2014 Aprilia SRV-850 (Service Manual)

SERVICE STATION MANUAL
(EN) 677522
SRV 850
SERVICE STATION
MANUAL
SRV 850
THE VALUE OF SERVICE

As a result of continuous updates and specific technical training programmes for Aprilia products, only
Aprilia Official Network mechanics know this vehicle fully and have the specific tools necessary to carry
out maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding
it, its regular maintenance and the use of original Aprilia spare parts only are essential factors!
For information on the nearest Official Dealer and/or Service Centre consult our website:
www.aprilia.com
Only by requesting aprilia original spare parts can you be sure of purchasing products that were
developed and tested during the actual vehicle design stage. All aprilia original spare parts undergo
quality control procedures to guarantee reliability and durability.
The descriptions and images in this publication are given for illustrative purposes only and are not binding.
While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &
C. S.p.A. 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.
The Aprilia trademark is the property of Piaggio & C. S.p.A.
© Copyright 2012 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com
SERVICE STATION MANUAL
SRV 850
This manual provides the main information to carry out regular maintenance operations on your vehicle.
This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been
deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, Piaggio & C. S.p.a. commits itself
to continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all Aprilia Sales Outlets and its International
Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of
need or further queries on repair and check procedures, consult Aprilia CUSTOMER DEPARTMENT,
which will be prepared to provide any information on the subject and any further communications on
updates and technical changes related to the vehicle.
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 Sections marked with this 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
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
INJECTION INJEC
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
INDEX OF TOPICS
CHARACTERISTICS CHAR
SRV 850 Characteristics
This section describes the general specifications of the vehicle.
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well-
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spare parts may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. Using unsuitable
coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.
CHAR - 7
Characteristics SRV 850
Vehicle identification
Chassis prefix (A):

ZAPM55103
Engine prefix (B):

M554M
Dimensions and mass
CHAR - 8
WEIGHT AND DIMENSIONS

Specification Desc./Quantity
Maximum height 1350 mm
Width 800 mm
Wheelbase 1585 mm
Length 2240 mm
Kerb mass 276 ± 13 kg
Empty weight 260 ± 13 kg
Maximum ground allowed 460 kg
Engine
ENGINE
Type 90° V-twin engine, 4-stroke, with double spark plug
Engine capacity 839 cm3
Bore x stroke 88 x 69 mm
Compression ratio 10.5 ± 0.5 : 1
Engine idle speed 1,250 ± 100 rpm
Timing system 4 valves, single overhead camshaft, chain-driven.
Valve clearance Inlet: 0.15 mm
Outlet: 0.15 mm
MAX. torque 75 Nm at 6,000 rpm
MAX. power 56 kW at 7,750 rpm
Lubrication Engine lubrication by a dry sump system, with double lobe
pump (one for delivery and one for return), controlled by a chain
and paper filter.
Lubrication pressure 3.5 ÷ 4 bar
Minimum lubrication pressure (100° C) 0.8 bar
Fuel system Multipoint electronic injection with single Ø 38-mm throttle body
and electric fuel pump.
Cooling Forced-circulation coolant system.
Fuel Unleaded petrol (95 RON)
TECHNICAL SPECIFICATIONS
OIL PUMP
Type Trochoidal
Rotor washers Delivery pump: 12 mm
Scavenge pump: 22 mm
Assembly clearances Lobe ends: 0.04 ÷ 0.1 mm
External rotor radial clearance 0.05- 0.12 mm
Levelness 0.1 mm
BY-PASS
Type with piston
Plunger diameter Ø 14-0.016 -0.043 mm
Unloaded spring length 52 mm
Calibration pressure 4.5 bar
OIL FILTER
Type Paper with pressure relief and anti-drain back by-pass valves
CHAR - 9
OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH

Calibration 0.3 - 0.6 bar
HEAD LUBRICATION CONTROL JET

Diameter 1 ± 0.05 mm *
* Tightening torque 5÷7 N·m
PISTON COOLING NOZZLE

Diameter Ø 1 ± 0.05 mm
CRANKCASE VENTILATION CHECK

Device metal reed valve and decantation chamber
Cooling system capacity 2.4 l
Recommended fluid AGIP PERMANENT SPEZIAL
Sealing pressure Cap calibrated at 0.9 bar
THERMOSTAT
Type Wax-type, with deviator
Starts opening at 85±2°C
ELECTRIC VENTILATION
Type With piston
Electric ventilation starts at 105°C
Electric ventilation stops at 100°C
WATER PUMP
Type Centrifugal
Control Gear on oil delivery pump
RADIATOR
Type Aluminium, with horizontal circulation
EXPANSION TANK
Calibration Automatic bleeding, in parallel with the radiator
Transmission
TRANSMISSION
Main drive Automatic expandable pulley variator with torque server, V-
belt, automatic dry self-ventilating clutch.
CHAR - 10
Secondary reduction
Gear reduction unit in oil bath.
Final transmission Chain-driven
Capacities
CAPACITY
Engine oil 2.5 l (without oil filter replacement)
2.6 l (with oil filter replacement)
Cooling system fluid ~ 2.4 l
Fuel tank (reserve) ~18,8 l ± 0,5 l (~3 l)
Electrical system
ELECTRICAL SYSTEM
Starter Electric
Ignition Electronic, inductive, high efficiency ignition, integrated with the
injection system, with variable advance and separate HV coil.
Ignition advance Three-dimensional map managed by control unit
Spark plug NGK CR7EKB
Alternative spark plug -
Battery 12V/14 Ah, sealed battery
Generator Three-phase alternating current, 450W.
Frame and suspensions
FRAME AND SUSPENSIONS

Chassis Double cradle with tubular and steel stamped plates
Front suspension Hydraulic telescopic fork, single plate, ø 41-mm straight stems.
Front suspension travel 126 mm
Oil quantity per stem 295 ± 3 cm³
Unloaded spring length ----- mm
Rear suspension Single shock absorber that acts directly on the fork.
Rear suspension travel 135 mm
Brakes
BRAKES
Front brake Ø 300-mm double disc brake with hydraulic control activated
by the handlebar right-hand lever.
Two floating callipers, ø 28 double plunger
Rear brake Ø 280-mm disc brake, with hydraulic servo operated from the
handlebar with the left-hand lever.
One floating calliper with a single plunger
CHAR - 11
Wheels and tyres
WHEELS AND TYRES

Wheel rim type Light alloy wheel rims.
Front rim 16'' x 3.50
Rear rim 15'' x 4.50
Front tyre Tubeless, 120/70 - 16" 57H
Rear tyre Tubeless, 160/60 - 15" 67H
Front tyre pressure (with passenger) 2.5 bar (-)
Rear tyre pressure (with passenger) 2.75 bar (-)
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 pad fixing screw@ 10 - 14
injector fixing screw 3-4
Intake 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
Clutch ring nut 65 - 75
External transmission cover screws 5÷7
Internal transmission cover screws 11 - 13
Air deflector screws 3-4
Air outlet grid screws 3-4
CHAR - 12
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
COOLING
Name Torque in Nm
Water pump rotor cover 3 ÷ 4 Nm (2.2 ÷ 2.95 lb ft)
bleed screw 3 ÷ 4 Nm (2.2 ÷ 2.95 lb ft)
Water pump rotor 4 ÷ 5 Nm (2.95 ÷ 3.69 lb ft)
Water pump gear protection plate tightening screws 3 ÷ 4 Nm (2.21 ÷ 2.95 lb ft)
CHASSIS
Name Torque in Nm
Side stand bolt nut 37 Nm
Screws fixing side stand button 6 Nm
Screw fixing electric fan - radiator 2 - 3 Nm
Screw fixing radiator - chassis 5 - 7 Nm
HANDLEBAR
Name Torque in Nm
Screws fixing handlebar supporting plate - steering tube 50 - 55 Nm
Screws fixing frame - supporting plate 4.5 - 7 Nm
Screws fixing half-handlebars - supporting plate 20 - 25* Nm
Screw fixing half-handlebar insert - half-handlebar 20 - 25* Nm
Handlebar cover fixing screw 2.5 - 4 Nm
Brake pump stand fixing screws 7 - 10 Nm
(°) Apply LOCTITE 243 threadlock
MISCELLANEOUS
Name Torque in Nm
Starter motor retainers 11 Nm - 13 Nm (8.11 lb ft - 9.59 lb ft
BRAKING SYSTEM
Name Torque in Nm
Brake pipes / rear brake calliper coupling 20 ÷ 25
Brake pipes / brake pump coupling 16 ÷ 20
Screws fixing front brake disc to rim 25
Screws fixing rear brake disc to rim 25
Screws fixing brake pump to handlebar 7 ÷ 10
Screw fixing three-way union to the chassis --
Screws fixing front brake calliper to fork 20 ÷ 25
Screw fixing rear brake calliper to supporting plate 20 ÷ 25
Screw fixing parking brake calliper to supporting plate 24 ÷ 27
Brake calliper bleed screw 4÷7
Parking brake adjusting nut 10
Nut fixing rear brake pipe retaining clip 11 - 13
Pin fixing parking brake pads 15 to 20
Brake pipes / three-way union coupling 18 ÷ 23
Brake pipes / front brake calliper coupling 16 ÷ 20
Rear brake pad fixing pins 15 to 20
CHAR - 13
Overhaul data
Assembly clearances
Cylinder - piston assy.
HEIGHT TO MEASURE THE PISTON

A 10 mm (0.393 in)
B 43 mm (1.69 in)
CYLINDER - PISTON
Cylinder Ø C 88 mm (+0.018; -0.01) mm (3.4645 in (+0.0007; -0.00039) in)
Piston Ø P 87.968 mm (+/- 0.014 mm) (3.4632 in (+/- 0.0005)in)
COUPLING CATEGORIES
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 ÷ 87.004 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
NOTE
CHAR - 14
THE ROTATION DIRECTION OF THE ENGINE IS OPPOSITE TO THE DIRECTION OF TRAVEL,

THEREFORE THE ASSEMBLY OF THE PISTONS ARE ORIENTED IN A DIFFERENT WAY:
THE FRONT CYLINDER PISTON (FRONT TRAVEL) MUST BE FITTED WITH THE ARROW
TURNED TOWARDS THE INTAKE.
THE REAR CYLINDER PISTON, UNLIKE THE FRONT ONE, MUST BE FITTED WITH THE ARROW
TURNED TOWARDS THE EXHAUST. THE PISTON RINGS MUST BE FITTED WITH THE «TOP»
REFERENCE OR THE TRADEMARK FACING UP.
- Calculate the coupling clearance between pin
and connecting rod small end.
Characteristic
Standard clearance:
0.015 - 0.029 mm
- Measure the diameter of the bearings on the pis-

ton.
Characteristic
Standard diameter:
22 + 0.006 +0.001 mm
- Calculate the pin - piston coupling clearance.

NOTE
THE PIN HOUSINGS HAVE TWO LUBRICATION CHANNELS FOR THIS REASON MEASURE THE
DIAMETER ACCORDING TO THE PISTON AXIS
Characteristic
Standard clearance:
0.001 ÷ 0.010 mm
- Check that coating is free from flakes.

- Check that the coupling surface with the head is
not worn or misshapen.
Characteristic
Maximum run-out allowed:
0.05 mm
- Pistons and cylinders are classified according to their diameter. This coupling is carried out in pairs
(A-A, B-B, C-C, D-D).
CHAR - 15
Piston rings
* Fit piston rings «2» and «3» with the mark «TOP» facing up.
** Position the opening in the rings as shown in this figure.
*** Value «A» of the sealing ring inside the cylinder.
Check the size of the sealing ring opening:

Compression ring: 0.15 ÷ 0.35 mm. Max. value: 0.5 mm
Scraper ring: 0.25 ÷ 0.50 mm. Max. value: 0.65 mm
Scraper ring: 0.25 ÷ 0.50 mm. Max. value: 0.65 mm
Rings/slots coupling clearances:

Carefully clean the sealing rings housings.
Check coupling clearances by placing a thickness
gauge between the ring and the slot as shown in
the figure.
Top ring: Standard coupling clearance:
0.01÷0.06 mm
Maximum clearances allowed after use: 0.10
mm
Middle ring: Standard coupling clearance:
0.02÷0.07 mm
CHAR - 16

mm
Oil scraper ring: Standard coupling clear-
ance: 0.01÷0.06 mm
mm
If clearances measured exceed the maximum val-
ues specified in the table, the piston should be
replaced by a new one.
Cylinder head
Clean all the coupling surfaces thoroughly before servicing the head. Pay attention to the position of
the springs and valves so as not to change the original position upon refitting them
- Using a trued bar and a thickness gauge, check

that the cylinder head surface is not worn or dis-
torted.
Characteristic
Maximum run-out allowed:
0.1 mm
- In case of irregularities, replace the head.

- Check the sealing surfaces for the inlet and exhaust manifold.
- Check that the camshaft and the rocker pin bearings show no signs of wear.
- Check that the head cover show no signs of wear.
- Check that the coolant sealing buffer is not rusted.
- Fit the valves into the cylinder head.

- Alternatively test the intake and exhaust valves.
- The test should be carried out by filling the mani-
fold with fuel and checking that the head does not
ooze through the valves when they are just press-
ed by the fingers.
CHAR - 17
Measure the camshaft seat bearings and rocking

lever support pins with a bore meter
HEAD BEARINGS
Bearing "A" 42 +0.025
Bearing "B" 19.5 -0.2
Bearing "C" 13 +0.018
- Measure the unloaded spring length.
Characteristic
Standard length:
44.4 mm
Limit allowed after use:
42.4 mm
- Remove any carbon deposits from the valve

seats.
- Check the width of the mark on the valve seat
«V» with Prussian blue.
Characteristic
Standard value:
1 - 1.3 mm
Limit allowed:
1.6 mm
- If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45°
milling cutter and then grind.
- Replace the head in case of excessive wear or damage.
VALVE STANDARD LENGTH

Inlet: 95.0 ± 0.3 mm
Outlet: 94.2 ± 0.3 mm
CHAR - 18
- Measure the diameter of the valve stem at the three positions indicated in the diagram.
STANDARD DIAMETER
Inlet: 4.987 ÷ 4.972 mm
Outlet: 4.975 ÷ 4.960 mm
MINIMUM DIAMETER ALLOWED

Inlet: 4.96 mm
Outlet: 4.945 mm
- Calculate the clearance between the valve and

its guide.
- Check the deviation of the valve stem by resting

it on a «V» shaped support and measuring the ex-
tent of the deformation using a dial gauge.
Characteristic
Limit value allowed:
0.1 mm
CHAR - 19
- Check the concentricity of the valve head by

placing a dial gauge at right angles to the valve
head and rotating it on the «V» shaped support.
Characteristic
Limit allowed:
0.03 mm
Measure the valve guides.
Characteristic
Valve guide:
5+0.012 mm
- After measuring the valve guide diameter and the

valve stem diameter, check the clearance be-
tween guide and stem.
EXHAUST
Standard clearance: 0.025 - 0.052 mm
Limit allowed: 0.09 mm
INTAKE
Standard clearance: 0.013 ÷ 0.04 mm
Limit allowed: 0.08 mm
CHAR - 20
- Check that there are no signs of wear on the

mating surface with the set screw articulated ter-
minal.
- If no faults are found during the above checks,

the same valves can be reused. For better sealing
results, we recommend grinding the valve seats.
Grind the valves gently with fine-grained lapping
compound. Upon grinding, keep the cylinder head
in horizontal position. This will prevent the lapping
compound residues from penetrating between the
valve stem and the guide (see figure).
CAUTION
TO AVOID SCORING THE MATING SURFACE, DO NOT ROTATE THE VALVE WHEN NO LAPPING
COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A
SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
CAUTION
DO NOT CHANGE THE VALVE FITTING POSITION (RH - LH).
- Check the camshaft bearings for signs of abnormal wear or scores.
- Using a micrometer, measure the camshaft bearings.
STANDARD DIAMETER
Bearing A Ø: 42- 0.060 -0.085 mm
Bearing B Ø: 20- 0.020 -0.041 mm
MINIMUM DIAMETER ALLOWED

Bearing A Ø: 41.910 mm
Bearing B Ø: 19.940 mm
- Using a gauge, measure the height of the cams.
CHAR - 21
STANDARD HEIGHT
intake 33.988 mm
exhaust 33.417 mm
LIMITS ALLOWED
intake 33.740 mm
exhaust 33.170 mm
Standard axial clearance: 0 ÷ 0.22 mm
Maximum axial clearance allowed: 0.3 mm
- Check there are no signs of wear on the contact pads with the cam and on the articulated plate of the
set screws.
- In case of wear, replace the component.
- Check there are no signs of wear or scoring on the rocking lever pins.
Characteristic
Standard diameter:
Ø 13 - 0.010 -0.018 mm
- Check the inside diameter of each rocking lever.
Characteristic
Standard diameter:
Ø 13 + 0.026 +0.015 mm
CHAR - 22
Slot packing system

MEASUREMENT «A» IS A PROTRUSION OR RECESS VAL-
UE OF THE PISTON CROWN COMPARED WITH THE CYL-
INDER PLANE.
MEASUREMENT «A» ALLOWS TO DETERMINE THE
THICKNESS OF THE GASKET «B» THAT HAS TO BE FIT-
TED INTO THE CYLINDER BASE IN ORDER TO RESTORE
THE COMPRESSION RATIO. THE MORE THE PLANE
FORMED BY THE PISTON CROWN PROTRUDES BEYOND
THE PLANE FORMED BY THE CYLINDER UPPER END,
THE THICKER THE GASKET TO BE USED AT THE CYLIN-
DER BASE «B» SHOULD BE. ON THE OTHER HAND, THE
MORE THE PISTON CROWN IS RECESSED INTO THE CYL-
INDER TOP PLANE, THE SMALLER THE GASKET THICK-
NESS.
Characteristic
Compression ratio
10.5 ± 0.5 : 1
BASE GASKET THICKNESS

Name Measure A Thickness
MEASURE TAKEN «A» - 0.185 ÷ - 0.10 0.4 ± 0.05
MEASURE TAKEN «A» - 0.10 ÷ + 0.10 0.6 ± 0.05
MEASURE TAKEN «A» + 0.10 ÷ + 0.185 0.8 ± 0.05
NOTE
VALUES INDICATED WITH «-» REFER TO RECESSES OF THE PISTON CROWN FROM THE
CYLINDER PLANE.
NOTE
SIZE «A» MUST BE MEASURED WITHOUT ANY GASKET FITTED AT «B»
Products
RECOMMENDED PRODUCTS TABLE

Product Description Specifications
AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116
- DOT 3/4 - ISO 4925 - CUNA NC 956
DOT 4
eni i-Ride PG 5W-40 Synthetic based lubricant for high-per- JASO MA, MA2 - API SL - ACEA A3
formance four-stroke engines.
AGIP PERMANENT SPECIAL Ethylene glycol-based antifreeze fluid ASTM D 3306 - ASTM D 4656 - ASTM D
with organic inhibition additives. Red, 4985 - CUNA NC 956-16
ready to use.
AGIP GP 330 Water repellent springy calcium spray R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 -
grease. I.A.T.A. 2 - I.M.D.G. class 2 UN 1950 Pag.
9022 EM 25-89
AGIP GREASE PV2 Ivory smooth-textured, slightly-stringy TL 9150 066, symbol NATO G 460
anhydrous calcium-base grease.
AGIP FORK 7.5 W Oil for fork. -
AGIP ROTRA MP 80W-90 Lubricant for gears. API GL-5
AGIP CHAIN LUBE SPRAY Spray grease lubricant. -
UNIT OF MEASURE - CONVERSION - ENGLISH SYSTEM TO INTERNATIONAL SYSTEM (IS).

