) 1.5 Nm (1.11 lbf ft)
License plate holder self-tapping fixing screw - 4.2 (5) 1 Nm (0.74 lbf ft)
Tank cover TCEI fixing screw - M6x16 (4) 10 Nm (7.38 lbf ft)
Countersunk head screw fixing mesh stud bolt - M8x35 (2) 25 Nm (18.44 lbf ft)
Tank protection TBEI fixing screw - M5x12 (1) 6 Nm (4.42 lbf ft)
ENGINE MAIN RETAINERS
Name Torque in Nm
hex headscrew fixing transmission cover on engine crankcase
- M6x35 (13) 12 Nm (8.85 lbf ft)
Central crankcases hex headfixing screw - M8x60 (11) 25 Nm (18.44 lbf ft)
hex headscrew fixing flywheel cover on engine crankcase -
M6x35 (16) 12 Nm (8.85 lbf ft)
Overhaul data
Assembly clearances
Cylinder - piston assy.
CAUTION
EACH CYLINDER TYPE, MADE OF ALUMINIUM OR CAST IRON, MUST BE COUPLED TO THE
SPECIFIC PISTON, AS SHOWN IN THE FOLLOWING TABLE.
- Pistons and cylinders are classified according to their diameter. This coupling is carried out in pairs
(A-A, B-B, C-C, D-D).
COUPLING CATEGORIES BETWEEN THE PISTON AND THE ALUMINIUM CYLINDER
Name Initials Cylinder Piston Play on fitting
Cylinder - Piston A 87.990 - 87.997 87.954 - 87.961 0.029 ÷ 0.043
Cylinder - Piston B 87.997 - 88.004 87.961 ÷ 87.968 0.029 ÷ 0.043
Cylinder - Piston C 88.004 - 88.011 87.968 ÷ 87.975 0.029 ÷ 0.043
Cylinder - Piston D 88.011 - 88.018 87.975 ÷ 87.982 0.029 ÷ 0.043
- Pistons and cylinders are classified according to their diameter. The coupling is carried out in pairs
(M-M, N-N, O-O, P-P).
COUPLING CATEGORIES BETWEEN THE PISTON AND THE CAST IRON CYLINDER
Name Initials Cylinder Piston Play on fitting
Cylinder - Piston M 87.990 - 87.997 87.933 - 87.940 0.050 - 0.064
Cylinder - Piston N 87.997 - 88.004 87.940 - 87.947 0.050 - 0.064
Cylinder - Piston O 88.004 - 88.011 87.947 - 87.954 0.050 - 0.064
Cylinder - Piston P 88.011 - 88.018 87.954 - 87.961 0.050 - 0.064
NOTE
THE ROTATION DIRECTION OF THE ENGINE AND OPPOSITE TO RUNNING, CONSEQUENTLY
THE PISTONS ARE ORIENTED IN A DIFFERENT WAY WHEN INSTALLING:
THE FRONT CYLINDER PISTON (RUNNING FRONT) MUST BE FITTED WITH THE ARROW TO-
WARDS THE INTAKE.
Characteristics MSS Mana GT ABS
CHAR - 20