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Aprilia Na 850 Mana 2009 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Mana 850 Year: 2009 Model Variant: GT (Gear Transfer) 👋 Introduction Market Position Vehicle Segment: Sport Touring / Naked Sportbike with unique automatic transmission. Target Audience: Riders seeking a comfortable, practical, yet engaging motorcycle with the convenience of automatic shifting. Competitive Analysis Key Competitors 2009: Honda VFR800, Kawasaki Z1000, Yamaha FZ8, Ducati Monster series (for performance/style aspect). Key Features Unique Selling Proposition: The integrated CVT automatic transmission (hence 'Mana') offering distinct riding modes and seamless operation, combined with a sporty chassis and V-twin engine. Design Philosophy: Blend of sportbike performance with touring comfort and everyday usability. 📋 Manual Details Coverage Areas Manual Type: Full Service Repair Manual Language: English Format: Digital (PDF assumed for comprehensive service manuals of this era) Page Count Estimated Page Count: 300-500 pages (typical for a full service manual) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, inspection, timing, valve adjustment, cylinder head, pistons, crankshaft, lubrication system. Engine Management: Fuel injection system (EFI), throttle body, injectors, ECU diagnostics, sensor testing (MAP, TPS, IAT, O2), ignition system, spark plugs, coils. Transmission Drivetrain: Continuously Variable Transmission (CVT) operation, maintenance, service, inspection. Final drive assembly, chain and sprockets (if applicable to variant), oil. Brakes: Hydraulic brake system, front and rear calipers, master cylinders, brake lines, brake fluid specifications and bleeding procedures, ABS (if equipped). Suspension: Front telescopic forks (adjustment, seals, oil change), rear monoshock absorber (preload, damping adjustment, linkage service). Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting (headlights, taillights, indicators), horn, fuse box, relay functions. Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, fuel pressure testing. Cooling System: Radiator, coolant, water pump, thermostat, fan operation, coolant capacity and type. Frame Chassis: Frame inspection, steering head bearings, swingarm bearings, wheel bearings. Bodywork: Fairing removal and installation, seat, fuel tank cover, fenders, accessory fitting. Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment/lubrication (if applicable), brake pad inspection, tire pressure checks. Troubleshooting: Diagnostic flowcharts, common problem identification and solutions for engine, electrical, and mechanical systems. Repair Procedures: Step-by-step instructions for component disassembly, repair, and reassembly, including engine internals, transmission, brakes, suspension. Diagnostic Tests: Procedures for testing sensors, actuators, ignition system components, fuel system pressure, electrical circuits. Technical Specifications: Torque values, clearances, fluid capacities, electrical resistance values, diagnostic trouble codes (DTCs). Technical Depth Depth Of Coverage: Comprehensive from basic owner maintenance to full engine and transmission rebuilds. Includes detailed diagnostic procedures for electronic systems. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) - Searchable, bookmarkable, printable. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Physical Format Potential: Professionally bound (if printed version), spiral binding for lay-flat use. Paper Type Physical Format Potential: Durable paper stock suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 8-valve, SOHC V-twin Displacement: 839.3 cc Bore X Stroke: 90 mm x 66 mm Compression Ratio: 9.4:1 Performance Horsepower Claimed: 75 HP @ 7,750 rpm Torque Claimed: 77.2 Nm (57 lb-ft) @ 5,000 rpm Fuel System Fuel Delivery: Sequential Electronic Fuel Injection (EFI) with 38mm throttle bodies Fuel Type: Unleaded gasoline, minimum 95 RON (octane rating) Ignition Ignition System: Electronic ignition, TCI (Transistor Controlled Ignition) 🔧 Transmission Standard Transmission Type: Continuously Variable Transmission (CVT) with 3 distinct modes (Touring, Sport, Manual via paddle shifters). Final Drive: Chain drive (though the 'Mana' implies a unique final drive, review of specific 2009 model confirms chain drive) Features Transmission Control: Electronically controlled automatic with manual override. 📐 Dimensions Exterior Length: 2150 mm (84.6 in) Width: 810 mm (31.9 in) Height: 1105 mm (43.5 in) Wheelbase: 1515 mm (59.6 in) Weights Dry Weight: 184 kg (405.7 lbs) Wet Weight: Approx. 205 kg (452 lbs) (with all fluids) Cargo Storage Compartment: Under-seat storage designed to fit a full-face helmet (a unique feature). 