1 Inch (in) 25.4 Millimetres (mm)
1 Foot (ft) 0.305 Meter (m)
1 Mile (mi) 1.609 Kilometre (km)
1 US Gallon (USgal) 3.785 Litre (l)
CHAR - 23
1 Pound (lb) 0.454 Kilogram (kg)
1 Cubic inch (in³) 16.4 Cubic centimetres (cm³)
1 Foot pound (ft lb) 1,356 Newton meter (Nm)
1 Miles per hour (mi/h) 1.602 Kilometres per hour (km/h)
1 Pound per square inch (PSI) 0.069 (bar)
1 Fahrenheit (°F) 32+(9/5) Celsius (°C)
CHAR - 24
INDEX OF TOPICS
TOOLING TOOL
Tooling SRV 850
APPROPRIATE TOOLS
Stores code Description
001330Y Tool for fitting steering seats
001330Y014 Tool for fitting steering seats
020004Y Punch for removing steering bearings

from headstock
020668Y Steering ring nut wrench
020306Y Punch for assembling valve seal rings
020382Y012 bush (valve removing tool)
TOOL - 26
SRV 850 Tooling

020431Y Valve oil seal extractor
020128Y Piston fitting band
020470Y Pin retainers installation tool
020475Y Piston position checking tool
020512Y Piston fitting fork
020478Y Punch for driven pulley roller casing
TOOL - 27
Tooling SRV 850

020565Y Flywheel lock calliper spanner
020659Y Tool to remove clutch and replace belt
020660Y Driving pulley lock
020713Y Flywheel extractor
020527Y Engine support base
020658Y Engine plate
TOOL - 28
SRV 850 Tooling

020664Y Flywheel side crankshaft fitting tip
020665Y Transmission side crankshaft fitting tip
020709Y Engine support
020680Y Diagnosis Tool
020469Y Reprogramming kit for vehicle diagnostic

tester
020661Y Water pump overall seal replacement kit
TOOL - 29
Tooling SRV 850

020663Y Water pump shaft oil seal punch
020193Y Oil pressure check gauge
020434Y Oil pressure check fitting
020480Y Petrol pressure check kit
020331Y Digital multimeter
TOOL - 30
SRV 850 Tooling

020648Y Single battery charger
002465Y Calliper for circlips
020621Y HV cable extraction adaptor
020330Y Stroboscopic light to check timing
020335Y Magnetic mounting for dial gauge
TOOL - 31
Tooling SRV 850

020262Y Crankcase splitting plate
001467Y007 Driver for OD 54-mm bearings
001467Y031 Bell
001467Y035 Bearing housing, out ø 47 mm
001467Y002 Driver for OD 73 mm bearing
020329Y Mity-Vac vacuum-operated pump
TOOL - 32
SRV 850 Tooling

020150Y Air heater mounting
020151Y Air heater
001467Y003 Nut
001467Y004 Lug / Taper pin
001467Y005 Screw
001467Y006 Pliers to extract 20 mm bearings
TOOL - 33
Tooling SRV 850

001467Y001 Pliers to extract Ø 25-mm bearings
001467Y008 Pliers to extract 17 mm ø bearings
001467Y014 Calliper to extract ø 15-mm bearings
020357Y 32x35-mm Adaptor

020359Y 42 x 47-mm adaptor
020655Y Adaptor 62x68 mm
020670Y Adaptor 34 mm
TOOL - 34
SRV 850 Tooling

020375Y 28 x 30 mm adaptor
020364Y 25-mm Guide
020412Y 15-mm guide
020439Y 17-mm guide
020483Y 30 mm guide
TOOL - 35
Tooling SRV 850

020654Y 35 mm guide
020662Y 50 mm guide
020376Y Adapter handle
020667Y Wrench for fork pin adjustment ring nut
020632Y 22-mm Hexagonal spanner
020633Y Clamp for sealing ring driving of Kayaba

41-mm and Marzocchi 40-mm forks
TOOL - 36
INDEX OF TOPICS
MAINTENANCE MAIN
Maintenance SRV 850
Follow these steps to reset the service icons:
1. With the key set to OFF, hold down the

"SET" button and turn the key to ON : the
"BELT" and "SERVICE" icons start flashing.
2. Push the "CLOCK" button for less than 1
second and the icons are displayed sequen-
tially. The icon selected remains ON and the
other is no longer displayed.
3. Press the "CLOCK" button again for more
than 3 seconds to reset the relative mainte-
nance step and the icon is no longer dis-
played.
Maintenance chart
MAINTENANCE TABLE
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN, R:REPLACE, A: ADJUST, L:LUBRICATE
* (Rated: 0.15 mm INT and OUT) restore only if deviation is over 0.05 mm
** Replace every two years
Km x 1000 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Engine oil R R R R R R R R R R R
Engine oil level - Check/top-up I I I I I I I I I I
Oil filter R R R R R R R R R R R
CVT drive belt R R R R R
Variator rollers and sliders R R R R R R R R R R
Ignition spark plug R R R R R
CVT filter air (mesh-sponge) cleaning C C C C C
Air filter I R I R I R I R I R
Throttle body (cleaning) C C C
ECU software update I I I
Valve clearance * I I I
Pinion support unit oil I R R R R R R R R R R
Final drive L L L L R L L L R L L L R L L L R L L L R
Brake pads I I I I I I I I I I I I I I I I I I I I I
Safety fasteners I I I I I I
Throttle control (adjustment) A A A A A A A A A A A
Electrical system and battery I I I I I I I I I I I
Coolant level ** I I I I I I I I I I I
Brake fluid level I I I I I I I I I I I
Tyre pressure and wear A A A A A A A A A A A
Steering I I I I I I I I I I I
Suspension I I I I I I I I I I
Centre stand and saddle hinge I I I I I I I I I I I I I I I I I I I I I
Vehicle road test I I I I I I I I I I I
Operation Time 6 1 1 1 2 1 2 1 2 1 1 1 4 1 1 1 2 1 2 1 270
0' 5' 6 5' 7 5' 8 5' 7 5' 6 5' 0 5' 6 5' 7 5' 8 5' '
0' 0' 0' 0' 0' 0' 0' 0' 0'
MAIN - 38
SRV 850 Maintenance
Checking the spark advance
See also
Spark plug
To replace the rear cylinder spark plugs:

- Fold the saddle forward, unscrew the six screws
«A» and remove the cover «B».
- Disconnect caps «C» of the HV wire of the spark

plugs.
- Unscrew the spark plugs using the wrench sup-
plied.
- Upon refitting, place the spark plugs into the hole at the due inclination and tighten them by hand.
- Only use the wrench to lock spark plugs in place.
- Place caps «C» fully over the spark plugs.
- Refit cover «B».
CAUTION
SPARK PLUGS MUST BE REMOVED WHEN THE ENGINE IS COLD. SPARK PLUGS MAINTE-
NANCE OPERATIONS ARE DESCRIBED IN THE SCHEDULED MAINTENANCE TABLE. USING
NON-CONFORMING ELECTRONIC CENTRAL UNITS AND ELECTRONIC IGNITIONS OR SPARK
PLUGS OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY DAMAGE THE ENGINE.
NOTE
USE OF SPARK PLUGS OTHER THAN THE INDICATED TYPE OR UNSHIELDED SPARK PLUG
CAPS CAN LEAD TO FAULTS IN THE VEHICLE 'S ELECTRICAL SYSTEM.
MAIN - 39
Maintenance SRV 850
To replace the front cylinder spark plugs:

- Undo screw «D» and remove lid «E».
- Disconnect caps «F» of the HV wire of the spark

plugs.
- Unscrew the spark plugs using the wrench sup-
plied.
- Upon refitting, place the spark plugs into the hole at the due inclination and tighten them using the
supplied spark plug wrench.
- Tighten the two spark plugs.
- Place caps «F» fully over the spark plugs.
- Refit the lid «E».
CAUTION
SPARK PLUGS MUST BE REMOVED WHEN THE ENGINE IS COLD. SPARK PLUGS MAINTE-
NANCE OPERATIONS ARE DESCRIBED IN THE SCHEDULED MAINTENANCE TABLE. USING
NON-CONFORMING ELECTRONIC CENTRAL UNITS AND ELECTRONIC IGNITIONS OR SPARK
PLUGS OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY DAMAGE THE ENGINE.
NOTE
USE OF SPARK PLUGS OTHER THAN THE INDICATED TYPE OR UNSHIELDED SPARK PLUG
CAPS CAN LEAD TO FAULTS IN THE VEHICLE 'S ELECTRICAL SYSTEM.
Characteristic
Spark plug
NGK CR7EKB
Electrode gap
0.7 ÷ 0.9 mm
MAIN - 40
SRV 850 Maintenance
Air filter
- Release the blow-by pipe from the retainer

clamp.
- Operating from the left side of the vehicle, undo

the six screws indicated and remove the sleeve
retainer clamp.
- Remove the filtering element from inside the air

cleaner.
- Slide off the blow-by vapour recovery pipe.
- Remove the air cleaner external part.
MAIN - 41
Maintenance SRV 850
- From both sides of the vehicle release the closing

spring eyelets and remove the spring.
- Turn the internal part of the air cleaner in order

to release the retainers on the chassis.
- Remove the air cleaner internal part.
- Remove the battery compartment access cover

«C» by undoing the four screws «D ».
- Remove the access cover to the cap of expan-
sion tank «E» by undoing the four screws «F».
MAIN - 42
SRV 850 Maintenance
- Undo the two screws «G».
- Remove the central cover «H» holding it as

shown in the figure and pulling it towards the rear
part of the vehicle.
- Release clip «I» and remove the filter housing

cover «L».
For filter cleaning:

- Hold the air filter upright and tap it several times
on a clean cloth.
- If required, clean the air filter with a blast of com-
pressed air (direct the air from the inside to the
outside of the filter) opposite to the sense the air
flow travels under regular operation.
- Clean the external side of the air filter with a clean
cloth
MAIN - 43
Maintenance SRV 850
- Remove the cap «M» regularly, drain the content

into a container and send it to a recycling bank.
AIR DEFLECTOR FILTER

For filter removal:
- Remove the side fairings.
- Undo the three indicated screws and remove the

air deflector.
- Remove the filter.
For filter cleaning:

- Wash the sponge with water and mild soap.
- Dry it with a clean cloth and short blasts of compressed air.
- Soak it in a mixture of 50% petrol and 50% specific oil.
- Gently squeeze the filtering element with your hands without wringing it; let it drip dry and then refit.
Recommended products
AGIP FILTER OIL Special product for the treatment of foam filters.
-
MAIN - 44
SRV 850 Maintenance
Engine oil
In four stroke engines, the engine oil is used to lubricate the distribution elements, the bench bearings
and the thermal group. An insufficient quantity of oil can cause serious damage to the engine.
In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should
be considered normal, especially if during the run-in period. Consumption levels in particular can be
influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".
Replacement
Replace oil and filter as indicated in the scheduled maintenance table.
In order to facilitate oil drainage, remove lid «A»

and loosen the cap/dipstick «B».
The engine should be emptied by draining the oil

through the drainage plug «C» placed under the
engine crankcase.
MAIN - 45
Maintenance SRV 850
Since a certain quantity of oil still remains in the

circuit, refill with approx. 2600 cm³ of oil through
the cap «A». The engine has a reference «G» in-
dicating that the maximum oil level has been
reached inside the crankcase. This reference must
be used only when changing oil, whereas the cap/
dipstick «B» must be used when checking oil level.
Then start up the vehicle, let it run for a few mi-
nutes and shut it off. After about 5 minutes, check
the level and, if necessary, top-up but never ex-
ceeding the MAX level reference mark «G» sight
glass on the right crankcase. For top-ups and oil
changes, use new oil of the recommended type.
eni i-Ride PG 5W-40 Synthetic based lubricant
for high-performance four-stroke engines.
JASO MA, MA2 - API SL - ACEA A3
Always check the oil level before carrying out top-ups. For topping-up:
- Unscrew and remove cap «B».
- Top up the oil in the reservoir until you reach the correct level.
- Pour oil in small quantities and wait until it is distributed throughout the engine before checking the
level through the right crankcase sight glass «G».
The oil must reach the "MAX oil level" reference mark on the corresponding sight glass «G» on the right
crankcase.
WARNING
PROCEED TO TOP-UP WITH ENGINE OIL WHILE THE ENGINE IS WARM.

DO NOT GO BEYOND THE "MAX" MARK ON THE CRANKCASE OR BELOW THE "MIN" LEVEL
MARK ON THE DIPSTICK TO AVOID SEVERE ENGINE DAMAGE.
MAIN - 46
SRV 850 Maintenance
Check
For oil level check:

- Keep the vehicle perfectly upright, with both
wheels on the ground.
- Remove cover «A» holding it and pulling it out.
- Unscrew the dipstick cap «B» and check that the

oil level exceeds the «MIN» mark.
In order to check oil level properly, keep the engine
running for about 2 minutes and then wait at least
5 minutes once the engine is off.
Engine oil filter
To access the oil cartridge filter:

- Remove mat «D».
MAIN - 47
Maintenance SRV 850
- Undo the six screws «E» and remove the spoiler.
- Remove the cartridge filter «F» and fit a new one

taking care to lubricate the sealing O-rings of the
filter with engine oil.
eni i-Ride PG 5W-40 Synthetic based lubricant
for high-performance four-stroke engines.
JASO MA, MA2 - API SL - ACEA A3
Oil pressure warning light
The vehicle is equipped with a telltale light on the

dashboard that lights up when the key is turned to
the «ON» position. However, this light should
switch off once the engine has been started.
If the light turns on during braking, at idling
speed or while turning a corner, it is necessary
to check the oil level and the lubrication sys-
tem.
Checking the valve clearance
Front head
- Remove the plastic parts in order to free the head
cover access.
- Undo the six fixing screws and remove the tappet
cover together with the gasket.
- Check the valve clearance, and if necessary, re-
store the correct clearance.
Characteristic
MAIN - 48
SRV 850 Maintenance
Valve clearance
Intake: 0.15 mm
Exhaust: 0.15 mm
See also
Rear head
- Remove the plastic parts in order to free the head
cover access.
- Undo the six fixing screws and remove the tappet
cover together with the gasket.
- Check the valve clearance, and if necessary, re-
store the correct clearance.
Characteristic
Valve clearance
Intake: 0.15 mm
Exhaust: 0.15 mm
See also
Checking
- According to the procedure described in the «Engine Chapter» fit the tappet cover.
See also
Check coolant when the engine is cold as indica-

ted in the scheduled maintenance table.
To check:
- Rest the vehicle upright on the stand, undo the
four screws «A» and remove cover «B» partially.
- The fluid level should always be between the

«MIN» and «MAX» level marks indicated on the
knee-guard panel.
- If the coolant level is close to the minimum mark
«MIN», top-up when the engine is cold.
CAUTION
THE RECOMMENDED COOLANT MUST BE USED FOR

TOP-UPS TO AVOID DAMAGING THE ENGINE.
MAIN - 49
Maintenance SRV 850
AGIP PERMANENT SPECIAL Ethylene glycol-
based antifreeze fluid with organic inhibition
additives. Red, ready to use.
ASTM D 3306 - ASTM D 4656 - ASTM D 4985 -
CUNA NC 956-16
The front and rear brake fluid reservoirs are both

positioned on the handlebars.
Proceed as follows:
- Rest the vehicle onto the centre stand, with the
handlebar centred.
- Check the fluid through the specific sight glass.
- Top-up whenever the level is below the MIN ref-
erence «C» for the left reservoir, and reference
«D» for the right reservoir.
A certain lowering of the level is caused by wear
on the pads.
- Undo screws «B» and remove the reservoir cap

«A». Top-up using only the fluid specified, without
exceeding the maximum level.
This procedure applies to the rear brake pump top-
up operation; follow the same procedure for the
front brake pump.
Under standard climatic conditions, replace cool-
ant as indicated in the scheduled maintenance
table.
AGIP BRAKE 4 Brake fluid.
Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4
- ISO 4925 - CUNA NC 956 DOT 4
Headlight adjustment
MAIN - 50
SRV 850 Maintenance
Proceed as follows:
- Place the vehicle in running order and with the
tyres inflated to the prescribed pressure, on a flat
surface 10 m away from a white screen situated in
a shaded area, making sure that the longitudinal
axis of the vehicle is perpendicular to the screen;
- Turn on the headlight and make sure that the limit
of the light beam projected on the screen does not
exceed 9/10 of the height of the center of the head-
lamp from the ground and is no less than 7/10.
Otherwise, adjust the headlight.
To adjust:
- Unscrew screws «A» and remove the cover.
- Turn screw «B». Turn it anticlockwise to raise the

light beam and turn it clockwise to lower it.
DRIVE CHAIN
MAIN - 51
Maintenance SRV 850
To check the drive chain clearance:

- Stop the engine.
- Position the vehicle on the centre stand.
- Remove the chain guard.
- Act on the rear wheel so that a link notch matches point «A».
- Tighten the chain and check that the distance between the chain link lower notch and point «A» is 38
mm ± 2 mm.
- Rotate the wheel to check the vertical oscillation of the chain in other positions; clearance should
remain constant for all the wheel rotation phases. Adjust the chain if clearance is uniform but out of the
specified limit.
To adjust the drive chain clearance:

- Loosen the wheel axle lock nut «B».
- Loosen the two screws «C» on both sides.
MAIN - 52
SRV 850 Maintenance
- Insert a pin through the holes on the planetary

gears supporting the axle and rotate them to obtain
the ideal chain tension. There are references on
the planetary gears supporting the axle, proceed
so that the reference indicated is the same on both
sides of the fork.
Drive chain cleaning

Do not wash the chain with water jets, vapour jets,
high-pressure water jets and highly flammable sol-
vents. Wash the chain with fuel oil or kerosene.
Maintenance operations should be more frequent
if there are signs of early rust. Lubricate the chain
with a recommended product whenever necessa-
ry after washing and drying it.
AGIP CHAIN LUBE SPRAY Lubricating grease
spray.
-
PINION UNIT
The pinion unit oil should be checked and replaced
as shown in the scheduled maintenance table.
Make sure the level does not fall below the
"MAX" reference shown in the figure. Otherwise:
- Undo screw «D».
- Restore the level by adding recommended oil
with a syringe taking care not to exceed the
"MAX" reference mark indicated in the figure.
WARNING
DO NOT EXCEED THE "MAX" LEVEL WHEN TOPPING UP.
AGIP ROTRA MP 80W-90 Gear oil
API GL - 5 Performance level
- Tighten the drain screw to the prescribed torque.
Locking torques (N*m)

Pinion unit oil filling screw 13 - 15
MAIN - 53
Maintenance SRV 850
MAIN - 54
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
Troubleshooting SRV 850
This section makes it possible to find what solutions to apply when troubleshooting.
For each failure, a list of the possible causes and pertaining operations is given.
Engine
Excessive oil consumption/Exhaust smoke
EXCESSIVE CONSUMPTION
Possible Cause Operation
Wrong valve adjustment Adjust the valve clearance properly
Overheated valves Remove the head and the valves, grind or replace the valves
Misshapen/worn valve seats Replace the head unit
Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings
Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings
fitted properly
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal
Worn valve oil seal Replace the valve oil seal
Worn valve guides Check and replace the head unit if required
Insufficient lubrication pressure
POOR LUBRICATION PRESSURE

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Oil pump with excessive clearance Perform the dimensional checks on the oil pump components
Oil filter too dirty Replace the cartridge filter
Oil level too low Restore the level adding the recommended oil type
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Faulty clutch Check that there is no grease on the masses. Check that the
clutch mass faying surface with the bell is mainly in the centre
with equivalent characteristics on the three masses. Check that
the clutch housing is not scored or worn in an anomalous way
Insufficient braking
INEFFICIENT BRAKING SYSTEM

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are
not worn, scored or warped. Check the correct level of fluid in
the pumps and change brake fluid if necessary. Check there is
no air in the circuits; if necessary, bleed the air. Check that the
front brake calliper moves in axis with the disc.
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace
TROUBL - 56
SRV 850 Troubleshooting

Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift
of the disc with a dial gauge and with wheel mounted on the
vehicle.
Brakes overheating
BRAKE OVERHEAT
Defective plunger sliding Check calliper and replace any damaged part.
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Clogged compensation holes on the pump Clean carefully and blast with compressed air
Swollen or stuck rubber gaskets Replace gaskets.
Steering and suspensions
Heavy steering
STEERING HARDENING
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: if they are recessed or if the balls are squashed, replace
them.
Excessive steering play
EXCESSIVE STEERING CLEARANCE

