2007 Aprilia NA 850 Mana Service & Repair Manual (P/N 854171)

Aprilia Service Station Manual 854171 is the 2007 service publication for the NA 850 Mana, covering scheduled maintenance, mechanical repair, and electronic diagnosis.

• Maintenance: Scheduled inspections, engine oil and filter changes, spark-plug service, and valve-clearance checks and adjustment.

• Engine repair: Engine removal, cylinder-head and piston work, cam timing, crankcase separation, crankshaft inspection, and oil-pump overhaul.

• CVT and clutch: Drive-belt and variator-slider replacement, pulley-bearing service, clutch inspection, and transmission reset requirements.

• Electrical diagnosis: Marelli injection and transmission ECU troubleshooting, Axone parameters, immobilizer faults, CAN communication, connector pin-outs, sensor resistance data, and fuse specifications.

• Suspension and chassis: Fork disassembly and reassembly, wheel-bearing checks, steering-bearing adjustment, rear shock removal, and exhaust service.

• Cooling and brakes: Coolant replacement and bleeding, water-pump seal work, radiator removal, rear and parking-caliper removal, and front brake-pad removal.

This manual is suited to mechanics familiar with internal engine work and electrical testing, with access to the specified measuring tools and Axone diagnostic equipment.

Engine Repair and Scheduled Maintenance

The maintenance section outlines service intervals from 1,000 km through 80,000 km, along with time-based fluid and hose replacement schedules.

Engine procedures distinguish front and rear camshafts, timing references, and tone-wheel arrangements. Cylinder-base gasket selection uses piston projection measurements, while the lubrication circuit and diagnosis guide support investigation of low oil pressure.

Overhaul limits: Several piston-ring, wrist-pin, connecting-rod small-end, and main-bearing selection checks refer to a Specifications chapter that is not included in this file.

Crankshaft fitting notes explain how incorrect alignment of the specified installation tips can damage the main bushings.

CVT Belt, Pulley, and Clutch Service

Mechanical procedures cover the driving and driven pulleys, control bushings, clutch spring, and final-drive shaft bearings. Special tools include clutch/belt tool 020659Y and driving-pulley holding tool 020660Y.

The electronic sections distinguish Axone reset functions for OBD 2006 modules from the two-phase routines used with earlier yellow- or black-label modules.

The replacement-ECU warning explains why reusing a worn belt can make the new controller misjudge wear and cause belt failure.

Injection, Transmission, and Wiring Diagnostics

Fault-code entries pair error causes with sensor, connector, and harness checks. This helps isolate the source of a GEAR warning before replacing transmission components.

Throttle-body coverage includes throttle-position autodetection and self-adjustable parameter resets after cleaning. Separate diagnostics cover the lambda probe, engine-oil-pressure switch, driving-pulley position sensor, and driven-pulley speed sensor.

The general wiring diagram is supported by component locations and harness-side connector views, including throttle/idle-motor and driven-pulley sensor connections. Glove-box light wiring differs by serial number; the manual distinguishes the layouts by Bi/R versus V wiring.

Working on modern motorcycle electrical systems presents inherent risks to both the technician and the sensitive control modules.

Fork, Brake, and Cooling-System Work

The front-fork exploded view accompanies seal and bushing replacement, damper bleeding, and oil-level specifications. Chassis illustrations identify swingarm and exhaust components.

Brake procedures focus on removing the rear and parking calipers and the front brake pads. The braking section does not provide a full hydraulic overhaul or ABS diagnostic procedure.

The cooling circuit diagram accompanies radiator, fan, and expansion-tank removal. Water-pump mechanical-seal replacement is covered with the engine installed; shaft and shaft-oil-seal work requires opening the crankcase.

Examples of Oil-Pressure and Clutch Inspection Data

These are a few of the inspection specifications included in the engine and CVT sections.

The lubrication diagnosis guide lists approximately 4.5 bar at 1,400 rpm with oil at 20°C, and approximately 1.5 bar at the same speed with oil at 80°C.

For clutch inspection, the minimum permitted friction-material thickness is 1 mm.

PDF Navigation, Diagram Detail, and Page Count

Search and diagram detail: Text search is not usable in this file, and there are no embedded PDF bookmarks. Small labels in the general wiring diagram remain partly difficult to read when enlarged; the separate component-connector views are clearer.

One printable, English-language 268-page PDF. The total includes six opening pages comprising the cover, introductory material, topic index, and one blank page, as well as all section divider and end pages.