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Thread: Mana "Gear" issues

  1. #1
    apriliaforum newb
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    Mana "Gear" issues

    Evening guys,

    help needed.

    bought my mana couple of month ago.
    Last couple of days been having "Gear" warning issues.

    GEAR SYMBOL and warning light will come on 2-3 times during a 20mile journey.
    the bike will not change up or down and will be stuck in the gear it was in when it goes into GEAR warning.
    seems to happen at random intervals, mainly after hard acceleration and the easing off slightly or at around a70-90mph constant speed.
    bike will come up with GEAR SYMBOL and will be stuck in the gear it was in. When you come to A stop the bike wants to lurch forward. I then have to switch off and back on sometimes several times to reset it.

  2. #2
    apriliaforum prov-nov Gdaz's Avatar
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    Search this forum for "Variator Threads" or "Greasing Variator Threads". If your bike is an early model it is likely that this may be the cause. If you got it from a dealer, take it back under your warranty and have them perform the work for you (if as in Australia, you get a 3 month warranty on second hand motor vehicles from a dealer).

  3. #3
    apriliaforum newb
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    Thanks for the reply.

    been away, just got back and stripped the cvt.
    there seemed to be grease in the variator threads. Cleaned it out and re greased. All back together and taken for a run. No change. Gear light comes on, no rain, touring or sport showing, just the gear symbols. Any other thoughts?

  4. #4
    apriliaforum Member
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    Hey, welcome to the club (
    i am suffering from the same thing for a year or two....
    there was a guy from Luxembourg (if i remember right) who manage to get rid of it by changing potentiometer but this requires to retrain TCU while here in Michigan I have no Aprilia service (so no aprilia diagnostic tools) at all......

  5. #5
    apriliaforum Junkie AndyT's Avatar
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    Hi Guys, if you have no other apparent symptoms of belt wear or variator problems this might be the relay that switches things. It has been the subject of several threads on here and I tracked down a link to one of them for you.

    http://www.apriliaforum.com/forums/s...ghlight=relais
    2009 Mana GT ABS; Andreani fork cartridges with uprated springs; Dorsoduro hand guards and heated grips; 30mm handlebar risers; Digital tachograph: Modified woodcraft folding brake pedal; R&G frame sliders

  6. #6
    apriliaforum Member
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    i have changed this thing already and overall transmission behavior became somehow smoother however "gear" still persists....

  7. #7
    apriliaforum Member
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    Hi Pharao,
    i am thinking about the same thing and I even purchased a new sensor, but in order to replace it I have to retrain TCU.... but since I have no Aprilia service around me I got stuck.....
    in the dealership where I purchased my MANA the only think they have is GameBoy for aprilia scooters but I doubt it has TCU retraining option....

  8. #8
    apriliaforum newb
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    Update,

    the bike has has been sorted.
    several resets and software updates later.

    the issue was found.

    the platic transmission shaft inside the transmission was bent, and the two bearings worn either end, probably done at the the belt service.
    Bearings and shaft replaced and it's all good.
    i know I have seen posts about the same issue, get a mechanic to check this, it solved my issues and now have a very happy Mana

  9. #9
    apriliaforum newb dhodesigns's Avatar
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    Requesting your insight on this problem you got fixed.

    Quote Originally Posted by Gumball View Post
    Update,

    the bike has has been sorted.
    several resets and software updates later.

    the issue was found.

    the platic transmission shaft inside the transmission was bent, and the two bearings worn either end, probably done at the the belt service.
    Bearings and shaft replaced and it's all good.
    i know I have seen posts about the same issue, get a mechanic to check this, it solved my issues and now have a very happy Mana

    My 2009 Mana recently went through what you had discribed. I sent my local Aprilia mechanic this thread but we are a bit unclear on which part you got replaced to solve the problem. Can you please take a look at the attached image and see if you can point out which part you mentioned. Thanks so much.

    dho
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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    Click image for larger version. 

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  10. #10
    apriliaforum prov-nov jpsplus's Avatar
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    the only plastic shaft in this region is:Name:  intermediate shaft.jpg
Views: 108
Size:  97.8 KB

    please correct me if I am wrong

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