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.
Noisy suspension
NOISY SUSPENSION
Faults in the suspension system If the front suspension is noisy, check: the efficiency of the front
shock absorber; the condition of the ball bearings and relevant
lock-nuts, the limit switch rubber buffers; and the movement
bushings. In conclusion, check the tightening torque of the
wheel hub, the brake calliper, the shock absorber disc in the
attachment to the hub and the steering tube.
TROUBL - 57
Troubleshooting SRV 850
Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION

Faulty or broken seals Replace the shock absorber Check the condition of wear of the
steering covers and the adjustments.
TROUBL - 58
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

Electrical system SRV 850
1. 12V 14Ah Battery

2. Starter solenoid contact
3. Chassis ground
4. Chassis engine ground
5. N. 01 - 40A Fuse
6. N. 02 - 15A Fuse
7. N. 04 - 15A Fuse
8. N. 05 - 15A Fuse
9. N. 06 - 7.5A Fuse
10. N. 07 - 5A Fuse
11. Regulator
12. Flywheel
13. Ignition switch
14. Main solenoid switch
15. N. 08 - 15A Fuse
16. N. 03 - 15A Fuse
17. N. 11 - 7.5A Fuse
18. N. 12 - 7.5A Fuse
19. LV socket
20. Antitheft
ELE SYS - 60
SRV 850 Electrical system
21. Turn indicator switch

22. Turn indicator control
23. Helmet compartment light switch
24. Light unit
25. Front left turn indicator
26. Left rear turn indicator
27. Front right turn indicator
28. Rear right turn indicator
29. Actuator
30. Provision for actuator control receiver
31. Saddle button
32. N. 09 - 10A Fuse
33. N. 10 - 7.5A Fuse
34. Hand brake
35. Instrument panel
36. C.D.I.
37. Decoder
38. Fuel gauge
39. Engine temperature sensor (Instrument)
40. Mode button
41. Low beam solenoid
42. GPS wiring
43. Front daylight running light
44. License plate light
45. Rear tail light
46. High beam solenoid
47. Light switch
48. High beam
49. Low beam
50. Front headlamp
51. Accessories pre-installation
52. horn button
53. Horn
54. Tip over sensor
55. Diagnostics socket
56. Engine stop
57. N.1 Lambda probe
58. N.2 Lambda probe
ELE SYS - 61
59. Air temperature sensor

60. Engine temperature sensor (C.D.I.)
61. Speed sensor
62. Barometric pressure sensor
63. Engine idle speed adjustment
64. Throttle valve potentiometer
65. Engine speed sensor
66. N.1 fuel injector
67. N.2 fuel injector
68. HV coil
69. Injection load solenoid
70. Electric fan relay
71. Fuel pump
72. Electric fan
73. Stop button
74. Stand switch
75. Starter button
76. Starter maintenance solenoid
77. Solenoid of the starter solenoid
78. Starter solenoid coil
79. Stop light
80. Reset receiver radio
81. Ambient temperature sensor
Key
Ar: Orange Az: Light Blue Bi: White Bl: Blue Gi: Yellow Gr:Grey
Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple
Dashboard
KEY
A = Immobilizer / antitheft LED
ELE SYS - 62
B= Speedometer with twin scale (km/h and mph)

C = CLOCK switch
D = Digital display
E= SET switch
F= Rpm indicator
G = Fuel gauge
H = Warning light for parking brake engaged
I = Engine control telltale light and injection system failure warning light
L = Low fuel warning light
M = Engine stop warning light
N= Turn indicator warning light
O = Low oil pressure warning light
P = ATC (Aprilia Traction Control) Diagnosis / Operation (not used)
Q = ABS warning light (not used)
R = High beam warning light
Components arrangement
ELE SYS - 63
1. Anti-theft device preparation: remove the front

shield to reach it.
2. Accessories pre-installation: remove the front

shield to reach it.
3. Provision for actuator control receiver remove

the front shield to reach it.
4. Control unit: remove the front shield to reach it.
ELE SYS - 64
5. Barometric pressure sensor: remove the front

shield to reach it.
6. Turn indicator control device: remove the front

shield to reach it.
7. Diagnosis socket: to reach it, remove the battery

cover.
8. Battery: to reach it, remove the battery cover.
Characteristic
Battery
12V/14 Ah, sealed battery
ELE SYS - 65
9. Remote controls: remove the front shield to

reach it.
KEY
A. Relay for electric fan
B. Starter remote control relay
C. Main relay
D. Injection load relay
E. Start-up maintenance relay
F. Low beam light relay
G. High beam light relay
H. Starter remote control
I-L. Relay for windscreen
10. Fuses: to reach it, remove the battery cover.
11. Front cylinder H.V. coil: to reach it, remove the

left fairing.
12. Stand button: remove the left footrest to reach

it.
ELE SYS - 66
13. Rear cylinder H.V. coil: remove the right fairing

to reach them.
14. Fuel level transmitter: remove the right fairing

to reach them.
Electric characteristic
Full tank position
<= 5 Ohm
Empty tank position
98 ± 5 Ohm
15. Plug socket: to reach it, open the helmet com-

partment.
Plug socket
12 V - 180 W MAX
16. Immobilizer antenna: remove the shield back

plate to reach it.
ELE SYS - 67
17. Immobilizer decoder: remove the front shield

to reach it.
18. G.P.S. pre-installation : to reach it, remove the

handlebar central cover.
19. Electrical controls management device: re-

move the front shield to reach it.
20. Fall sensor: remove the front shield to reach it.
ELE SYS - 68
21. Voltage regulator: remove the front shield to

reach it.
Control voltage
14 ÷ 14.7 V at 1000÷8000 rpm
22. Horn: remove the front shield to reach it.
Ground points
There are three ground points in the electrical system:
A. Located on the left part of the chassis. Remove

the shield back plate to reach them.
B. Located on the control unit in the front part of

the vehicle. Remove the front shield to reach it.
ELE SYS - 69
C. Located on the engine in the right part of the

vehicle. Remove the right side fairing to reach it.
Electrical system installation
ELE SYS - 70
Front side
1. Remote control unit

2. To the left turn indicator
3. To the regulator
4. HV coil
5. To the side stand switch
ELE SYS - 71
6. Engine wire unit

7. Ground point
8. To the battery
9. Start-up remote control switch
10.Remote control switches - electric windshield switches
ELE SYS - 72
1. Saddle opening actuator

2. To the right control unit on the handlebar
3. Voltage regulator
4. To the right turn indicator
5. Snail horn
6. Electric fan connection
7. Starter motor cable
8. Regulator - flywheel connector
9. Parking brake switch
10.To the left control unit on the handlebar
11.GPS wiring
12.To the immobilizer aerial
13.Immobilizer ECU
14.Saddle opening receiver
17. Dispositivo comando lampeggiatori

18. Predisposizione accessori
19. Predisposizione ricevitore per comando attuatori
20. Dispositivo gestione comandi elettrici
21. Predisposizione antifurto
22. Collegamento proiettore
ELE SYS - 73
23. Centralina elettronica iniezione
1. Saddle opening receiver

3. External temperature sensor
4. To the side stand switch
5. To the instrument panel
6. Remote control switches - electric windshield switches
7. Electric windshield motor
8. Injection electronic control unit
9. Overturn sensor
10.Connection between main system and the system on the engine
11.GPS wiring
12.Buttons control device on the handlebar
13.Turn indicator control device
14.To the battery negative
15.To the battery positive
16.Diagnostic socket for hand-held computer
17.Battery
18.Cable from engine control unit
19.Starter motor cable
20.Electric windshield motor cable
ELE SYS - 74
21.Chassis wire unit

22.Voltage regulator cable
28. Collegamento commutatore a chiave

29. Antenna immobilizer
30. Decoder immobilizer
31. Connessione gruppo cavetti proiettore
32. Al gruppo comandi sinistro
33. Al gruppo comandi destro
34. Al collegamento di predisposizione GPS
ELE SYS - 75
Back side
1. To the license plate light

3. To the fuel level transmitter
4. To the fuel pump
5. Rear cylinder HV coil
6. Ground point
ELE SYS - 76

2. Rear cylinder coil
3. Plug socket and helmet compartment light
1. Left turn indicator connection

2. To the left turn indicator
3. Fuel level transmitter
1. Plug socket for accessories

2. Helmet compartment light
3. Rear turn indicators
ELE SYS - 77
1. Air temperature sensor

2. Throttle valve sensor
3. Stepper motor
4. Rear cylinder fuel injector
5. Rpm timing sensor
6. Engine temperature sensor
7. To the front cylinder fuel injector
8. To the rear cylinder HV coil
9. Oil pressure sensor
10.To the voltage regulator
11.Starter motor cable
12.Rear cylinder fuel injector
13.To the front cylinder fuel injector
14.Speed sensor connector
15.Lambda probe connector
16.Lambda probe
18. Presa di corrente per accessori

19. Illuminazione vano portacasco
ELE SYS - 78
20. Iniettore benzina cilindro anteriore

21. Iniettore benzina cilindro posteriore
22. Pulsante illuminazione vano portacasco
Conceptual diagrams
Ignition
ELE SYS - 79
1. 12V 14Ah BATTERY

4. CHASSIS ENGINE GROUND
6. N.02 - 15A FUSE
7. N.04 - 15A FUSE
10. N.07 - 5A FUSE
13. IGNITION SWITCH
14. MAIN SOLENOID SWITCH
33. N.10 - 7.5A FUSE
36.C.D.I.
65.ENGINE SPEED SENSOR
66.N.1 FUEL INJECTOR
67. N.2 FUEL INJECTOR
68. H.V. COIL
69. INJECTION LOAD SOLENOID
71. FUEL PUMP
Battery recharge and starting
Key
1. 12V 14Ah BATTERY
2. STARTER SOLENOID CONTACT
ELE SYS - 80
3. CHASSIS GROUND
4.CHASSIS ENGINE GROUND
5. N.01 - 40A FUSE
6. N.02 - 15A FUSE
10. N.07 - 5A FUSE
11.REGULATOR
12. FLYWHEEL
13. IGNITION SWITCH
16. N.03 - 15A FUSE
32. N.09 - 10A FUSE
33. N.10 - 7.5A FUSE
36. C.D.I. 73 STOP BUTTON
74. STAND SWITCH
75. STARTER BUTTON
76. STARTER MAINTENANCE SOLENOID
77. SOLENOID OF THE STARTER SOLENOID
78. STARTER SOLENOID COIL
79. STOP LIGHT
ELE SYS - 81
Level indicators and enable signals section
KEY
1. 12V 14Ah BATTERY
3. CHASSIS GROUND
4. CHASSIS ENGINE GROUND
6. N.02 - 15A FUSE
8. N.05 - 15A FUSE
9. N.06 - 7.5A FUSE
10. N.07 - 5A FUSE
13. IGNITION SWITCH
15. N.08 - 15A FUSE
17. N.11 - 7.5A FUSE
33. N.10 - 7.5A FUSE
35. 36 C.D.I. INSTRUMENT PANEL
37. DECODER
38. FUEL GAUGE
56. ENGINE STOP
60.ENGINE TEMPERATURE SENSOR (C.D.I.)
ELE SYS - 82
Devices and accessories
KEY
24. LIGHT UNIT
29. ACTUATOR
30. PROVISION FOR ACTUATOR CONTROL RECEIVER
31. SADDLE BUTTON
32. N.09 - 10A FUSE
33. N.10 - 7.5A FUSE
34. HAND BRAKE
35. INSTRUMENT PANEL
36. C.D.I.
39. ENGINE TEMPERATURE SENSOR (INSTRUMENT)
40. MODE BUTTON
51. ACCESSORIES PRE-INSTALLATION
52. HORN BUTTON
53. HORN
54. TIP OVER SENSOR
59. AIR TEMPERATURE SENSOR
61. SPEED SENSOR
ELE SYS - 83
62. BAROMETRIC PRESSURE SENSOR

63. ENGINE IDLE SPEED ADJUSTMENT
64. THROTTLE VALVE POTENTIOMETER
69. INJECTION LOAD SOLENOID
70. ELECTRIC FAN RELAY
72. ELECTRIC FAN
81. AMBIENT TEMPERATURE SENSOR
Lights and turn indicators
KEY
15. N.08 - 15A FUSE
17.N.11 - 7.5A FUSE
18. N.12 - 7.5A FUSE
21. TURN INDICATOR SWITCH
22.TURN INDICATOR CONTROL
25. LEFT FRONT TURN INDICATOR
26. LEFT REAR TURN INDICATOR
27.RIGHT FRONT TURN INDICATOR
28. RIGHT REAR TURN INDICATOR
ELE SYS - 84
32. N.09 - 10A FUSE

33.N.10 - 7.5A FUSE
34. HAND BRAKE
36. C.D.I.
41. LOW BEAM SOLENOID
43. FRONT DAYLIGHT RUNNING LIGHT
44. LICENSE PLATE LIGHT
45. REAR DAYLIGHT RUNNING LIGHT
46. HIGH BEAM SOLENOID
47. LIGHT SWITCH
48. HIGH BEAM
49. LOW BEAM
50. FRONT HEADLAMP
73.STOP BUTTON
79. STOP LIGHT
Injection
Key
1. 12V 14Ah BATTERY
3.CHASSIS GROUND
ELE SYS - 85
6. N.02 - 15A FUSE

7. N.04 - 15A FUSE
8. N.05 - 15A FUSE
9. N.06 - 7.5A FUSE
10. N.07 - 5A FUSE
13. IGNITION SWITCH
17. N.11 - 7.5A FUSE
18. N.12 - 7.5A FUSE
33. N.10 - 7.5A FUSE
36. C.D.I.
55. DIAGNOSTICS SOCKET
57. N.1 LAMBDA PROBE
58. N.2 LAMBDA PROBE
65. ENGINE SPEED SENSOR
69.INJECTION LOAD SOLENOID
71. FUEL PUMP
Checks and inspections
This section is dedicated to the checks on the electrical system components.
Immobiliser
The EMS system is independent from the immo-

bilizer antitheft device.
Its functions are:
- Start-up enabled by key recognition.
- Deterrent flashing.
The system consists of:

-EMS system control unit
- Decoder
- Aerial
- master key
- service key
ELE SYS - 86
- Deterrent and diagnosis LED
Virgin circuit
When control unit (ECU) and decoder are not pro-
grammed, the following conditions occur:
- Key switch set to «OFF»:
Deterrent flashing inactive.
- Key switch set to «ON»:
Ignition and injection disabled and LED on with
solid light.
When the key switch is set to "ON", the LED
switches on as shown in the figure.
The LED is turned on by the decoder.
Specific tooling
To connect the diagnostic tester, open the battery
inspection port and pull out the EMS diagnosis
socket. Remove the protection cap and connect
the tester terminal.
Power the diagnostic tester by connecting the ter-

minals to the battery poles, or the specific connec-
tor to the socket inside the helmet compartment.
Set the switch to "ON" and select the diagnostic tester menu to the immobiliser function.
Scroll the pages to display the control unit data.
NOTE
AN UNPROGRAMMED SYSTEM CANNOT BE DETECTED UPON FIRST FITTING, OR IN CASE
THE DECODER AND THE CONTROL UNIT ARE REPLACED CONCURRENTLY.
The information will be as follows:
Unprogrammed control unit «ON»
ELE SYS - 87
Start-up disabled «ON»

Key number Zero › 250
1 Replacing the small cylinder

- Remove the original master key transponder and install it on the master key of the new cylinder.
- Program the system again as described in the injection chapter.
2 Decoder replacement
When the decoder is replaced it is necessary to program the system again.
Programming is indispensable for the engine start-up. (see injection chapter).
3 Control unit replacement

Programming is indispensable when the control unit is replaced to enable the engine start-up.
In this case it is sufficient to switch to "ON" using the master key.
NOTE
THE SERVICE KEY IS NOT USED FOR PROGRAMMING.
- WHEN NOT PROGRAMMED, THE CONTROL UNIT ALLOWS NO FUNCTIONAL DIAGNOSIS ON
THE ENGINE.
4 Replacing or duplicating service keys
Keys can be duplicated using the blank keys and the original master key.
WITH MASTER KEY

When the key switch is set to "ON" and program-
ming is performed normally, the LED switches on
as shown in the figure.
After the confirmation flash when switching to
"ON", a number of flashes are emitted, equal to the
number of keys used for programming.
WITH SERVICE KEYS

«ON», the LED remains off.
ELE SYS - 88
Switching from «ON» to «OFF» with programmed

system causes the intermittent switching on of the
LED, with an antitheft effect.
This occurs with any key used for programming.
If the scooter is not used, the deterrent light stops automatically after 48 hours to prevent discharging
the battery. A new 48-h cycle starts by switching from "OFF" to "ON" and "OFF" again.
Diagnostic codes
The LED indication is divided into 3 steps:

1st step: A flash: "ON" switching recognition
2nd step: Series of flashes: diagnosis code indication
3rd step: Steady light on or off:
on = start-up disabled off = start-up enabled
Diagnostic code - 1 flash
Code 1 indicates a non-programmed system.

If the code is still displayed after having carried out
the programming procedure, repeat the procedure
carefully observing the "ON" times of each key.
If the code is still displayed, proceed as follows:

- Disconnect the battery negative.
- Remove the control unit connector.
- Remove the main decoder connector.
NOTE
TO ACCESS THE COMPONENTS, SEE THE COMPONENTS LAYOUT CHAPTER.
ELE SYS - 89
1- With a multimeter, check the continuity between

pin 7 of the vehicle side connector control unit and
pin 6 of the decoder connector.
YES go to 3 NO go to 2
2 - Repair or replace the wiring.

3 - Check the connections carefully
4 - Restore
5 - Replace the decoder. Connect the battery. Repeat the programming. YES go to 7 NO go to 6
6 - Disconnect the battery, replace the control unit, connect the battery. Repeat the programming.
7 - The system is OK
Diagnostic code - 2 flashes
Code no. 2 denotes a system where the decoder

does not perceive the transponder signal.
- Start-up disabled
- Injection telltale light on, steady
In this case, proceed as follows:
1 - Check whether the code is repeated using the

second key.
2 - Failure detected with the service key Replace
and program again. Failure detected with the mas-
ter key.
Replace the transponder using one from the new
cylinder kit.
Replace decoder and control unit.
Program again.
3 - Check the proper connection of the aerial con-
nector.
ELE SYS - 90
4 - Restore the connection and check the presence

of the code
5 - Disconnect the aerial connector and check con-
tinuity (8 ± 2 W).
6 - Replace the aerial.

