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Aprilia · Overhead-cam four-stroke twin, dry sump, gearbox shares engine oil, chain drive

Mana 850

Library entry covers 2007-2016

39 factory 32 guideline

Published source

aprilia Mana GT ABS UK-NL 2009 Ed.01 use and maintenance book, Scheduled maintenance table pp.172-181

Factory owner's handbook. Covers Mana 850 GT ABS owner's manual UK-NL 2009 Ed.01 (894140).

71 items for a 2012 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Dry sump (separate oil tank)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Automatic or semi-automatic
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2012 Aprilia Mana 850

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 1,600 km or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 2,000 km

1 item

Check brake pads and discs

Brakes

Factory

Manual: Break pads - Check and replace if necessary. Factory: EVERY 2000 KM (1243 MI)

Every 5,000 km or 12 months

6 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Adjust automatic / semi-automatic clutch

Primary and gearbox

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline

Every 6,500 km or 12 months

1 item

Inspect, clean and gap spark plugs

Engine

Guideline

Every 9,500 km or 12 months

5 items

Inspect coolant hoses and clamps

Engine

Guideline
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 km

24 items

Bolts, nuts and screws tightening - Check and restore tightening torque

Engine

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Braking systems - Check

Engine

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Change engine oil

Engine

Factory

Manual: Engine oil - Change. Factory: At 1000 km (621 mi) checks; then at 10000 KM (6214 MI) and each 10,000 km block
Coolant - Check, top-up or change if necessary

Engine

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
General vehicle operation - Check

Engine

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Lights circuit - Check, adjust aiming or replace if necessary

Engine

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Safety switches - Check

Engine

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Suspensions and setting - Check and adjust if necessary

Engine

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter - Clean. Factory: Clean at 10k/30k/50k; replaced at 20k/40k
Clean battery terminals, check charge and strap

Ignition and electrics

Factory

Manual: Battery - Check terminal tightening.
Diagnosis for engine control unit and transmission ECU - Check

Primary and gearbox

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Transmission air filter - Clean

Primary and gearbox

Factory

Factory: Every 10,000 km block
Transmission bolts, nuts and screws tightening - Check and restore tightening torque

Primary and gearbox

Factory

Factory: As printed: AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Transmission gears and anti-vibration buffer - Control, check tightening, adjust and replace if necessary

Primary and gearbox

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Final transmission (chain, crown and pinion) - Check and clean, adjust, grease or replace if necessary

Final drive

Factory

Factory: As printed: AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 40000 KM (24855 MI); AT 50000 KM (34069 MI)
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings and steering clearance.
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Fork oil seals - Check and clean.
Brake discs - Check and clean, replace if necessary.

Brakes

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Brake fluid - Check, top-up or change if necessary.

Brakes

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Parking brake calliper - Check and adjust if necessary

Brakes

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings - Check.
Tire pressure - Adjust

Wheels and tires

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Tires - Check and replace if necessary

Wheels and tires

Factory

Factory: As printed: AT 1000 KM (621 MI); AT 10000 KM (6214 MI); AT 20000 KM (12427 MI); AT 30000 KM (18641 MI); AT 40000 KM (24855 MI)
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Transmission cables - Check, adjust and grease. Factory: Also at 1000 km

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 19,500 km or 2 years

2 items

Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 20,000 km

5 items

Drive belt - Replacement (CVT)

Engine

Factory

Factory: Listed at 20,000 and 40,000 km; variator sliders replaced too
Replace oil filter

Engine

Factory

Manual: Engine oil filter - Replace. Factory: Listed at 10,000, 30,000, 50,000, 70,000 km
Replace spark plugs

Engine

Factory

Manual: Spark plug - Replace. Factory: Listed at 20,000, 40,000, 60,000, 80,000 km
Variator sliders - Replace

Engine

Factory

Factory: As printed: AT 20000 KM (12427 MI); AT 40000 KM (24855 MI)
Replace air filter element

Fuel and air

Factory

Manual: Air filter - Replace. Factory: Listed at 20,000 and 40,000 km

Every 30,000 km

3 items

Check and adjust valve clearances

Engine

Factory

Manual: Tappet clearance - Check and adjust. Factory: Listed at 30,000, 60,000 and 80,000 km
Synchronize throttle bodies

Fuel and air

Factory

Manual: Throttle body - Clean and reset self-adjustable parameters. Factory: Listed at 30,000 and 60,000 km
Replace chain and sprockets (wear based)

Final drive

Factory

Manual: Final transmission (chain, crown and pinion) - Replace. Factory: Listed at 30,000 and 60,000 km; checked every 10,000 km

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 38,500 km or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 2 years

5 items

Replace coolant

Engine

Factory

Manual: Coolant - Change. Factory: EVERY 24 MONTHS
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Change fork oil

Front end

Factory

Manual: Fork oil - Change. Factory: EVERY 24 MONTHS
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Factory

Manual: Brake fluid - Change. Factory: EVERY 24 MONTHS

Every 4 years

3 items

Replace fuel lines

Fuel and air

Factory

Manual: Fuel pipes - Replace. Factory: EVERY 4 YEARS
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

2 items

Fuel pipes - Check and clean, replace if necessary

Fuel and air

Factory

Factory: As printed: AT 30000 KM (18641 MI)
Drive chain - Check and lubricate

Final drive

Factory

Factory: As printed: AT 1000 KM (621 MI)

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.