🛡️ Safety Features Ratings ABS Availability: Optional ABS (Anti-lock Braking System) Active Features Braking System: Dual 320mm front discs with radial four-piston calipers, 280mm rear disc with twin-piston caliper. Tires: Tubeless radial tires. Front: 120/70-17, Rear: 180/55-17 (standard fitment). Passive Features Lighting: Halogen headlight, LED taillight. 💡 Technology Features Infotainment Dashboard Display: Digital instrument cluster with speedometer, tachometer, fuel gauge, gear indicator (for manual mode), clock, trip meters, engine temperature, and mode indicators. Driver Assistance Riding Modes: Three distinct selectable modes for the CVT: Touring (smooth, economical), Sport (responsive, higher RPM engagement), and Manual (sequential shifting via handlebar-mounted paddles). Connectivity Diagnostic Port: On-board diagnostics (OBD) port for electronic fault code retrieval and analysis. 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 miles) or annually, whichever comes first. Air Filter Check: Check every 6,000 km (3,700 miles), clean/replace as needed. Spark Plug Replacement: Every 12,000 km (7,500 miles). Valve Clearance Check: Every 12,000 km (7,500 miles)....
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Aprilia Na 850 Mana 2009 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Mana 850
Year:
2009
Model Variant:
GT (Gear Transfer)
👋 Introduction
Market Position
Vehicle Segment:
Sport Touring / Naked Sportbike with unique automatic transmission.
Target Audience:
Riders seeking a comfortable, practical, yet engaging motorcycle with the convenience of automatic shifting.
Competitive Analysis
Key Competitors 2009:
Honda VFR800, Kawasaki Z1000, Yamaha FZ8, Ducati Monster series (for performance/style aspect).
Key Features
Unique Selling Proposition:
The integrated CVT automatic transmission (hence 'Mana') offering distinct riding modes and seamless operation, combined with a sporty chassis and V-twin engine.
Design Philosophy:
Blend of sportbike performance with touring comfort and everyday usability.
📋 Manual Details
Coverage Areas
Manual Type:
Full Service Repair Manual
Language:
English
Format:
Digital (PDF assumed for comprehensive service manuals of this era)
Page Count
Estimated Page Count:
300-500 pages (typical for a full service manual)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, inspection, timing, valve adjustment, cylinder head, pistons, crankshaft, lubrication system.
Engine Management:
Fuel injection system (EFI), throttle body, injectors, ECU diagnostics, sensor testing (MAP, TPS, IAT, O2), ignition system, spark plugs, coils.
Transmission Drivetrain:
Continuously Variable Transmission (CVT) operation, maintenance, service, inspection. Final drive assembly, chain and sprockets (if applicable to variant), oil.
Brakes:
Hydraulic brake system, front and rear calipers, master cylinders, brake lines, brake fluid specifications and bleeding procedures, ABS (if equipped).
Suspension:
Front telescopic forks (adjustment, seals, oil change), rear monoshock absorber (preload, damping adjustment, linkage service).
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting (headlights, taillights, indicators), horn, fuse box, relay functions.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel lines, fuel pressure testing.
Cooling System:
Radiator, coolant, water pump, thermostat, fan operation, coolant capacity and type.
Frame Chassis:
Frame inspection, steering head bearings, swingarm bearings, wheel bearings.
Bodywork:
Fairing removal and installation, seat, fuel tank cover, fenders, accessory fitting.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment/lubrication (if applicable), brake pad inspection, tire pressure checks.
Troubleshooting:
Diagnostic flowcharts, common problem identification and solutions for engine, electrical, and mechanical systems.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly, including engine internals, transmission, brakes, suspension.
Diagnostic Tests:
Procedures for testing sensors, actuators, ignition system components, fuel system pressure, electrical circuits.
Technical Specifications:
Torque values, clearances, fluid capacities, electrical resistance values, diagnostic trouble codes (DTCs).
Technical Depth
Depth Of Coverage:
Comprehensive from basic owner maintenance to full engine and transmission rebuilds. Includes detailed diagnostic procedures for electronic systems.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format) - Searchable, bookmarkable, printable.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Physical Format Potential:
Professionally bound (if printed version), spiral binding for lay-flat use.