7 - Check the proper position of the aerial.
8 - Place it in proper position
9 - Replace the decoder and check the presence of the code
Diagnostic code - 3 flashes

perceives a transponder not provided for by pro-
gramming.
- Start-up disabled
1- Check whether the code is still displayed using the master key
2 - Program again using all service keys
3 - Check that all components (keys - decoder - control unit) are properly matched.
4 - Restore
5 - Replace decoders and control unit. Program the components again.
Ignition circuit
No spark plug
HV coil primary check

WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
ELE SYS - 91
Disconnect the connector and measure the resist-

ance between coil pins. If values are correct, check
wiring continuity.
For the front cylinder coil:
- Sky Blue cable between coil and pin 10 of the
control unit engine-side connector.
- Black-Green cable between coil connector and
injection load remote control base.
For the rear cylinder coil:
- Pink-Black cable between coil and pin 38 of the
control unit engine-side connector.
- Black-Green cable between coil connector and
injection load remote control base.
Restore connections if necessary.
High voltage coil primary resistance value
0.7 ÷ 0.9 Ohm
HV coil secondary check

Disconnect the spark plug caps and measure the
resistance between both.
Resistance value of high voltage coil secon-
dary with spark plug caps
~ 17000 Ohm
If values are incorrect, disconnect the caps and

measure the resistance directly between the HV
cable terminals.
High voltage coil secondary resistance value
~ 7000 Ohm
If values are correct, measure the resistance of one cap.
Spark plug cap resistance
~ 5000 Ohm
ELE SYS - 92
Battery recharge circuit
The recharge system is provided with a three phase alternator with permanent flywheel.
The alternator is directly connected to the voltage regulator.
This, in its turn, is connected directly to the ground and the battery positive passing through the 40A
protective fuse.
The three-phase generator provides good recharge power and at low revs a good compromise is ach-
ieved between generated power and idle stability.
Remote controls check
There are two types of remote controls in the elec-

trical system, those operating as "circuit breakers"
«A», and those operating as a "switches" «B».
CHECKING REMOTE CONTROLS «A» OPER-

ATING AS CIRCUIT BREAKERS
1) Check that, given regular conditions, there is no
continuity between terminals 30 and 87.
2) Apply 12V voltage to power terminals 85 and 86
of the remote control.
3) With the remote control powered, check that
there is continuity between terminals 30 and 87.
4) If these conditions are not fulfilled, the remote
control is damaged and must be replaced.
CHECKING REMOTE CONTROLS «B» OPER-

ATING AS SWITCHES
1) Check that, given regular conditions, there is no
continuity between terminals 30 and 87 but that
there is continuity between terminals 30 and 87a.
2) Apply 12V voltage to power terminals 85 and 86
of the remote control.
ELE SYS - 93
3) With the remote control powered, check that

there is continuity between terminals 30 and 87.
There must not however be continuity between
terminals 30 and 87a.
4) If these conditions are not fulfilled, the remote
control is damaged and must be replaced.
Switches check
To check buttons and switches, check that, according to their position, the continuity of contacts is
correct as indicated in the following charts.
Key
Ar: Orange Az: Light Blue Bi: White Bl: Blue Gi: Yellow Gr:Grey
Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple
TURN INDICATOR SWITCH
ENGINE STOP SWITCH
ELE SYS - 94
LIGHT SWITCH
STARTER BUTTON
HORN BUTTON
HELMET COMPARTMENT LIGHT BUTTON
ELE SYS - 95
«MODE» BUTTON
Stator check
Checking the stator windings

WARNING
THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.
1) Remove the right central chassis cover.
2) Disconnect the connector between stator and
regulator with the three yellow cables as shown in
the photograph.
3) Working on the stator connector pin, measure
the resistance between each of the yellow termi-
nals and the other two.
Resistance:
0.2 - 1 Ω
4) Check that there is insulation between the each yellow cable and the ground.
5) If values are incorrect, replace the stator.
Voltage regulator check
With a perfectly charged battery and after removing the fuses for lights (No. 8 and 11), measure the
voltage at the battery poles with the engine running at about 5,000 rpm.
The voltage should not exceed 14.7 Volt.
In case higher voltages are detected, replace the regulator.
In case of voltage values lower than 14 Volt, check the stator and the corresponding cable harness.
ELE SYS - 96
Recharge system voltage check
Look for any leakage

1) Access the battery by removing the specific compartment in the shield back plate.
2) Check that the battery does not show signs of losing fluid before checking the output voltage.
3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole
(-) of the battery and the black cable and only then disconnect the black cable from the negative pole
(-) of the battery.
4) With ignition key still at OFF, the reading detected by the ammeter must be ≤ 0.5 mA.
Charging current check

WARNING
BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORK-
ING ORDER.
1) Place the vehicle on its centre stand
2) With the battery correctly connected to the circuit, place the tester terminals between the battery
terminals..
3) Turn on the engine, increase the engine rpm and, at the same time, measure the voltage.
Control voltage
14 ÷ 14.7 V at 1000÷8000 rpm
Maximum current output check.

- Connect a 12V-55W twin-filament bulb to the
battery poles as shown in the figure.
- Connect the diagnostic tester to the socket in the
battery compartment, power it and start the active
diagnosis for the electric fan.
ELE SYS - 97
- With the engine off and the panel set to «ON»

with the lights on, allow the battery voltage to stop
at 12V.
- Connect a DC ammeter clamp to the 2 recharge
positive poles in the regulator output.
- Start the engine and rev it up to a high engine
speed while reading the value on the pincer.
With an efficient battery a value must be detected:
> 20A
ELE SYS - 98
Start up system check
KEY
1. Battery 12V 14Ah
2. Starter remote control contact
3. Chassis ground
5. Fuses No. 01 - 40A
ELE SYS - 99
6. Fuses No. 02 - 15A

10. Fuses No. 07 - 5A
13. Key switch
14. Main remote control switch
16. Fuses No. 03 - 15A
32. Fuses No. 09 - 10A
33. Fuses No. 10 - 7.5A
36. C.D.I.
56. Engine stop
73. Stop button
74. Crutch button
75. Starter button
76. Starter maintenance solenoid
77. Starter solenoid relay
78. Starter solenoid coil
WARNING
DISCONNECTED.
If the starter motor does not work, proceed as follows:
1) Check the starter motor ground connection.
2) Check the continuity of the Red cable between the starter motor and the start-up remote control
switch. Also check continuity between the latter and the battery.
3) Check the start-up remote control switch.
4) Check that the Black cable of the start-up remote control switch is earthed.
5) Check the continuity of the Orange-Blue cable between the start-up remote control switch, start-up
remote control switch relay and the start-up maintenance relay.
6) Check the start-up remote control switch relay and the start-up maintenance relay.
7) Check 40A fuse, fuse No. 3, the continuity of the Red-Black cable connecting them and the continuity
of the Blue cable between the fuse box (fuse No. 3) and the start-up remote control switch relay.
8) Check the start-up maintenance relay ground connection (Black cable).
9) Check the continuity of the following cables, restore them if necessary:
- between the starter button Grey-Black cable (negative multimeter probe) and the start-up maintenance
relay Grey-White cable (positive probe). Also check continuity between the latter and pin 28 of the
control unit vehicle-side connector.
- between the stand button White-Green cable (negative multimeter probe) and pin 38 of the control
unit vehicle-side connector, (positive multimeter probe).
- between stop buttons, start-up remote control switch relay and pin 23 of the control unit vehicle-side
connector (Grey-Green cable).
ELE SYS - 100

- between pin 1 of the control unit vehicle-side connector, start-up remote control switch relay and start-
up maintenance relay (Orange-White cable).
10) Check the control unit power supply:
- Check there is voltage between pin 4 of the control unit vehicle-side connector and ground. If there is
no voltage, check the continuity of the cable harness and fuse No. 7.
- With the key switch set to «ON», check there is voltage between pin 17 of the control unit vehicle-side
connector and ground. If there is no voltage, check the continuity of the cable harness, fuses No. 2 and
10, the main relay and the ignition switch contacts.
11) Check the fuse No. 9 and the continuity of the Purple-White cable in the fuse box output with the
stop buttons.
12) Check the continuity of the cable harness between fuse No. 10 and the engine stop switch (White-
Black cable). Also check continuity between the latter (positive multimeter probes, Yellow-Green cable)
and pin 27 of the control unit vehicle-side connector (negative probe, Green cable).
13) Check the contacts of the starter button, stop buttons, stand button and engine stop switch.
Horn control
KEY
1. Battery 12V 14Ah
6. Fuses No. 02 - 15A
32. Fuses No. 09 - 10A
ELE SYS - 101

52. Horn button

53. Horn
WARNING
DISCONNECTED.
If the horn does not work:
1) Check the working order of fuse No. 2.
2) Check contacts «A» and «B» of the key switch.
3) Check the main relay.
4) Check that the Brown-Black cable of the main
relay is earthed.
5) With the key switch set to «ON» check if there
is voltage between the Orange cable of the main
relay and the ground connection.
6) If there is no voltage, check the continuity of the
cable harness with the fuse box.
8) Check the horn button contacts.
9) Check if there is voltage between the Yellow-
Pink cable of the horn button, with the latter press-
ed, and the ground connection. If there is no
voltage, check the continuity of the cable harness
between the main relay, fuse box and button.
10) Check the continuity of the Yellow-Pink cable
between the horn and the button, and whether the
Black cable of the horn is earthed. Repair the cable
harness if necessary.
ELE SYS - 102

Turn signals system check
KEY
1. Battery 12V 14Ah
8. Fuses No. 05 - 15A
13. Key switch
17. Fuses No. 11 - 7.5A
21. Turn indicator switch
22. Turn indicator control
25. Front left turn indicator
26. Rear left turn indicator
27. Front right turn indicator
28. Rear right turn indicator
WARNING
DISCONNECTED.
ELE SYS - 103

If the turn indicators do not operate correctly:

1) Check the working order of bulbs.
3) Check if there is voltage between pin 6 (Orange-
Blue) and 9 (Black) of the turn indicator control
device connector. If there is no voltage, check the
continuity of the cable harness.
4) Check contacts «G» and «H» of the key switch.
6) With the key switch set to «ON», check if there
is voltage between pin 8 (Yellow-Black) and 9
(Black) of the turn indicator control device connec-
tor. If there is no voltage, check the continuity of
the cable harness.
7) Check the turn indicator switch contacts.
8) With the turn indicator switch pressed, check if
there is voltage between pins 2 and 9 (switch to
the left) and pins 3 and 9 (switch to the right) of the
turn indicator control device.
9) If there is no voltage, check the continuity of the
cable harness between the fuse box and the turn
indicator switch. Also check continuity between
the latter and the turn indicator control device.
10) Check the continuity of the cable harness be-
tween the bulbs and the turn indicator control de-
vice.
level indicators
FUEL GAUGE
KEY
ELE SYS - 104

38. Fuel gauge

WARNING
DISCONNECTED.
If faults are detected:
1) With a multimeter, check the resistance values
between the White-Green cable and the Black ca-
ble of the fuel level transmitter by moving the arm
with the float.
2) If the transmitter works, but the indication on the
multimeter is not exact, check the continuity of the
cable harness between transmitter and multime-
ter.
Full tank position
<= 5 Ohm
Empty tank position
98 ± 5 Ohm
Lights list
KEY
1. Battery 12V 14Ah
2. Starter remote control contact
ELE SYS - 105


5. Fuses No. 01 - 40A
6. Fuses No. 02 - 15A
8. Fuses No. 05 - 15A
13. Key switch
15. Fuses No. 08 - 15A
17. Fuses No. 11 - 7.5A
32. Fuses No. 09 - 10A
36. C.D.I.
41. Low beam relay
43. Front head light
44. Licence plate lighting
45. Rear tail light
46. High beam relay
47. Light switch
48. High beam
49. Low beam
50. Front headlamp
73. Stop button
79. Stop light
WARNING
DISCONNECTED.
TAIL LIGHT CHECK
1) Check the bulbs and replace them as indicated in the bulb table.
2) Check fuse No. 5 and contacts «G» and «H» of the ignition switch.
3) Check the continuity of the cable harness between the battery, fuse box (fuse No. 5) and contacts
of the ignition switch.
4) Check fuse No. 11.
5) Check the continuity of the cable harness between the contacts of the ignition switch, fuse box (fuse
No. 11) and bulbs.
6) Check that the Black cables of the bulbs are earthed.
LOW BEAM LIGHT CHECK
1) Check the bulb and, if necessary, replace it as indicated in the bulb table.
4) Check the main relay
ELE SYS - 106

5) Check that the Brown-Black cable of the main relay is earthed.

6) With the key switch set to «ON», check if there is voltage between the Orange cable of the main
7) If there is no voltage, check the continuity of the cable harness with the fuse box (fuse No. 2).
9) Check the continuity of the cable harness between the main relay, fuse box (fuse No. 8) and the low
beam light relay (Red-Green cables).
10) Check the low beam light relay.
11) Check the continuity of the cable harness between the low beam light relay and the bulb (Brown-
White cable).
12) Check the continuity of the cable harness between the low beam light relay and the control unit
vehicle-side connector (Yellow-Grey cable).
13) Check that the Black cable of the bulb is earthed.
HIGH BEAM LIGHT CHECK
1) Check the bulb and, if necessary, replace it as indicated in the bulb table.
2) Check the continuity of the cable harness between the light switch and the low beam light relay
(Brown-White cable).
3) Check the light switch contacts.
4) Check the continuity of the cable harness between the light switch and the high beam light relay
(Purple cable).
5) Check the high beam light relay.
6) Check the continuity of the cable harness between the high beam light relay and fuse No. 8 (Red-
Green cable).
7) Check that the Black cable of the high beam light relay is earthed.
8) Check the continuity of the cable harness between the high beam light relay and the bulb (Purple-
White cable).
9) Check that the Black cable of the bulb is earthed.
10) If the high beam light does not work in flashing mode:
- Check the continuity of the cable harness of the main relay and fuse No. 9 (Orange cable).
- Check fuse No. 9.
- Check the continuity of the cable harness between the fuse box (fuse No. 9) and the light switch
(Purple-White cable).
- Check the high beam flash switch contacts.
- Check the continuity of the cable harness between the high beam flash switch and the high beam light
relay (Purple cable).
STOP LIGHT CHECK
1) Check LEDs and replace the rear light assembly if necessary.
ELE SYS - 107


4) Check the main relay.
5) Check that the main relay and ground Brown-Black cable is earthed.
6) With the key switch set to «ON», check if there is voltage between the Orange cable of the main
7) If there is no voltage, check the continuity of the cable harness with the fuse box (fuse No. 2).
8) Check fuse No. 9 and the continuity of the cable harness with the main relay (Orange cable).
9) Check the continuity of the cable harness between fuse No. 9 and the stop buttons (Purple-White
cables).
10) Check that the stop buttons work properly.
11) Check the continuity of the cable harness between the stop buttons and the rear light (Grey-Green
cable).
12) Check that the Black cable of the rear light is earthed.
LIGHT BULBS TABLE

Front side light bulb Type: ALL GLASS (light blue)
Power: 12V - 5W
Quantity: 2
High/low beam bulb Type: HALOGEN H11
Power: 12V - 55W
Quantity: 3
Turn indicator bulb Type: BULB (Amber)
Power: 12V - 10W
Quantity: 2 RHS + 2 LHS
Rear tail light bulb Type: LED
Power: -
Quantity: 1
License plate bulb Type: ALL GLASS
Power: 12V - 5W
Quantity: 1
Helmet compartment light bulb Type: FESTOON BULB
Power: 12V - 5W
Quantity: 1
Stop light bulb Type: LED
Power: -
Quantity: 1
Instrument panel bulb Type: ALL GLASS
Power: 12V - 2W
Quantity: 4
Turn indicator warning light bulb Type: ALL GLASS
Power: 12V - 1.4W
Quantity: 2
Fuses
The electrical system is equipped with twelve fuses for the protection of various circuits of the system
divided into two fuse boxes «C» and «D» located inside the battery compartment accessible by re-
moving the four screws «A» and removing the cover plastic «B». The chart shows the position and
specifications of the fuses in the vehicle.
CAUTION
ELE SYS - 108

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO
BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF
ELECTRIC WIRE).
FUSES
Fuse No. 1 Capacity: 40A
Protected circuits:Recharge, fuses No. 3 and 8
(accessible by removing front legshield).
ELE SYS - 109

Protected circuits:Main relay, fuses No. 9 and 10.
Protected circuits:LV socket, antitheft, helmet compartment
light button, actuator control receiver pre-installation, saddle
button (live).
Protected circuits:Injection load relay.
Fuse No. 5 Capacity: 7.5 A
Protected circuits:Turn signals device, Fuses No. 11 and 12
(live).
Protected circuits: Instrument panel.
Protected circuits: ECU, decoder.
Protected circuits:Low-beam light relay, high-beam light re-
lay.
Protected circuits (live):Accessories pre-installation, light
switch, control unit, horn, stop buttons.
Protected circuits (live):Control unit, decoder, injection load
relay, electric fan relay, stand button, engine stop switch, start-
er button, starter maintenance solenoid.
Protected circuits (live):Turn indicator control device, actua-
tor control pre-installation, daylight running lights, license plate
light, instrument panel.
Protected circuits (live):Antitheft device, instrument panel,
GPS wiring.
Sealed battery
Commissioning sealed batteries
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if
required, before storing the vehicle and, afterwards, every six months.
INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE
1) Voltage check
Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 ÷ 14.70V
-Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
ELE SYS - 110

Maximum 24 h
3) Constant current battery charge mode
-Charge current equal to 1/10 of the nominal capacity of the battery
- Charge time: 5 h
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
Cleaning the battery

The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. THE USE OF A
FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE-
HICLE OR EVEN CAUSE A FIRE.
CAUTION
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. FAILURE TO
CHARGE THE BATTERY ADEQUATELY BEFORE BEING PUT INTO OPERATION WILL LEAD TO
A PREMATURE FAILURE OF THE BATTERY.
If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge
the battery.
The battery runs down completely in the course of three months. If it is necessary to refit the battery in
the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked
(-) must be connected to the negative clamp while the other two red wires marked (+) must be con-
nected to the clamp marked with the + positive sign.
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if re-
quired, before storing the vehicle and afterwards every six months.
INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE
1) Voltage check up
Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 to 14.70V
- Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity
- Charge time:
ELE SYS - 111

10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the battery rated capacity
- Charge time: Maximum 5 h
Connectors
CAUTION
JOINTS ARE SEEN FROM THE CONNECTOR INPUT SIDE.
ENGINE CONTROL UNIT CONNECTOR
3.Throttle potentiometer (Orange-Light Blue)
5. Engine temperature (Grey-Green)
9. Idle adjusting motor (Light Blue-Yellow)
10. HV coil Cylinder 2 (Light Blue)
13. Barometric pressure signal (Orange)
14. Air temperature sensor (White-Grey)
17. Idle adjusting motor (Light Blue-Red)
18. Idle adjusting motor (Light Blue-Black)
19. Idle adjusting motor (Orange-Red)
20. Negative sensors (Light Blue-Green)
22. Positive sensors (Red-Blue)
25. Engine speed sensor (White)
28. Injector Cylinder 1 (Red-Yellow)
29. Throttle potentiometer (Grey-Black)
32. Throttle potentiometer (Brown-Yellow)
34. Engine speed sensor screen (Black)
35. Engine speed sensor (Red)
37. Injector Cylinder 2 (Blue)
38. HV coil cylinder 1 (Pink-Black)
ELE SYS - 112

VEHICLE CONTROL UNIT CONNECTOR

1. Start-up remote control switch relay (Orange-
White)
4. Battery positive (White-Red)
6. Injection loads relay (Black-Purple)
7. Immobilizer Decoder (Orange)
8. Low beam relay (Yellow-Grey)
9. Rpm indicator (Brown)
13. Injection warning light (Brown-White)
14. Electric fan relay (Blue-Yellow)
16. Diagnostic socket (Purple-White)
17. Live positive (White-Black)
18. Engine warning light inhibited (Light Blue-Yel-
low)
21. Oxygen sensor signal No. 2 (Purple)
22. Oxygen sensor ground No. 1 (White-Green)
23. Stop lights (Grey-Green)
24. Vehicle speed signal (Brown-Red)
27. Engine stop switch (Green)
28. Starter button (Grey-White)
31. Oxygen sensor ground No. 2 (Black-Green)
32.Oxygen sensor signal No. 1 (Grey-Red)
35. Overturn sensor (Yellow)
38. Stand switch (White-Blue)
INSTRUMENT PANEL CONNECTOR «A»

2. Fuel level indicator (White-Green)
3. Water temperature sensor (Green-Yellow)
4. Water temperature sensor ground (Brown-
Black)
5. Remote MODE button (Green)
6. Oil pressure sensor (Pink-White)
7. Left turn indicator warning light (Pink)
8. Right turn indicator warning light (White-Blue)
9. High beam warning light (Purple)
10. Parking brake warning light (Light Blue-Black)
11. Engine speed signal (Brown)
ELE SYS - 113

12. Ambient temperature sensor (Yellow-Blue)

13. Ambient temperature sensor ground (White-
Yellow)
low)
15. Immobilizer warning light (Red-Green)
16. Engine check warning light (Brown-White)
17. ABS warning light wiring (Red-Black)
18. SPORT warning light wiring (Red-Black)
19. ATC warning light wiring (Red-Black)
INSTRUMENT PANEL CONNECTOR «B»

5. Instrument panel lighting (Yellow-Black)
6. Battery positive (Red-Black)
11. Ground (Red-Black)
12. Live positive (Yellow-Black)
IMMOBILIZER DECODER CONNECTOR

2. Immobilizer warning light (Red-Green)
4. Ground lead (Black)
6. Control unit (Orange)
REAR CYLINDER HV COIL CONNECTOR

1. Injection loads relay (Black-Green)
2. Control unit (Red-Black)
ELE SYS - 114

FRONT CYLINDER HV COIL CONNECTOR

2. Control unit (Light Blue)
REAR CYLINDER INJECTOR CONNECTOR

1. Control unit (Red-Yellow)
FRONT CYLINDER INJECTOR CONNECTOR

1. Control unit (Blue)
ANTITHEFT DEVICE PRE-INSTALLATION

CONNECTOR
1. Left turn indicators (Pink)
2. Right turn indicators (White-Blue)
4. Battery positive (Blue)
5. Live positive (Red-Black)
6. Helmet compartment lighting bulb (Blue-Black)
7. Channel selection (Green)
8. Alarm output (Light Blue)
ELE SYS - 115

SADDLE OPENING RECEIVER CONNECTOR

1. Aerial (Purple)
2. Saddle opening actuator (Yellow-Grey)
3. Reset (White)
4. Battery positive (Blue)
11. Channel selection (Green)
12. Alarm output (Light Blue)
TURN INDICATOR CONTROL DEVICE CON-

NECTOR
2. Left turn indicator switch (White-Pink)
3. Right turn indicator switch (Blue-Black)
4. Left turn indicators (Pink)
5. Right turn indicators (White-Blue)
6. Battery positive (Orange-Blue)
GPS WIRING CONNECTOR

2. Live positive (Red-Black)
WIRING FOR ACCESSORIES - CONNECTOR

2. Live positive (Purple-White)
ELE SYS - 116

VOLTAGE REGULATOR CONNECTOR

1. Battery positive (Red-Black)
DIAGNOSTICS SOCKET CONNECTOR

3. Control unit (Purple-White)
IDLE ADJUSTMENT MOTOR CONNECTOR

1. Control unit (Light Blue-Red)
2. Control unit (Orange-Red)
3. Control unit (Light Blue-Yellow)
4. Control unit (Light Blue-Black)
FUEL PUMP CONNECTOR

ELE SYS - 117

FUEL LEVEL TRANSMITTER CONNECTOR

3. Instrument panel (White-Green)
STAND SWITCH CONNECTOR

2. Control unit (White-Green)
OXYGEN SENSOR CONNECTOR No. 1

1. Ground (White-Green)
2. Oxygen sensor signal (Grey-Red)
OXYGEN SENSOR CONNECTOR No. 2

1. Ground lead (Black-Green)
2. Oxygen sensor signal (Purple)
ELE SYS - 118

AIR TEMPERATURE SENSOR CONNECTOR

1. Control unit (White-Grey)
2. Control unit negative (Light Blue-Green)
WATER TEMPERATURE SENSOR CONNEC-

TOR
1. Control unit (Grey-Green)
2. Instrument panel (Green-Yellow)
4. Instrument panel (Brown-Black)
VEHICLE SPEED SENSOR CONNECTOR

3. Control unit positive (Red-Blue)
ENGINE RPM SENSOR CONNECTOR

1. Control unit (White)
2. Control unit (Red)
3. Sensor screen (Black)
ELE SYS - 119

THROTTLE SENSOR CONNECTOR

1. Control unit (Grey-Black)
2. Control unit (Brown-Yellow)
3. Control unit (Orange-Light Blue)
EXTERNAL TEMPERATURE SENSOR CON-

NECTOR
1. Control unit (White-Yellow)
2. Control unit negative (Yellow-Blue)
BAROMETRIC PRESSURE SENSOR CONNEC-

TOR
1. Control unit positive (Red-Blue)
ROLL-OVER SENSOR CONNECTOR

1. Control unit (Yellow)
ELE SYS - 120

INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Engine from vehicle SRV 850
This section describes the operations to carry out when removing the engine from the vehicle.
Exhaust assy. Removal
- Support the vehicle adequately.

- Remove the helmet compartment.
- Remove the rear swingarm.
- Undo the three screws indicated, collect the
washers and remove the heat-protection cover.
- Undo the three screws indicated and collect the

washers.
ENG VE - 122
SRV 850 Engine from vehicle
- Unscrew the two retainers fixing the silencer to

the muffler supporting arm.
- Remove the silencer together with the gasket.
- Remove the return springs of the centre stand.
- Unscrew the nut fastening the rear pin.
ENG VE - 123
- Remove the stand rear pin and collect the wash-

er.
- Remove the centre stand plus the four bushings.
- Unscrew the nut fastening the front pin.
- Unscrew the front pin and collect the washer.

- The attachment plate of the centre stand is now
free. For size reasons, it can only be removed after
being released from the catalytic converter retain-
ers.
ENG VE - 124
- The stand fixing pins also fasten the muffler sup-

porting bracket.
- Undo the upper screw fixing it to the engine, and
the muffler supporting arm is now free.
- Release the muffler supporting arm from the cat-

alytic converter.
- Unscrew the two nuts fixing the front exhaust

manifold.
- Unscrew the nut indicated, loosen the clamp, and

remove the front exhaust manifold together with
the gasket and the graphite bushing.
ENG VE - 125
- Undo the three screws indicated and remove the

rear exhaust manifold cover.
- Unscrew the two nuts fixing the rear exhaust

manifold.
- Loosen the clamp by undoing the screw indica-

ted.
- Disconnect the lambda probe connector.
ENG VE - 126
- Undo the screw fixing the catalytic converter to

the supporting bracket to the engine.
- The catalytic converter is now free.
- Release the attachment plate of the centre stand.
- Remove the catalytic converter.
- Remove rear exhaust manifold together with the

gasket and the graphite bushing.
- Unscrew the two retainers fixing the catalytic

converter support to the engine.
- Check the silent-block for wear; replace it if nec-
essary.
ENG VE - 127
KEY:
A: Nut fixing head - exhaust manifold
B: Centre stand front bolt nut
C. Centre stand rear bolt nut
D: Screw fixing silencer - muffler support arm
E: Screw fixing catalytic converter - catalytic converter support
F: Screw fixing muffler support arm - engine
G: Manifold retainer clamp
H:Silencer fixing screw
- Follow the removal steps but in reverse order; be careful to tighten to the prescribed torques.
MUFFLER TIGHTENING TORQUES

Name Torque in Nm
Nut fixing head - exhaust manifold 16 ÷ 18
Centre stand front bolt nut 34 ÷ 39
Centre stand rear bolt nut 74 ÷ 81
Screw fixing silencer - muffler support arm 11
Silencer fixing screw 22
Screw fixing catalytic converter - catalytic converter support 22 ÷ 24
Screw fixing muffler support arm - engine 24 ÷ 27
ENG VE - 128
Removal of the engine from the vehicle
REMOVAL
- Support the rear part of the vehicle adequately.
- Remove the helmet compartment and the side
cases.
- Remove the external air cleaner.
- Get a container of suitable capacity and empty
the cooling system; remove the pipes from the ro-
tor cover.
- Remove the rear swingarm.
Remove the complete muffler unit.
- Remove the pinion unit.
- Unscrew the fuel tank cap and keep it in place so
as to keep the tank pressurised.
- Disconnect the delivery and reverse fuel pipes
from the pump.
- From both cylinders disconnect: the injector con-
nector, undo the screw and release it from the
retainer clamp, remove the pipes connecting both
injectors.
NOTE
BE VERY CAREFUL WHEN PULLING OUT THE CARBU-
RETTOR PIPING SINCE AN EXCESSIVE FORCE MAY DAM-
AGE THE PLASTIC INSERTS ON THE PUMP BODY. UPON
REASSEMBLY, IT IS THEREFORE NECESSARY TO
SLIGHTLY PRESS THE PIPING AND THE RETAIN RIM TO-
WARDS THE PUMP, THEN KEEP THE RIM PRESSED AND
PULL THE COUPLING UPWARDS.
- Remove the clamp indicated and disconnect the

water outlet pipe from the heads.
ENG VE - 129
- Disconnect the blow-by intake pipes from the fil-

ter housing.
- Remove the spark plug tubes.

- Unscrew the nut and disconnect the positive from
the starter motor.
- Disconnect the engine minimum oil pressure sen-

sor connector.
- Remove the two retainer clamps.
ENG VE - 130
- Disconnect the ground lead from the retainer on

the flywheel cover.
- Disconnect the speed sensor connector.
- Disconnect the stator connector and release the

wiring from the indicated clamps.
- Prepare two plates under the engine block so as

to create a supporting base.
ENG VE - 131
- Lower the vehicle so as to rest the engine in a

horizontal position on the plates previously placed.
- Loosen the six fuel tank retainers to the chassis.

- Unscrew the nut indicated from both sides of the
engine and remove the fixing pin. Be particularly
careful when detaching the right half-tank to let the
pin come out.
CAUTION
THE ENGINE IS NOW FREE FROM ITS REAR RETAINERS.
- Release the engine from the front retainers, un-

screwing from both sides the nuts indicated; re-
move the two screws from the internal part.
CAUTION
THE ENGINE IS NOW FREE FROM ITS RETAINERS AND
DISCONNECTED FROM THE CHASSIS.
- Partially lift the rear section of the chassis so as to free it from the engine.
NOTE
GUIDE THE CHASSIS SO AS TO RELEASE IT FROM THE RIGHT-SIDE FRONT HEAD COVER.
- Disconnect the following connectors: engine
revs, Stepper motor, TPS, intake air temperature
and coolant temperature sensor.
ENG VE - 132
- Undo the screw fixing the wiring retaining brack-

ets on the engine.
- Undo the screw fixing the throttle control pipe re-

taining bracket.
- Lift the rear section of the chassis completely so

as to get free access to the throttle body fixing
screws.
- Undo the three screws fixing the throttle body to
the inlet manifold
- The engine is now free.
ENG VE - 133
REAR SUPPORT SERVICE

- Undo the two nuts indicated and collect the wash-
ers.
- Remove the link rods.

- Slide off the pin.
- Check the silent-block and the Teflon bushings
for wear; replace the components if necessary.
FRONT SUPPORT SERVICE

- Undo the indicated screw from both sides of the
vehicle and remove the supports.
- Check the silent-block for wear; replace the com-

ponents if necessary.
See also

Checking
Air filter
FITTING
ENG VE - 134
KEY:
A: Nut fixing silent-block plate - chassis
B: Nut fixing silent-block plate
C. Pin fixing nut - M14
D: Pin fixing nut - M10
ENG VE - 135
E: Upper nut fixing engine support link rods - chassis

F: Lower nut fixing engine support link rods - chassis
- Follow the removal steps but in reverse order; be careful to tighten to the prescribed torques.
ENGINE TO CHASSIS LOCKING TORQUES

Name Torque in Nm
Nut fixing silent-block plate - chassis 22 ÷ 25
Nut fixing silent-block plate 33 ÷ 41
Pin fixing nut - M14 124 ÷ 153
Pin fixing nut - M10 47 ÷ 52
Upper nut fixing engine support link rods - chassis 33 ÷ 41
Lower nut fixing engine support link rods - chassis 33 ÷ 41
- Restore all the retainers, check the engine oil level and top-up with the recommended oil type if nec-
essary.
- Fit the complete muffler unit.
- Fit the pinion unit, the rear fork together with the wheel and check if the chain tension is adequate.
- Fill and bleed the cooling circuit.
- Check the functioning of the accelerator and the electrical devices.
ENG VE - 136
INDEX OF TOPICS
ENGINE ENG
Engine SRV 850
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
- Undo the four air deflector fixing screws.
ENG - 138
SRV 850 Engine
- Undo the twelve screws fixing it to the engine

crankcase.
- Loosen the driven pulley shaft fixing nut with an

offset wrench and lock pulley shaft rotation using
a hex box-spanner.
- Remove the nut and collect the washer.
- Remove the transmission cover with a mallet to

help extracting both shafts from their bearings.
- Check that both bearings rotate freely; otherwise,

replace them.
ENG - 139
Engine SRV 850
NOTE
EACH TIME THE TRANSMISSION COVER IS REMOVED,
REPLACE THE CRANKSHAFT ADJUSTING RING.
- Remove the adjusting ring.
- Replace it with a new one.
Air duct filter
- Undo the three indicated screws and remove the

air deflector.
ENG - 140
SRV 850 Engine
- Remove the filter.
Removing the driven pulley shaft bearing
- Remove the transmission cover.

- Remove the Seeger ring.
- Place transmission cover on a wood surface and

use the special tool so that it is adequately sup-
ported.
- Pull out the bearing using the special tool.
NOTE
BELL MUST BE PLACED INTO THE TRANSMISSION COV-
ER, CLOSE TO THE BEARING SEAT AND THE WOODEN
SURFACE, SINCE WITHOUT BELL THE ENTIRE COVER
STRUCTURE WOULD BEND. NOT ONLY IN THE AREA OF
MAXIMUM STURDINESS.
Specific tooling
020363Y 20-mm guide
Refitting the driven pulley shaft bearing
- Heat the transmission cover interior using the heat gun.
Specific tooling
020151Y Air heater
- Place the bearing onto the special tool with a little grease to prevent it from coming out.
ENG - 141
Engine SRV 850
- Install the new bearing using the special tool.
Specific tooling
020363Y 20-mm guide
- Refit the seeger ring.
Smontaggio cuscinetto supporto albero puleggia motrice
- Remove the transmission cover.

- Remove the seeger ring.
- Take out the bearing using the specific tool.
Specific tooling
Montaggio cuscinetto supporto albero puleggia motrice
- Heat the transmission cover interior using the heat gun.
Specific tooling
020151Y Air heater
ENG - 142
SRV 850 Engine
- Place the bearing onto the special tool with a little

grease to prevent it from coming out.
- Install the new bearing using the special tool.
Specific tooling
020363Y 20-mm guide
- Refit the seeger ring.
Removing the driven pulley
See also
Removing the driving pulley
Inspecting the clutch drum
- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.
NOTE
CHECK THE ECCENTRICITY MEASURED, 0.2 MM MAX.
Characteristic
Max. value:
175.5 mm
Standard value:
175+0+0.2 mm
Inspecting the clutch
- Check the thickness of the clutch mass friction material.
Characteristic
Minimum thickness permitted:
1 mm
ENG - 143
Engine SRV 850
- The masses must not show traces of lubricants. Otherwise, check the driven pulley unit seals.
NOTE
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST
NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH
TO TEAR.
- Do not open the masses using tools to prevent a
variation in the return spring load.
Removing the clutch
Remove the clutch together with the driven pulley using the specific tool.
CAUTION
WHILE PERFORMING THESE OPERATIONS, AVOID CONTACT WITH OIL OR GREASE WHICH
COULD MAKE THE FAYING SURFACES BETWEEN THE BELT AND THE HALF-PULLEYS SLIP-
PERY.
Specific tooling
020659Y Tool to remove clutch and replace belt
- Place the clutch assembly on the tool by inserting

the pins in the ventilation holes.
- Fit the centring bushing until it stops.
- Unscrew the ring nut using the adaptor.
ENG - 144
SRV 850 Engine
- Screw until the clutch is completely disassem-

bled.
Pin retaining collar
- Extract the collar using 2 screwdrivers.
- Remove the 4 guide pins.

- Extract the moving driven half-pulley.
Removing the driven half-pulley bearing
- Check that the bushing is free from wear and

damage; otherwise replace the fixed driven half-
pulley.
- Remove the lock ring using pliers.
ENG - 145
Engine SRV 850
- Using the special tool inserted through the roller

bearing, pull out the ball bearing.
NOTE
PROPERLY SUPPORT THE PULLEY TO PREVENT DAM-
AGING THE THREADING.
Specific tooling
020456Y Ø 24 mm adaptor
020364Y 25-mm Guide
NOTE
IF YOU NEED TO OVERHAUL THE BEARINGS ON AN ASSEMBLED DRIVEN PULLEY UNIT, IT IS
NECESSARY TO SUPPORT THE UNIT BY THE BELL
Specific tooling
- Remove the roller bearing using the special tool,

supporting the fixed half-pulley with the bell.
Specific tooling
020375Y 28 x 30 mm adaptor
020183Y 30 mm guide
Inspecting the driven fixed half-pulley
- Check that the belt contact surface is free from

wear.
- Measure the outer diameter of the pulley bushing.
Characteristic
Minimum admissible diameter
54.91 mm
Standard diameter:
55.00 -0.015-0.035 mm
ENG - 146
SRV 850 Engine
Inspecting the driven sliding half-pulley
- Check that the belt contact surface is free from

wear.
- Remove the 2 inside sealing rings and the 2 out-
side O-rings.
- Measure the movable half-pulley bushing inside
diameter.
Characteristic
Maximum admissible diameter:
55.05 mm
Standard diameter:
55.00 +0.035 0.00 mm
Refitting the driven half-pulley bearing
- Install a new roller bearing using the special tool.

NOTE
PLACE THE BEARING WITH THE WRITINGS AND THE EM-
BEDDED OIL GUARD FACING OUTWARDS.
- Properly support the half-pulley to prevent damaging the threading.

If you are working on the driven pulley unit fully assembled, use the special tool.
Specific tooling
020478Y Punch for driven pulley roller casing
ENG - 147
Engine SRV 850
- Install a new ball bearing using the special tool.
Specific tooling
020477Y 37 mm adaptor
020364Y 25-mm Guide
- Insert the Seeger lock ring.
Refitting the driven pulley
- Insert the new oil guards

- Insert the new O-rings
NOTE
O-RINGS ARE OF TWO SIZES. THE LARGE ONE IS INSTALLED ON THE MACHINING END RA-
DIUS, AT THE BASE OF THE HALF-PULLEY.
- Install the half-pulley on the bushing being careful
not to damage the top sealing ring during the in-
troduction.
- Make sure the pins and collar are not worn, re-
assemble the pins and collar.
- Using a bent beak greaser, lubricate the driven pulley unit with about 10 gr. of grease, this operation
should be carried out through one of the two holes into the bushing to obtain the exit of the grease from
the opposite hole. This operation is necessary to avoid the presence of grease beyond the O-rings.
AGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum di-
sulphide.
-
ENG - 148
SRV 850 Engine
Inspecting the clutch spring
- Measure the length of the movable driven half-

pulley spring while it is not loaded.
Characteristic
Standard length:
190.2 mm
Admissible limit after use:
182 mm
Refitting the clutch
- Prepare the specific tool as per the removal

phase.
- Preassemble the driven pulley unit.
- Insert the driven pulley unit, the spring with
sheath and clutch into the tool.
CAUTION
WHILE PERFORMING THESE OPERATIONS, AVOID CON-
TACT WITH OIL OR GREASE WHICH COULD MAKE THE
FAYING SURFACES BETWEEN THE BELT AND THE
HALF-PULLEYS SLIPPERY.
Specific tooling
020659Y Tool to remove clutch and replace
belt
- Compress the spring and insert the clutch on the
driven pulley bushing.
NOTE
BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE
BUSHING THREADED END.
ENG - 149
Engine SRV 850
- Screw the locking ring nut and tighten to the pre-

scribed torque.

Clutch ring nut 65 - 75
- With a specific tool, separate the two half-pulleys

and fit the belt according to its direction of rotation.
CAUTION
PLACE THE TWO HALF-RINGS ADEQUATELY SO THAT
THEY PERFECTLY ADHERE TO THE HALF-PULLEY.
- Screw the tool so as to separate the two half-

pulleys.
ENG - 150
SRV 850 Engine
- Position the belt.
- Unscrew until the tool frees from the half-pulley

and remove it.
Refitting the driven pulley
- Fit the driving belt in the driven pulley with the

specific tool.
- Fit the assembled unit on the shaft.
See also
Refitting the
clutch
Drive-belt
- Make sure the drive belt is not damaged and does not show abnormal wear.
- Replace as indicated in the scheduled maintenance table.
ENG - 151
Engine SRV 850
Removing the driving pulley
- Remove the O-ring as shown in the photograph.
- Lock the driving pulley using the appropriate tool.

- Unscrew the fixing nut and collect the belleville
spring and the washer.
Specific tooling
- Remove the roller container.
- Remove the driven pulley together with the belt.
ENG - 152
SRV 850 Engine
- Remove the clutch bell.
- Remove the driving half-pulley.
- Remove the spacer.