Paper Type
Physical Format Potential:
Durable paper stock suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 8-valve, SOHC V-twin
Displacement:
839.3 cc
Bore X Stroke:
90 mm x 66 mm
Compression Ratio:
9.4:1
Performance
Horsepower Claimed:
75 HP @ 7,750 rpm
Torque Claimed:
77.2 Nm (57 lb-ft) @ 5,000 rpm
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (EFI) with 38mm throttle bodies
Fuel Type:
Unleaded gasoline, minimum 95 RON (octane rating)
Ignition
Ignition System:
Electronic ignition, TCI (Transistor Controlled Ignition)
🔧 Transmission
Standard
Transmission Type:
Continuously Variable Transmission (CVT) with 3 distinct modes (Touring, Sport, Manual via paddle shifters).
Final Drive:
Chain drive (though the 'Mana' implies a unique final drive, review of specific 2009 model confirms chain drive)
Features
Transmission Control:
Electronically controlled automatic with manual override.
📐 Dimensions
Exterior
Length:
2150 mm (84.6 in)
Width:
810 mm (31.9 in)
Height:
1105 mm (43.5 in)
Wheelbase:
1515 mm (59.6 in)
Weights
Dry Weight:
184 kg (405.7 lbs)
Wet Weight:
Approx. 205 kg (452 lbs) (with all fluids)
Cargo
Storage Compartment:
Under-seat storage designed to fit a full-face helmet (a unique feature).
🛡️ Safety Features
Ratings
ABS Availability:
Optional ABS (Anti-lock Braking System)
Active Features
Braking System:
Dual 320mm front discs with radial four-piston calipers, 280mm rear disc with twin-piston caliper.
Tires:
Tubeless radial tires. Front: 120/70-17, Rear: 180/55-17 (standard fitment).
Passive Features
Lighting:
Halogen headlight, LED taillight.
💡 Technology Features
Infotainment
Dashboard Display:
Digital instrument cluster with speedometer, tachometer, fuel gauge, gear indicator (for manual mode), clock, trip meters, engine temperature, and mode indicators.
Driver Assistance
Riding Modes:
Three distinct selectable modes for the CVT: Touring (smooth, economical), Sport (responsive, higher RPM engagement), and Manual (sequential shifting via handlebar-mounted paddles).
Connectivity
Diagnostic Port:
On-board diagnostics (OBD) port for electronic fault code retrieval and analysis.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or annually, whichever comes first.
Air Filter Check:
Check every 6,000 km (3,700 miles), clean/replace as needed.
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Fluid Specifications
Engine Oil Type:
API SG, JASO MA certified synthetic or semi-synthetic motorcycle oil, SAE 10W-40 or 15W-50 depending on ambient temperature.
Engine Oil Capacity:
2.7 Liters (2.87 US qt) without filter change, 2.9 Liters (3.06 US qt) with filter change.
Brake Fluid Type:
DOT 4
Coolant Type:
Ethylene glycol-based coolant, 50% mixture with distilled water.
Coolant Capacity:
Approx. 2.1 Liters (2.2 US qt)
Known Issues
Cvtvibration:
Some owners have reported occasional minor vibrations at specific RPM ranges or during mode transitions, though generally considered robust.
Fuel Pump Reliability:
Rare instances of fuel pump issues, typically addressed with careful diagnosis and replacement.
Electrical Connectors:
Standard motorcycle maintenance practice to ensure all electrical connectors are clean and secure to prevent minor electrical gremlins.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian motorcycle manufacturer known for its performance-oriented and innovative models, particularly in the racing and sportbike segments.
Model Evolution
Introduction Year:
The Aprilia Mana 850 was first introduced in 2007, with the GT variant and revised styling appearing for the 2009 model year.
Key Innovations:
Pioneered the integration of a sophisticated CVT automatic transmission in a large-displacement motorcycle, offering a unique user experience.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards for the 2009 model are not widely documented, the Mana series was recognized for its innovative approach to automatic transmission in motorcycles.
Ratings
Owner Satisfaction:
Generally positive among owners who appreciated its unique blend of performance, comfort, and convenience, particularly for commuting and touring.
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