NOTE
THE SPACER IS CONICAL; UPON REFITTING BE CARE-
FUL TO INSERT IT WITH THE SMALLER DIAMETER FAC-
ING THE INSIDE.
- Undo the five fixing screws and remove the air

switch.
ENG - 153
Engine SRV 850
Inspecting the rollers case
- Check that the inside bushings shown in the fig-

ure exhibit no signs of abnormal wear and meas-
ure the inside diameter.
CAUTION
DO NOT LUBRICATE OR CLEAN THE BUSHINGS
Characteristic
Maximum admissible diameter:
40.045 mm
Standard diameter:
40.00 +0.009 +0.034 mm
- Measure the pulley sliding bushing outside di-

ameter shown in the figure.
Characteristic
39.05 mm
Standard diameter:
40.00 -0.015 -0.040 mm
- Check that the rollers are not damaged or worn.
Characteristic
Ø 24.5 mm
Standard diameter:
25.0 ± 0.1 mm
ENG - 154
SRV 850 Engine
- Check the guide shoes for the variator back-plate

are not worn.
- Check the wear of the roller housings and of the
belt contact surfaces on both pulley halves.
Characteristic
Standard clearance:
0.01 ÷ 0.1 mm
Refitting the driving pulley
- Follow the removal steps but in reverse order being careful to tighten to the prescribed torques with
the specific tool.
Specific tooling

Drive pulley nut 252 ÷ 278 Air switch screw 3 ÷ 4
End gear shaft
«A» - CHAIN
- Lubricate, check and restore chain tension as in-
dicated in the scheduled maintenance table; see
the «Maintenance» Chapter.
- To replace, follow the instructions in the following
pages.
«B» - CROWN
- The crown is fastened to an anti-vibration buffer
flange to the rear wheel.
pages.
«C» - PINION
- The pinion is an integral part of the pinion unit.
pages.
ENG - 155
Engine SRV 850
PINION UNIT REMOVAL

- Remove the rear fork axle.
- Remove the footrest and the fairing on the right
side.
- Prepare a container of suitable capacity and undo
the lower screw to drain the oil.
CAUTION
IT IS NOT POSSIBLE TO DRAIN ALL THE OIL CONTAINED

THROUGH THE DRAINAGE SCREW. DURING REMOVAL
AND SERVICE OPERATIONS, TAKE CARE NOT TO SPILL
THE OIL CONTAINED INSIDE.
- Pull the chain until the oil sealing cap tightening

screw, that forms part of the pinion unit shaft, is at
a position that allows the access of a screwdriver.
- Loosen the tightening screw.
- Undo the three screws fixing it to the frame.
- Remove the pinion unit together with the chain.

CAUTION
PAY ATTENTION TO THE OIL REMAINING IN THE SEAL-

ING CAP
ENG - 156
SRV 850 Engine
- Release the pinion from the chain.

CAUTION
BE CAREFUL THAT THE DRIVING SLIDERS DO NOT FALL.
PINION UNIT SERVICE

- Fasten the support in a vice.
- Remove both engine-side driving sliders.
NOTE
THE FOUR DRIVING SLIDERS (TWO ON THE SUPPORT SIDE AND TWO ON THE ENGINE SIDE)
ARE INTERCHANGEABLE. MARK THEM SO AS TO RESPECT THE FITTING CLEARANCE CRE-
ATED DURING THE MOVEMENT PHASE.
- Loosen the eight screws fixing the pinion to the
driving bushing from the safety plate.
- Undo the eight screws.
ENG - 157
Engine SRV 850
- Detach the oil sealing cap together with the fixing

ring.
NOTE
NOTE THE POSITION OF THE FIXING RING. THE MA-
CHINED SURFACE SNAPS ON THE CAP.
- Remove the shaft together with the driving slid-

ers.
- Check that the shaft and the four driving sliders
exhibit no signs of abnormal wear.
ENG - 158
SRV 850 Engine
- Undo the six fixing screws and remove the cover

from the opposite side.
- Undo the four screws and remove the plate.

NOTE
THE PLATE FORMS AN INTEGRAL UNIT WITH THE PINION
DRIVING BUSHING AND THE SUPPORT. ONCE THE
PLATE IS UNSCREWED, REMOVE THE PINION.
- Remove the pinion driving bushing plus the pin-

ion, bearings and spacer from the support.
- Slide off the components from the driving bush-

ing.
ENG - 159
Engine SRV 850
- Remove the oil seal indicated.
- Fit the specific tool and pull out the bearing work-
ing from inside the pinion unit.
Specific tooling
020662Y Guide 50 mm
- Drive a new bearing with the specific tool working

from outside the pinion unit.
Specific tooling
020662Y Guide 50 mm
ENG - 160
SRV 850 Engine
- Fit the specific tool and drive a new oil seal work-
ing from inside the pinion unit.
Specific tooling
020662Y Guide 50 mm
- Fit the new components on the driving bushing,

pinion, bearings and bushing, following the se-
quence indicated in the photograph, being careful
to place the bushing properly.
- In the support, fit the pinion driving bushing plus

with the pinion, bearings and spacer previously
assembled.
- Fit the plate and tighten the four fixing screws

using the recommended product from the opposite
side.
* Loctite 243 medium-strength

Screw for plate locking pinion driving bush-
ing 4 ÷ 6*
ENG - 161
Engine SRV 850
- Grease the driving sliders with the recommended

product.
- Fit the shaft together with the seeger ring and the
support side driving sliders.
AGIP GREASE PV2 Ivory smooth-textured,
slightly-stringy anhydrous calcium-base
grease.
TL 9150 066, symbol NATO G 460
- Fit the seeger ring in the seat.
- Fit the oil sealing cap with the fixing ring, com-
plying with the position indicated during removal.
NOTE
FIT THE OIL SEALING CAP EDGES UNDER THE SAFETY
PLATE.
- Tighten the eight screws fixing the pinion to the

driving bushing and with a punch fold the tongues
of the safety plate.
- Grease the driving sliders with the recommended
product.
- Fit both engine side driving sliders.
grease.
ENG - 162
SRV 850 Engine
- Fit the cover and tighten the six fixing screws to

the prescribed torque using the recommended
product from the opposite side.
(*) Apply Loctite 243 medium-strength

Screws fixing pinion unit cover 4 ÷ 5*
PINION UNIT FITTING

- Fit the complete pinion unit in its housing on the
engine.
- Fit the oil sealing cap over the pinion unit shaft.
- Tighten the clamp to the prescribed torque.

Oil sealing casing clamp 3 ÷ 5
- Tighten the three fixing screws to the prescribed

torque.

Screws fixing pinion unit - chassis 50
- Tighten the oil drain screw «B» to the prescribed torque.

Pinion unit oil drain screw 13 ÷ 15
- Undo the oil filling screw «D».
- Fill up to the oil level with the recommended product following the indications described in the figure.
ENG - 163
Engine SRV 850
WARNING
DO NOT EXCEED THE "MAX" LEVEL WHEN TOPPING UP.

AGIP ROTRA MP 80W-90 Lubricant for gears.
API GL-5
- Tighten the oil filling screw «D» to the prescribed

torque.

Pinion unit oil filling screw 13 ÷ 15
CROWN REPLACEMENT
- Remove the rear wheel.
- Undo the five screws fixing the crown to the anti-
vibration buffer.
- Replace the crown with a new one and tighten the fixing screws using the recommended product.
(*) Apply Loctite 243 medium-strength

Crown fixing screws 22.5 ÷ 27.5*
CHAIN REPLACEMENT
- Release the chain from the rear wheel.
- Remove the complete pinion unit so as to release the chain.
- Replace the chain with a new one and following the indications described in the specific sections, fit
the pinion unit and the wheel. Restore the correct chain clearance following the indications in the
«Maintenance» Chapter.
Refitting the transmission cover

- Follow the removal steps but in reverse order being careful to tighten to the prescribed torques with
the specific tool.
ENG - 164
SRV 850 Engine

Driven pulley nut 153 ÷ 187 Internal transmission cover screws 11 ÷ 13 External transmission
cover screws 5 ÷ 7
End gear
PINION UNIT SHAFT BEARING REMOVAL

- The toothed wheel (pinion unit shaft) rotates on
two bearings located on both crankcase halves. To
replace, proceed as follows.
- Transmission-side crankcase half:
- Remove the driven pulley shaft axle and the
toothed wheel.
- Acting on the specific tool, take out the bearing.
Specific tooling
001467Y035 Bearing housing, out ø 47 mm
ENG - 165
Engine SRV 850
- Flywheel-side crankcase half:

- Remove the oil seal and the bearing with the
specific tool.
Specific tooling
020662Y Guide 50 mm
PINION UNIT SHAFT BEARING FITTING

- The toothed wheel (pinion unit shaft) rotates on
two bearings located on both crankcase halves. To
fit, proceed as follows.
- Transmission-side crankcase half:
- Heat the crankcase using the heat gun.
Specific tooling
020151Y Air heater
- Insert the pinion unit shaft bearing until it stops against the bottom of the seat using the specific tool.
Specific tooling
020363Y 20-mm guide
- Flywheel-side crankcase half:

Specific tooling
020151Y Air heater
ENG - 166
SRV 850 Engine
- Fit the oil seal until it stops against the bottom of the seat using the specific tool.
Specific tooling
020662Y 50 mm guide
- Insert the driven pulley shaft bearing until it stops

against the bottom of the seat using the specific
tool.
Specific tooling
020662Y 50 mm guide
ENG - 167
Engine SRV 850
Removing the driven pulley shaft bearing
- Slide off the toothed wheel (pinion unit shaft).
- Slide off the driven pulley shaft from one side and
with a screwdriver remove the oil seal from the
other side.
ENG - 168
SRV 850 Engine
- Remove the bearing with the specific tool.
Specific tooling
020483Y 30 mm guide
Inspecting the hub shaft
- Check the two shafts exhibit no wear or distortion

of the toothed surfaces, the bearing housings, and
the oil seal housings.
- In case of faults, replace the damaged parts.
Characteristic
Bearing diameter for driven pulley shaft:
A= Ø30 -0.01 -0.02 mm
B= Ø20 -0.01 -0.02 mm
Diameter for pinion unit shaft:
C= Ø20 -0.01 -0.02 mm
D= Ø50 -0.01 -0.023 mm
ENG - 169
Engine SRV 850
Refitting the driven pulley shaft bearing
Specific tooling
020151Y Air heater
- Insert the driven pulley shaft bearing until it stops against the bottom of the seat using the specific tool.
Specific tooling
020483Y 30 mm guide
- Fit the seeger ring.
- Fit the oil seal from outside the transmission-side

crankcase half.
ENG - 170
SRV 850 Engine
Refitting the hub bearings
- Place the two shafts as shown in the figure.
Flywheel cover
ENG - 171
Engine SRV 850
Removing the hub cover
- Remove the sixteen screws fixing it to the crank-

case.
- Remove the flywheel cover.

NOTE
THE COVER OFFERS RESISTANCE DUE TO THE FLYWHEEL MAGNETIC FIELD.
Removing the stator
- Unscrew the 3 fastening screws and remove sta-

tor and its wiring.
Inspecting the cover components
- Check the condition of the stator and the relevant

cable harness.
ENG - 172
SRV 850 Engine
- Check the continuity between the 3 phases.

NOTE
VALUES ARE STATED AT AMBIENT TEMPERATURE. A
CHECK WITH THE STATOR AT OPERATING TEMPERA-
TURE MAY RESULT IN VALUES HIGHER THAN THOSE
STATED.
Resistance:
0.2 - 1 Ω
- Check the ground insulation of each phase.

- If a fault is found, carry out a thorough check of
the cable harness that contains two types of cable:
Rigid cables close to the stator and flexible cables
close to the connector.
- Check that the winding is positioned so as not to

interfere with the heads of the retaining screws.
Refitting the stator
- Install the stator assembly together with the wir-

ing harness, tightening the 3 screws to the pre-
scribed torque.
NOTE
INSERT THE RUBBER WIRING SEALING GASKET INTO
THE SPECIAL SEAT ON THE CRANKCASE.

Stator retainers 8 - 10
ENG - 173
Engine SRV 850
Refitting the flywheel cover
- Follow the removal steps but in reverse order; be careful to tighten to the prescribed torque with the
specific tool.
CAUTION
CLOSING THE COVER MAY POSE A RISK TO THE OPERATOR DUE TO THE STRONG MAG-
NETISM OF THE FLYWHEEL. BE PARTICULARLY CAREFUL WITH YOUR HANDS AND FINGERS.
Flywheel cover screws 11 - 13
Flywheel and starting
The starter is sold as a complete part.

Before deciding to replace it, carry out the follow-
ing tests:
- Battery
Check the voltage after a pause:
Voltage >12.5V
- Check the correct connection of the negative ter-
minals (battery negative and starter motor nega-
tive) between them and to the chassis.
- Recharge and if necessary, replace the battery.

- Connect the diagnostic tester (see the «injection» chapter).
Connect the induction clamp of an ammeter to the positive power supply cable of the starter motor.
Remove the 7.5A fuse No. 10 (see the «fuses» chapter).
Switch in position "ON" with interrupt switch in position "RUN" and side stand raised.
Select the "PARAMETERS" function.
Start the engine (so that it cannot move) long enough to measure the rpm and starter absorption.
NOTE
THE DECLARED RPM VALUE IS THAT INDICATED BY THE TESTER, THE RPM READING IS NOT
THE REAL ONE, BUT IS VALID FOR DIAGNOSTIC PURPOSES.
Specific tooling
Absorption at trailing speed:
120 A
Revolution speed =
approx. 300-400 rpm
The starter system has a transmission between the motor armature and engine shaft equipped with
freewheel coaxial to the flywheel and torque limiter on the intermediate shaft.
ENG - 174
SRV 850 Engine
The limiter is calibrated to 100 Nm (10 kgm); this component protects the structure of the engine and
the starter kinematic mechanism in the event of incorrect starting with consequent inverse rotations.
The freewheel is used for a sufficiently silent starting.
The starter control (energised remote control) is slaved to enabling signals by the side stand and the
emergency OFF/RUN switch, which does not allow starting given dangerous conditions.
The starter control circuit is not controlled by the immobilizer system, therefore before insisting on the
starter system, check the consensus of the immobilizer.
In order to check the enabling switches circuit, see the «Electrical system» chapter, whereas to check
the engine shaft control transmission, follow what is described in the «Flywheel and starter system»
chapter.
Removing the starter motor
- Disconnect the electric terminals.

- Unscrew the nuts fixing it to the crankcase.
Removing the flywheel magneto
- Lock the flywheel and loosen the nut fixing it to

the shaft with the specific tool.
Specific tooling
ENG - 175
Engine SRV 850
- Fit the specific extractor, and unlock the flywheel

acting on the tool.
CAUTION
THE THREAD IS ANTICLOCKWISE.
Specific tooling
- Once it is unlocked, remove the flywheel.
- Unscrew the plate fixing screw.
- Remove the starting ring gear.
ENG - 176
SRV 850 Engine
- Undo the five fixing screws and remove the oil

pump compartment closing bulkhead.
- Remove the intermediate gear.
Inspecting the flywheel components
- Check the integrity of the magnets.

- Check that the magnet support cage is free from
deformation or cracks.
Starter gear rim
- Check that there is no wear or abnormal impres-

sions on the "rollers" of the freewheel and on the
surface of the starter ring gear hub.
- Check the hub outside diameter.
Characteristic
Hub outside diameter:
Diameter 45.665 + 0.008 +0.005 mm
ENG - 177
Engine SRV 850
- Check the inside diameter of the bushing of the

starter gearing.
- Check that the toothing is not worn.
Characteristic
Inside diameter of the bushing:
Diameter 27 + 0.020 +0.041 mm
NOTE
IF THE FAULTS DISCOVERED AFFECT THE HUB, REPLACE THE STARTER RING GEAR AND
FREEWHEEL.
IF ONLY THE BUSHING IS WORN, IT IS POSSIBLE TO REPLACE ONLY THE COMPLETE START-
ING RING GEAR. IN THAT CASE, CHECK ALSO THE DIAMETER AND THE SURFACE OF THE
CONNECTION ON THE CRANKSHAFT. IN CASE OR IRREGULARITIES, REPLACE THE CRANK-
SHAFT.
Intermediate gear
- Check that the toothing is not worn.

- Check the diameter of the two bearings.
Characteristic
Gear bearing diameter:
12 - 0 0.011 mm
Also check the shaft diameter on the flywheel cov-

er and on the engine crankcase.
Characteristic
Bearing diameter on the flywheel cover
12 + 0.034 -0.016 mm
ENG - 178
SRV 850 Engine
Characteristic
Bearing diameter on the engine crankcase:
12 + 0.034 -0.016 mm
NOTE
THE TORQUE LIMITER IS PROVIDED WITH 4 GEARS THAT HAVE THE FUNCTION OF CLUTCH
DRIVE PLATES.
Driven plates consist of 4 Belleville springs provi-
ded with grooved profiles; this assembly allows
transmitting torques below 100 Nm (10 kgm).
In case of incorrect start-up procedures, the torque
limiter prevents any kicks, resulting in inversion of
rotation direction of the crankshaft which would
impair the engine structure
The limiter assembly cannot be overhauled. In case of irregularities on the toothed discs, replace the
assembly.
Refitting the free wheel
- Make sure the freewheel faying surfaces are in good condition.

- Thoroughly clean the free wheel to remove LOCTITE residue.
- Degrease the threading of the holes in the free wheel and the clamping screws.
- Apply the recommended product to the end of the screws.
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock
ENG - 179
Engine SRV 850
- Fit the freewheel on the magneto flywheel making

sure that the ground side is in contact with the fly-
wheel itself, i.e. with wheel Seeger ring visible.
- Lock the six clamping screws in criss-cross fash-
ion to the prescribed torque.

Screw fixing freewheel to flywheel 13 - 15
- Oil the free wheel "rollers".
Refitting the intermediate gear
- Lubricate the gear housing on the engine crank-

case.
- Insert the intermediate gear with torque limiter
ENG - 180
SRV 850 Engine
- Lubricate the inside bushing and the starter ring

gear hub surface.
- Install the start-up rim on the flywheel turning it

clockwise and inserting at the same time.
Refitting the starter motor
- Check that the O-ring is in good working order

and lubricate it.
- Insert the starter motor.
- Tighten the 2 fastening screws to the prescribed
torque.

starter motor retainers 11 - 13
ENG - 181
Engine SRV 850
Cylinder assy. and timing system
Removing the intake manifold
- Remove the coolant pipes.
- Undo the six fixing screws.
ENG - 182
SRV 850 Engine
- Remove the inlet manifold.
Removing the rocker-arms cover
- Loosen the 6 special screws with stop and the

relevant rubber gaskets.
- Remove the tappet cover with relevant gasket.
Removing the timing system drive
- As indicated in the photograph, align the refer-

ences on the timing system gear of the rear cylin-
der with the reference on the cam cap valves.
NOTE
PLACING THE ENGINE AS INDICATED, IT IS IN THE COM-
BUSTION PHASE AND ALL THE VALVES ARE CLOSED.
THIS HELPS FITTING-REMOVAL OPERATIONS.
- Loosen the central screw on the tensioner.

- Unscrew the two retainers indicated in the pho-
tograph and remove the tensioner with the rele-
vant gasket.
ENG - 183
Engine SRV 850
- Lock the timing system gear with the specific tool,

undo the central fixing screw and collect the wash-
er.
- Release the chain from the sprocket and be care-
ful that it does not fall inside the transmission
housing.
- Remove the timing system gear and the tone
wheel from the camshaft.
CAUTION
THE TONE WHEEL IS ONLY ON THE REAR CYLINDER. IN
THE FRONT CYLINDER IT IS REPLACED BY A SPACER.
Specific tooling
- Repeat the operations for the front cylinder timing system gear.
Removing the cam shaft
- Unscrew the 3 fastening screws and remove

camshaft retaining bracket.
NOTE
REMOVING THE FASTENING SCREWS MAY BE DIFFI-
CULT. BE CAREFUL NOT TO DAMAGE THE INSIDE HEX-
AGON. IF NECESSARY, SEPARATE THE THREADS IN
ADVANCE.
- Remove the cam shaft.
ENG - 184
SRV 850 Engine
- Remove pins and rocking levers by the transmis-

sion side holes.
Removing the cylinder head
- The head removal operation is carried out in two separate stages, first on the rear cylinder, then on
the front one.
- If the heads are removed with the valves and the camshaft, follow the recommendations.
NOTE
THE PROPER TIMING IS NECESSARY DURING THE FITTING PHASE. THE HEADS MUST BE
CORRECTLY REMOVED WITH THE PISTONS AT TDC AND THE VALVES CLOSED.
- Remove the rear cylinder head following the indicated operations.
CAUTION
REMOVE THE HEADS AFTER PERFORMING THE TIMING OPERATION.
- Perform timing of the front cylinder (rotate the crankshaft by 270° towards the engine direction of
rotation), then remove the head following the indicated operations.
- Remove the engine rpm sensor and water tem-

perature sensor, these two components are only
fitted on the rear cylinder head.
ENG - 185
Engine SRV 850
- These operations are described once but apply

to both heads.
- Remove the spark plugs.
- Undo the two fixing nuts and collect the washers.
- Undo the spark plug side screw.
- Undo the two screws inside the timing system

side head.
NOTE
THE HEAD MAY BE REMOVED WITH THE CAMSHAFT,
ROCKING LEVER PINS AND FITTING BRACKET IF NEC-
ESSARY.
ENG - 186
SRV 850 Engine
- Loosen the 4 head-cylinder fixing nuts in two or

three stages and in a criss-crossed sequence.
- Remove the head, the two centring dowels, the
gasket and the lower chain guide slider
Removing the valves
- Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves.
Specific tooling
020382Y Valve cotters equipped with part 012 removal tool
CAUTION
ARRANGE THE VALVES SO AS TO RECOGNISE THE
ORIGINAL POSITION ON THE HEAD (FLYWHEEL SIDE
AND TRANSMISSION SIDE).
ENG - 187
Engine SRV 850
- Remove the oil guards using the special tool.
Specific tooling
020431Y Valve oil seal extractor
- Remove the spring supports.

NOTE
BLOW THE SEATS WITH COMPRESSED AIR TO FACILI-
TATE THE SPRING SUPPORT REMOVAL.
ENG - 188
SRV 850 Engine
Removing the cylinder - piston assy.

- Remove the coolant inlet pipes.
- The described operations refer to one cylinder
but apply to both.
- Extract the cylinder with the relevant gasket and

the centring dowel.
NOTE
THE SECOND CENTRING IS ENSURED BY A DOWEL SET
INTO THE CYLINDER.
CAUTION
TO PREVENT DAMAGING THE PISTON, SUPPORT IT
WHILE REMOVING THE CYLINDER.
- Remove the 2 piston pin locking rings by the spe-

cific housings.
- Extract the pin and remove the piston.
NOTE
USE PAPER OR A CLOTH TO CLOSE THE CYLINDER
HOUSING MOUTH ON THE CRANKCASE TO PREVENT
SLIPPAGE OF ONE OF THE PIN LOCKING RINGS INTO
THE CASE.
- Remove the piston sealing rings and the oil scra-

per.
CAUTION
NOTE THE ASSEMBLY POSITIONS OF THE LININGS TO
PREVENT INVERTING THE POSITION IN CASE OF REUSE.
NOTE
BE CAREFUL NOT TO DAMAGE THE SEALING RINGS
DURING REMOVAL.
Inspecting the small end

NOTE
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
ENG - 189
Engine SRV 850
See also
Inspecting the wrist pin

NOTE
TER.
See also
Inspecting the piston

NOTE
TER.
See also
Inspecting the piston rings

NOTE
TER.
See also
Interventions rules
Removing the piston
- Fit the piston and pin onto the connecting rod,

aligning the piston arrow towards the engine di-
rection of rotation.
- Insert the locking ring into the special tool, with

the opening in the position indicated on the tool.
S = left
D= right
ENG - 190
SRV 850 Engine
- Place the wrist pin stop ring into position using a

punch
- Install the pin lock using the key shown in the

figure.
Specific tooling
020470Y Pin retainers installation tool
NOTE
THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY.
CAUTION
USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING.
Choosing the gasket
- Provisionally fit the piston into the cylinder, without any base gasket.
- Install a dial gauge on the special tool using the short union, as shown in the figure.
Specific tooling
020475Y Piston position checking tool
- Using an abutment plane, reset the dial gauge

with a preload of a few millimetres.
- Finally fix the dial gauge.
- Check the perfect sliding of the feeler pin.
- Install the tool on the cylinder without changing
the dial gauge position.
- Lock the tool using the original head fixing nuts.
- Rotate the crankshaft up to the TDC (the inver-
sion point of the dial gauge rotation)
- Measure the deviation from the reset value.
ENG - 191
Engine SRV 850
- By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to
be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres-
sion ratio.
- Remove the special tool and the cylinder.
NOTE
IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORY
ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEAT
THE TOOL INSTALLATION BY INVERTING ITS POSITION.
See also
Refitting the piston rings
- Place the scraper ring spring on the piston.

- Install the scraper ring keeping the opening op-
posed to the spring junction and with the writing
"top" facing the piston crown. The chamfered side
of the oil scraper ring should always be facing the
piston crown.
- Fit the second lining with the identification letter
or the writing "top" facing the piston crown. In any
case, the step must be facing opposite the piston
crown.
- Install the first compression lining in the direction
imposed by the housing.
- It is advisable to use a fitter to facilitate the in-
stallation of the linings.
NOTE
THE TWO PISTON RINGS ARE MADE WITH A TAPERED
CYLINDRICAL CONTACT CROSS-SECTION. THIS IS TO
ACHIEVE A BETTER BEDDING.
- Misalign the lining openings at 120° as shown in the figure.

- Lubricate the components with engine oil.
ENG - 192
SRV 850 Engine
- The engine uses the first compression lining with an L section.
Refitting the cylinder
- Insert the cylinder base gasket with the thickness

determined above.
- Using the fork and the ring clamp, fit the cylinder
NOTE
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW
THE LUBRICATION DUCT AND LUBRICATE THE CYLIN-
DER LINER. CHECK THE PRESENCE OF THE TWO REF-
ERENCE DOWELS.
Specific tooling
020468Y Piston assembly band
020512Y Piston fitting fork
- Remove the specific tool.
ENG - 193
Engine SRV 850
- Make sure that the centring dowel is properly fit-

ted and insert the cylinder until it stops.
Inspecting the cylinder head

NOTE
TER.
See also
Inspecting the timing system components
- Check that the guide shoe and the tensioner shoe are not worn out.
- Check that the crankshaft pinion and the camshaft timing gear and crankshaft pinion exhibit no wear.
In case of wear of the sliding blocks, replace them. In case of wear of the chain or rim, replace the entire
unit.
NOTE
IF THE CHAIN HAS DAMAGED THE PINION, REPLACE THE CRANKSHAFT AS DESCRIBED IN
CHAPTER CRANKCASE AND CRANKSHAFT.
ENG - 194
SRV 850 Engine
Chain tensioner:
- Remove the centre screw with the washer and
the tensioner spring. Check that the one-way
mechanism is not worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
unit.
Inspecting the valve sealings

NOTE
TER.
See also
Inspecting the valves

NOTE
TER.
See also
Inspecting the valve stem guide clearance

NOTE
TER.
See also
Inspecting the springs and half-cones
- Check that the upper and lower supporting spring

washers, the cotters and the oil seal show exhibit
no signs of abnormal wear. Replace a component
when worn.
- Measure the unloaded spring length.

NOTE
ENG - 195
Engine SRV 850
TER.
See also
Refitting the valves

- Place the valve spring support washers on the
head.
- Fit the four oil seals alternately with the specific

tool.
Specific tooling
020306Y Punch for assembling valve seal
rings
- Lubricate the oil guards and the valve guides.
ENG - 196
SRV 850 Engine
- Fit the valves, the springs and the caps.
- With the specific tool equipped with the appro-

priate adaptor, compress the springs and fit the
cotters in their seats.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
NOTE
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REF-
ERENCE COLOUR ON COTTER SIDE (TURNS WITH GREATER PITCH).
Inspecting the cam shaft

NOTE
TER.
See also
Refitting the head and timing system components
- Heads are fitted in two separate stages.

- Fit the rear cylinder head and then the front cylinder head, following the indications described.
- Insert the chain guide sliding block.

- Insert the two centring dowels between head and
cylinder.
NOTE
ENG - 197
Engine SRV 850
THE FIGURE SHOWS THE INSERTION POSITION OF THE TWO CENTRING DOWELS BETWEEN
HEAD AND CYLINDER. THE DIRECTION OF INSTALLATION FOR THE GASKET IS FORCED BY
THE DOWELS.
- Fit the head gasket.
- The head gasket is made of steel and has a
standard thickness.
- Check that the head lubrication channel is per-

fectly clean. Clean with compressed air jets, if
required.
- Insert the head.
- Lubricate the stud bolts and the 4 fixing stud
bolts.
- Tighten the 4 fixing stud bolts crosswise to the prescribed torque as shown in the figure.

Head fixing stud bolts ***
*** Apply a preliminary torque of 10 Nm in a
crossed sequence.
- tighten with a torque of 13 N·m + 90° in a crossed
sequence.
- tighten again by 90° in a crossed sequence.
- Tighten the fastening nuts on the exhaust and on

the intake side to the prescribed torque.

Exhaust / intake head fixing nuts 10 - 12
ENG - 198
SRV 850 Engine
Undo the two screws inside the timing system side

head to the prescribed torque.

Exhaust / intake head fixing nuts 10 - 12
- Install the coolant temperature sensor with the

washer and tighten to the prescribed torque.
CAUTION
FAILURE TO OBSERVE THE TIGHTENING TORQUE CAN
DAMAGE THE SENSOR.

Coolant temperature sensor 21 ÷ 23
- Fit the spark plugs and tighten them to the prescribed torque.

Spark plug 12 ÷ 14
ENG - 199
Engine SRV 850
- Fit the rpm timing sensor and tighten to the pre-

scribed timing.

Rpm timing sensor screw 7.5 ÷ 8.5 Nm
- Insert the timing control belt on the crankshaft

according to the initial direction of rotation.
- Install the tensioner shoe with its spacer, tight-
ening the bolt to the prescribed torque, using the
recommended product.

Tensioner sliding block fixing screw 10 - 14
- Fit the pins and the rocking levers operating on
the transmission side.
- Lubricate the two rocking levers through the
holes at the top.
- Clean the camshaft by blowing with little com-

pressed air jets, especially the retaining plate
housing.
- Lubricate the 2 shafts.
- Insert the camshaft into the head with the cams
opposite the rocking levers.
- Remove any LOCTITE residues from the screws fixing the camshaft retaining bracket using a brush.
- Apply the recommended product to the fixing screws and tighten to the prescribed torque.
ENG - 200
SRV 850 Engine
- Insert the camshaft retain bracket with visible

countersinks and tighten the 3 fastening screws to
the prescribed torque, being careful not to damage
the inside hexagon.

Camshaft retaining bracket screws: 4 ÷ 6
- Finish closing the flywheel side crankcase with the components following the instructions described
in the specific sections.
- Using the TORX wrench, remove the timing

check cap.
- With the references aligned, operate on the driv-

ing pulley to turn the crankshaft until, the rear
cylinder timing reference mark «1» on the flywheel
is aligned to the crankcase reference mark.
- Fit the tone wheel, the timing system gear with

the chain and align the reference marks.
ENG - 201
Engine SRV 850
- Once the reference marks are aligned as indica-

ted with the reference marks on the valve cam cap,
tighten the screw with the washer to the prescribed
torque.

Timing system gear on camshaft screw 12 ÷ 14
- Place the tightener cursor in the rest position,

keeping the retain tab pressed.
- Insert the chain tensioner in the cylinder together

with the gasket and tighten the screws to the pre-
scribed torque.

timing chain tensioner screws 11 ÷ 13
- Check and restore the correct clearance of the

valves if necessary.
Characteristic
Valve clearance
Intake: 0.15 mm
Exhaust: 0.15 mm
ENG - 202
SRV 850 Engine
- Turn the crankshaft , acting on the driving pulley

by 270° so as to align the front cylinder timing ref-
erence mark «2» on the flywheel with the crank-
case reference mark.
- Repeat the fitting operations of the rear cylinder for the front cylinder timing head and components.
Refitting the timing chain

The ignition advance is determined electronically on the basis of parameters known by the control unit.
For this reason it is not possible to state the reference values based on the engine revs.
The ignition advance value can be measured at any time with the diagnostic tester.
It is possible to check whether the ignition advance determined by the injection system does in fact
correspond with the value actually activated on the engine, by means of the stroboscopic light.
Specific tooling
020460Y Scooter tester and diagnosis
020330Y Stroboscopic light for timing checking
- Unscrew the TDC reference inspection cap.

- Connect the stroboscopic light.
- Connect the diagnostic tester.

- Start the engine.
- Select the «parameter» function from the menu.
- Select the stroboscopic light control in the traditional four-stroke engine position (1 spark, 2 revs).
- Check that the real values of revs and ignition advance match those measured using the diagnostic
tester.
- Refit the inspection cap on the flywheel side.
Specific tooling
020460Y Scooter tester and diagnosis
If the values do not correspond, check:
ENG - 203
Engine SRV 850
- distribution timing
- rpm timing sensor
- injection control unit
Refitting the rocker-arms cover
- Check that the gasket is in good condition.
- Tighten the two screws indicated in the figure with

«1» and «2» to limit the reciprocal sliding of the
cover surface with the head surface.
- Tighten the remaining 4 screws in a criss-crossed
sequence (3,4,5,6).
NOTE
PAY ATTENTION TO THE CORRECT POSITION OF THE
GASKET.

Tappet cover fixing screws 7 - 9
Refitting the intake manifold
- Fit the intake manifold on the engine.
ENG - 204
SRV 850 Engine
- Fit the six fixing screws and tighten to the pre-

scribed torque.

inlet manifold fixing screws 11 - 13
Crankcase - crankshaft
- Remove the transmission cover, the driving and the driven pulleys, as described in the «Automatic
transmission» chapter.
- Remove the flywheel cover as described in the «Flywheel cover» chapter.
- Remove the flywheel with the starting system following the instruction given in "Flywheel and Starting
system".
- Remove the thermal parts (cylinders, heads, pistons) as described in the «Thermal group and Timing
system» chapter.
- Before opening the crankcase, check the crankshaft axial clearance.
ENG - 205
Engine SRV 850
Specific tooling
020262Y Crankcase splitting plate
020335Y Magnetic mounting for dial gauge
Characteristic
Standard clearance:
0.10 - 0.50 mm
Admissible increase limit after use:
0.60 mm
- Upper clearances are an indication of wear on the surfaces of the crankshaft casing support.
- To carry out an accurate measurement, measure the clearance in both directions between crankcase
and crankshaft.
Splitting the crankcase halves
- Working from the transmission side, undo the six

screws «A» and collect the washers.
- Turn the support so as to operate on the flywheel

side.
- Undo the three nuts fixing it to the support, collect
the washers and remove the three centring bush-
ings.
- Undo the seven screws «B» and collect the cop-
per washers.
- Undo the twelve screws «C» and collect the
washers.
ENG - 206
SRV 850 Engine
- Fit the specific tool on the flywheel-side crank-

shaft, being particularly careful that the tool match-
es the shaft perfectly.
CAUTION
FAILURE TO OBSERVE THIS RULE CAN DAMAGE THE
MAIN BUSHINGS.
Specific tooling
- Lubricate the external surface of the tip with petroleum jelly grease.
- Detach the crankcase halves while keeping the

crankshaft inserted on the transmission-side
crankcase half.
- Remove the coupling gasket.
ENG - 207
Engine SRV 850
ENG - 208
SRV 850 Engine
- Remove the tip.
Specific tooling
- Fit the specific tool on the transmission-side

crankshaft, being particularly careful that the tool
matches the shaft perfectly.
CAUTION
DUE TO THE TIP WEIGHT, BE CAREFUL THAT THE TOOL
FIT ADEQUATELY AND DOES NOT FALL; ALWAYS HOLD
IT WITH BOTH HANDS.
CAUTION
FAILURE TO OBSERVE THIS RULE CAN DAMAGE THE MAIN BUSHINGS.
Specific tooling
020665Y Transmission side crankshaft fitting tip
ENG - 209
Engine SRV 850
- Hold the tip with one hand and the crankshaft with
the other, pull the crankshaft upwards.
- Remove the crankshaft once the tip has been re-

moved from the bushings.
- Once the crankshaft has been removed it is possible to remove the transmission-side timing chain.
Inspecting the crankshaft components

NOTE
TER.
See also
Inspecting the crankshaft alignment

NOTE
TER.
See also
ENG - 210
SRV 850 Engine
Inspecting the crankcase halves
- Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts.
- Clean the jets and contacts carefully.
NOTE
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT
IMPROVES THE PISTON TOP COOLING. CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO
DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAK CAN CONSIDERABLY DE-
CREASE THE MAIN BUSHING AND CONNECTING ROD LUBRICATION PRESSURE.
NOTE
AS ALREADY DESCRIBED IN THE LUBRICATION CHAPTER, IT IS ESPECIALLY IMPORTANT
THAT THE BY-PASS HOUSING SHOWS NO WEAR THAT MAY IMPAIR THE PROPER SEALING
OF THE LUBRICATION PRESSURE ADJUSTMENT PISTON. THE HEAD LUBRICATION CHAN-
NEL IS EQUIPPED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICA-
TION. THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP.
Jet clogging impairs the head lubrication and the timing mechanisms.
A jet failure causes a decrease in the main bearing and connecting rod lubrication pressure.
- Check that the surfaces exhibit no dents or deformations, with special attention to the crankcase
coupling and the crankcase-cylinder surfaces.
- Defects in the crankcase coupling surface gasket can cause a drop in the oil pressure, thus affecting
the lubricating pressure.
- Check the main bearing seats that limit axial clearance in the crankshaft exhibit no wear. For the
dimensional check, refer to the instructions about checking the axial clearance and the dimensions on
the crankshaft
Inspecting the crankshaft plain bearings
- To obtain a good bushing lubrication it is neces-

sary to have both an optimal lubricating pressure
(4 bar) and a good oil flow rate; the bushings must
be correctly positioned so as not to obstruct the oil
supply channels.
- The main bushings are comprised of two half-
bearings, one with holes and channels for lubrica-
tion whereas the other is solid.
- The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is
arranged opposite the cylinder.
- To prevent obstructions in the oil feeding channels, the matching surface of the two half-bearings must
be perfectly perpendicular to the cylinder axis, as shown in the figure.
- The oil feeding channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
NOTE
ENG - 211
Engine SRV 850
TO KEEP THE BUSHINGS ON THE CRANKCASE IN SUCH POSITION, DRIVING IS FORCED ON

CAST-IRON RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES.
NOTE
TER.
See also
Coupling chart
NOTE
TER.
See also
Refitting the crankcase halves
- Fit the driven pulley shaft and the pinion unit axis.
- Fit the specific tool on the transmission-side

crankshaft, being particularly careful that the tool
matches the shaft perfectly.
CAUTION
MAIN BUSHINGS.
CAUTION
DUE TO THE TIP WEIGHT, BE CAREFUL THAT THE TOOL
FIT ADEQUATELY AND DOES NOT FALL; ALWAYS HOLD
IT WITH BOTH HANDS.
Specific tooling
020665Y Transmission side crankshaft fitting
tip
ENG - 212
SRV 850 Engine
NOTE
LUBRICATE THE BUSHINGS WITH ENGINE OIL BEFORE FITTING THE CRANKSHAFT.
CAUTION
FIT THE TRANSMISSION-SIDE TIMING CHAIN.
FIT THE DRIVE CHAIN BEFORE THE CRANKSHAFT.
- Fit the crankshaft with the driving pulley shaft in-
side the transmission-side crankcase half.
CAUTION
PLACE THE CONNECTING RODS PROPERLY.
- Simultaneously hold the crankshaft with one

hand and the tip with the other until the crankshaft
stops on the crankcase half.
- Remove the tip.
Specific tooling
020665Y Transmission side crankshaft fitting
tip
- Place the coupling gasket.
ENG - 213
Engine SRV 850
- Fit the specific tool on the flywheel-side crank-

shaft, being particularly careful that the tool match-
es the shaft perfectly.
CAUTION
MAIN BUSHINGS.
Specific tooling
NOTE
LUBRICATE THE BUSHINGS WITH ENGINE OIL BEFORE FITTING THE CRANKSHAFT.
- Be careful and fit the flywheel-side crankcase half
until there is a complete coupling.
ENG - 214
SRV 850 Engine
- Remove the tip.
Specific tooling
ENG - 215
Engine SRV 850
- Tighten the seven screws «B» with the copper

washers as far as they will go.
- Tighten the twelve screws «C» with the washers
as far as they will go.
- Tighten to the prescribed torques.

Engine crankcase coupling screws (M8) 25 ÷ 28
- Fit the centring bushings, the washers and screw

the fixing nuts to the support.
- Turn the support so as to operate on the trans-
mission side.
- Screw the six screws «A» with the washers and
tighten to the prescribed torque.

Engine crankcase coupling screws (M6) 11 ÷ 13
- Fit a new oil seal in the transmission-side crank-
case half on the driving pulley shaft.
- Fit the oil seal manually being careful that the in-
ternal lips are correctly placed on the crankshaft.
- With a pipe of the indicated size (inside Ø: 36.5

mm - outside Ø: 49.5 mm) set the oil seal at the
indicated distance; with a gauge check the driving
depth following the indications described in the fig-
ure.
Lubrication
NOTE
REFER TO THE SPECIFICATIONS CHAPTER FOR THE LUBRICATION SYSTEM SPECIFICA-
TIONS, .
See also
ENG - 216
SRV 850 Engine
Engine
Conceptual diagrams
LUBRICATION CIRCUIT
1 FRONT HEAD CAMSHAFTS
2 REAR HEAD CAMSHAFTS
3 CONNECTING ROD BUSHINGS
4 FRONT PISTON LUBRICATION JET
5 REAR PISTON LUBRICATION JET
6 STARTING RING GEAR BUSHING LUBRICATION
7 CRANKSHAFT BUSHINGS
8 WATER PUMP CONTROL DRIVING GEAR SHAFT LUBRI-
CATION
9 WATER PUMP SHAFT LUBRICATION
10 MINIMUM OIL PRESSURE SENSOR
11 NON-RETURN VALVE
12 OIL CARTRIDGE FILTER
13 POMPA MANDATA OLIO
14 BY-PASS VALVE
15 POZZETTO OLIO
16 SCAVENGE OIL PUMP:
17 SUCTION ROSE
18 OIL DRAINAGE PLUG
19 OIL RESERVOIR
20 OIL RESERVOIR FILTER
21 OIL PASSAGE FROM HUB TO RESERVOIR
The RED arrows indicate the oil pressure circuit.
The BLUE arrows indicate the oil scavenge circuit.
General characteristics
The lubrication system is divided into two sections:
ENG - 217
Engine SRV 850
- high pressure
- low pressure
The high pressure section includes all components located on the engine crankcase whereas the low
pressure section only refers to the thermal group.
The trochoidal pump is fitted into the sump and controlled by the chain.
To guarantee the integrity of the pump, a pre-filter is fitted.
Pump delivery is controlled by means of a piston-type by-pass calibrated to 4.5 bar. This valve is located
upline the cartridge filter.
The by-pass located before the cartridge filter improves the operating conditions for the filter, particularly
with cold oil.
The filter is equipped with an anti-drain back valve and a pressure relief valve; the latter intervenes
when the filtering mass causes a pressure drop above 1 ± 0.2 bar.
These conditions naturally occur only with cold oil and at high engine revs or if the filter is clogged.
The filtered oil is used to lubricate the water pump shaft and the driving gear shaft, to lubricate the main
bearings, the connecting rod head and the piston cooling nozzle, on the transmission-side bearing.
The main bearing on the transmission side is fitted with an oil seal and the respective drain line.
The supply line for the timing system comes from the flywheel-side bearing; delivery to the head is
controlled by the specific jet screwed on the engine crankcase; the supply line for the timing system to
the rear cylinder comes from the transmission-side bearing.
The components of the timing system function with low-pressure oil lubrication.
The camshaft bearings are installed directly on the aluminium of the head; the camshaft axial clearance
is partially compensated by the oil supplied to the smaller diameter bearing.
The camshaft supplies the lubricant to the rocking levers via the holes provided; these are installed in
a position to ensure that the lubrication is maintained even after the scooter has stopped. This is ach-
ieved when the camshaft reaches its most usual and likely position when the engine is shut off.
The oil used to lubricate the head returns to the sump via the chain casing channel and therefore it also
provides lubrication for the chain.
A one-way valve and a decantation chamber are used so that gases from the crankcase do not carry
any oil. The one-way valve is a metal reed valve; the decantation chamber has a drainage hole. A failure
in these components implies oil getting into the line supplying air to the engine.
Excessive oil vapours may result in clogged ducts on the throttle body.
In order to signal low oil pressure in the system, a pressure switch is used, located immediately after
the oil filter outlet.
The lubrication circuit does not include the piston or the pin, also in this case the cooling nozzle is
particularly important.
Diagnosis guide
1 - Minimum oil pressure warning light on with hot engine.
ENG - 218
SRV 850 Engine
AHEAD - go to 2
2 - Remove the minimum pressure switch electric connector.
Check that the warning light turns off.
YES - go to 3 NO go to 11
3 Check the actual oil pressure.
AHEAD - go to 4
4 - Remove the switch and fit the special tool with the relevant gasket.
Specific tooling
- Remove the dipstick with the oil filling cap and insert a cap fitted with the temperature probe supplied
with the special tool. Insert the probe to feel contact with the crankcase bottom and pull back a few
millimetres.
Specific tooling
020331Y Digital multimeter
AHEAD - go to 5
5 - Measure the pressure with cold and idling engine.
STANDARD VALUES
20°C Temperature
1200 rpm
approx. 4.5 bar
Specific tooling
6 - Let the engine warm up and repeat the check with hot oil.
STANDARD VALUES
80°C Temperature
1200 rpm
ENG - 219
Engine SRV 850
approx. 1.5 bar
7 - Replace the oil minimum pressure switch.
8 - If pressure lower than 1.3 ÷ 1.5 bar is measured.
AHEAD go to 9
9 - Replace the oil filter and repeat the pressure check with oil at 80°C.
10 - The failure was fixed.
It is recommended to respect the suggested number of kilometres covered.
11 - Check and restore the electrical system.
12 - If pressure lower than 4 bar is measured.
AHEAD go to 9
13 - Open the engine crankcase and check the by-pass efficiency.
14 - Check whether there is an irregular clearance on the crankshaft:
- axial clearance (see the "Crankcase and crankshaft" chapter)
- radial clearance, especially in the direction of the cylinder axis
- clearance according to the direction of rotation with the connecting rod in quadrature
15 - Replace damaged components.
16- Proceed with engine service operations.
17 - Open the engine crankcase and remove the oil pump as described in the "Crankcase and crank-
shaft" chapter.
- Check the oil pump as described in the following pages.
- Check that the cooling nozzle and the timing system feeding jet are properly installed.
- Visually inspect the crankshaft couplings and their sizes as per the «Specifications Chapter».
NOTE
POTENTIAL IRREGULARITIES IN COUPLINGS AND THE TIMING SYSTEM COMPONENTS CAN-
NOT BE DETECTED WHEN INSPECTING THE LUBRICATION PRESSURE. THEY MAY BECOME
EVIDENT BY AN INCREASE IN NOISE.
NOTE
IN CASE OF IRREGULAR PRESSURE ON THE CRANKCASE, CARRY OUT A VISUAL AND DI-
MENSIONAL INSPECTION OF THE TIMING SYSTEM COMPONENTS (SEE "THERMAL GROUP
AND TIMING SYSTEM" CHAPTER).
Oil pressure check

1 - In case of oil or oil filter leaks, check the lubrication pressure.
AHEAD go to 2
2 - Install the special tool.
Specific tooling
ENG - 220
SRV 850 Engine

AHEAD go to 3
3 - Check the system pressure with cold engine and medium - high speed.
Standard pressure < 6 bar
4 - Replace the damaged components.
5 - Check the working order of the adjustment by-pass (see "flywheel cover" chapter) and restore proper
sliding.
NOTE
STANDARD PRESSURES ARE OBTAINED USING OIL WITH THE PRESCRIBED VISCOSITY. A
HIGHER VISCOSITY CAUSES AN INCREASE OF THE SYSTEM PRESSURE.
1 - If oil consumption is above 250 g/1000 km on a run-in engine, proceed as follows.
AHEAD go to 2
2 - Check the presence of oil in the scavenge duct on the filter box.
3 - Check the one-way reed valve and the decantation chamber drainage hole.
4 - Check the thermal group seals (piston rings, valve guides and oil guards), see "Thermal group and
Timing system" chapter.
5 - Restore the valve or the drainage hole efficiency.
Oil pump
Removal
KEY:
A. Pressure pump
B. Scavenge oil pump
C. By-pass
ENG - 221
Engine SRV 850
- The lubrication system includes the pressure and scavenge oil pumps.
- To act on the pressure pump, remove the casing of the oil anti-backflow plate under the flywheel.
- To act on the scavenge oil pump, open the crankcase, and operate inside the flywheel-side crankcase
half.
- Operating from the outside undo the chain ten-

sioner pad fixing screws.
- Remove the chain tensioner pad.
- With the specific tool, lock and undo the fixing

screw and collect the washer.
- Remove the oil pump control crown.
NOTE
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
Specific tooling
ENG - 222
SRV 850 Engine
- Undo the two fixing screws and remove the oil

pump cover casing.
- Remove the pressure oil pump together with the

gasket.
- Operating from inside:

- Lock the scavenge oil pump shaft, undo the fixing
screw and collect the washer.
- Remove the water pump control gear, undo the

two screws indicated and collect the washers.
ENG - 223
Engine SRV 850
- Remove the casing of the oil anti-backflow plate.
- Remove the oil pump and the relevant gasket.
- Undo the four screws indicated.
- Remove the by-pass scavenge duct together with

its gasket.
Inspection
- The procedure is described once but applies to both pumps.
ENG - 224
SRV 850 Engine
- Undo the two screws and remove the oil pump

cover.
ENG - 225
Engine SRV 850
- Slide off the shaft together with the driving pins

of the rotors.
- Remove the two rotors and wash them thorough-
ly.
NOTE
VISUALLY INSPECT THAT ALL THE COMPONENTS ARE
IN GOOD CONDITIONS. MAKE SURE THERE ARE NO
SIGNS OF WEAR OR SCRATCHES. REPLACE THE COM-
PONENTS IF THERE ARE EVIDENT SIGNS OF WEAR.
- Once you check that the components are in good

conditions, fit the pump and check size.
- Fit the two rotors and align them following the
reference marks.
ENG - 226
SRV 850 Engine
- Fit the assembled rotors inside the pump body,

with the reference marks facing the inside.
CAUTION
ONCE THE ROTORS ARE FITTED IN THE PUMP BODY,
THE REFERENCE MARKS ON THEM MUST NOT BE VISI-
BLE.
- Measure the distance between rotors with a thick-

ness gauge at the position indicated.
Characteristic
Standard clearance:
0.04 - 0.1 mm
- Check the distance between external rotor and

pump body; see figure.
Characteristic
Standard clearance:
0.05 - 0.12 mm
ENG - 227
Engine SRV 850
- Check the levelness of the two rotor surfaces and

the pump body with a trued bar as a contrasting
plane as indicated in the figure.
CAUTION
FAILURE TO OBSERVE THESE RULES CAN SERIOUSLY
DAMAGE THE ENGINE. IF THE VALUES ARE NOT WITHIN
THE PRESCRIBED LIMITS, REPLACE THE COMPONENTS.
Characteristic
Limit values admitted:
0.1 mm
- Check all the conditions indicated above, after-

wards fit the plug and tighten the fixing screws to
the prescribed torque.

Cover screws 0.7 to 0.9 Nm
Refitting
- Operating from inside the flywheel-side crank-

case half:
- Fit the by-pass scavenge duct together with the
gasket and tighten the four fixing screws to the
prescribed torque.

By-pass scavenge duct fixing screws 11 ÷ 13
- Make sure the gasket is in the correct position.

NOTE
THE TOOTH OF THE GASKET MUST BE IN ITS SEAT.
ENG - 228
SRV 850 Engine
- Fit the scavenge oil pump and the casing of the

oil anti-backflow plate.
- Tighten the two screws indicated to the prescri-
bed torque.

Screws fixing oil pump to the crankcase 5 to 6
- Fit the water pump control gear on the oil pump

shaft.
- Tighten the locking screw with the washer to the
prescribed torque.

Water pump gear fixing screw 5 - 6
- Once the scavenge oil pump fitting is finished,

operate from outside the flywheel-side crankcase
half.
- Make sure the gasket is in the correct position.
NOTE
THE TOOTH OF THE GASKET MUST BE IN ITS SEAT.
- Fit the timing chain and the timing chain tensioner

pad.
- Tighten the fixing screw to the prescribed torque.

Tensioner sliding block fixing screw 10 - 14
- Fit the pressure oil pump.
ENG - 229
Engine SRV 850
- Fit the oil pump cover casing and tighten the two
screws to the prescribed torque.

Screws fixing oil pump to the crankcase 5 to 6
- Fit the oil pump control crown and the driving

chain.
- Using the specific tool tighten the fixing screw
with the belleville washer to the prescribed torque.
CAUTION
PLACE THE BELLEVILLE WASHER WITH THE CONVEX
PART FACING THE OIL PUMP CONTROL CROWN.
Specific tooling

Oil pump crown screw 10 ÷ 14
- Fit the tensioner pad and tighten the two screws
to the prescribed torque.

Oil pump chain tensioner pad 2 ÷ 3
ENG - 230
SRV 850 Engine
Water pump
Removal
NOTE
REPLACEMENT OF THE OVERALL SEALING CAN BE CARRIED OUT WITH ENGINE INSTALLED
ON THE VEHICLE, SEE «HIGHLIGHTED PROCEDURES».
Specific tooling
020661Y Water pump overall seal replacement kit
- Remove the six screws, the water pump cover

and the gasket with a screwdriver.
ENG - 231
Engine SRV 850
- Unscrew the water pump rotor with a 10-mm

wrench.
CAUTION
THE ROTOR THREAD IS ANTICLOCKWISE. THE PUMP
SHAFT HELPS REMOVING THE ROTOR AS THE GEARED
CONTROL CANNOT ROTATE IN REVERSE SENSE.
- Place two flat blade screwdrivers as shown in the figure so as to lever on the marked crankcase edge
and disassemble the overall seal, pressure-fitted on the rotor shaft.
CAUTION
USE TEFLON AS SHOWN IN THE FIGURE SO AS NOT TO DAMAGE THE WATER PUMP COVER
SEALING SURFACE.
Small scratches on the seat edge do not pose
functional problems.
Change the position of the screwdrivers if neces-

sary.
During seal disassembly, the ceramic may split.
ENG - 232
SRV 850 Engine
- Clean all the parts thoroughly before removing

them.
- Place the extractor together with the pin on the

fixed part of the ceramic seal.
- Without modifying the extractor position, make

three holes on the fixed part of the seal using the
pin supplied and a hammer.
NOTE
MAKE THE HOLES WITH A STRONG HIT.
MULTIPLE LIGHT BLOWS COULD DEFORM THE PART
WITHOUT PASSING THROUGH.
- Fix the extractor to the fixed part of the sealing

using the screws supplied with the tool.
CAUTION
FIX IT PROPERLY WITHOUT "TEARING" THE PLATE
ENG - 233
Engine SRV 850
- Complete the tool by fitting the bracket, the screw

and the nut.
- Hold the screw in position and operate the nut

until the fixed part of the sealing is completely re-
moved.
- Remove the extractor with the fixed part of the

overall seal.
- To work on the water pump shaft and the relevant

oil seal, open the engine crankcase and work from
inside the transmission-side crankcase half.
- Slide off the idle gear.
ENG - 234
SRV 850 Engine
- Slide off the water pump control gear together

with the shaft.
- Undo the two screws indicated and remove the

gear protection plate.
- Insert a punch on the water pump shaft seat and

remove the oil seal.
See also
Splitting the
crankcase halves
Assembly
- Fit the oil seal from the outside being careful not
to grease the contact surfaces.
- With the specific tool fit the seal until it stops.
Specific tooling
020663Y Water pump shaft oil seal punch
ENG - 235
Engine SRV 850
- Fit and lock the plate in its position by tightening

the two screws indicated to the prescribed torque.

Screws tightening water pump gear protection
plate 3 ÷ 4
- Fit the water pump shaft together with the control

gear.
- Fit the idle gear.
Overall seal fitting

CAUTION
CLEAN ALL THE COMPONENTS THOROUGHLY.
CAUTION
LUBRICATE THE ROTOR SHAFT WITH ENGINE OIL.
- Place the overall seal on the shaft.
ENG - 236
SRV 850 Engine
- Fit the tie rod by screwing it to the rotor shaft.

CAUTION
THE SHAFT THREAD IS ANTICLOCKWISE. SCREW IT
MANUALLY UNTIL IT STOPS.
- Place the calibrated punch (at preloading value).
- Fit the nut to the tie rod.
Keep the tie rod in position and screw the nut up

to the end of stroke.
The tool will drive the fixed part seat on the crank-
case and the movable part seat on the shaft, thus
obtaining the correct ceramic seal preloading.
ENG - 237
Engine SRV 850
- Screw the rotor. (anticlockwise thread).

Water pump impeller 4 ÷ 5
- Fit the pump cover with a new gasket, lubricate

the gasket previously with petroleum jelly grease.
- Tighten the six cover screws to the prescribed
torque.
NOTE
TO AVOID DEFORMATION, DO NOT LUBRICATE THE O-
RING WITH PETROLEUM GREASE.

Water pump rotor cover 3 to 4
ENG - 238
INDEX OF TOPICS
INJECTION INJEC
Injection SRV 850
Sistema di iniezione EMS

Il sistema di iniezione è del tipo sequenziale fasata con iniezione e accensione integrate.
L'iniezione è del tipo indiretta nel collettore mediante elettroiniettori.
L'iniezione e l'accensione sono fasate sul ciclo 4T mediante una ruota fonica calettata sul comando
dell'albero a camme del cilindro posteriore ed un sensore a variazione di riluttanza.
La carburazione e l'accensione sono gestite in funzione dei giri del motore e dell'apertura della valvola
gas. Ulteriori correzioni vengono attuate in base ai seguenti parametri:
- Temperatura del liquido di raffreddamento
- Temperatura dell'aria aspirata
- Pressione ambiente
Il sistema attua una correzione della alimentazione del minimo con motore freddo mediante un motorino
passo-passo (stepper motor) inserito su un circuito by-pass della valvola gas. La centralina gestisce il
motorino passo-passo ed il tempo di apertura degli iniettori garantendo così la stabilità del minimo e la
carburazione corretta.
In tutte le condizioni di funzionamento, grazie anche ai valori rilevati dalla sonda lambda, la carburazione
viene gestita modificando il tempo di apertura dell'iniettore.
La pressione di alimentazione della benzina viene mantenuta costante in funzione della pressione am-
biente.
Il circuito di alimentazione di tipo multipoint è costituito da:
- Pompa benzina
- Filtro benzina
- Iniettori
- Regolatore di pressione
La pompa, il filtro ed il regolatore sono inseriti nel serbatoio carburante mediante un supporto unico.
Gli iniettori sono collegati mediante tubi provvisti di attacchi rapidi. Ciò permette di ottenere una circo-
lazione continua evitando così il rischio di ebollizione del carburante. Il regolatore di pressione è posto
alla fine del circuito.
La pompa della benzina viene comandata dalla centralina EMS; ciò garantisce la sicurezza del veicolo.
Il circuito di accensione è costituito da:
- Bobine A.T con doppia candela di accensione.
- Cavetti A.T.
- Cappucci schermati
- Centralina EMS
- Candele
La centralina EMS gestisce l'accensione con l'anticipo ottimale garantendo nel contempo la fasatura
sul ciclo 4T (accensione solamente in fase di compressione).
L'impianto di iniezione-accensione EMS gestisce la funzionalità del motore mediante un programma
preimpostato.
INJEC - 240
SRV 850 Injection
Nel caso in cui venissero a mancare alcuni segnali in entrata, viene comunque garantito un funziona-
mento accettabile del motore, per permettere all'utente di raggiungere l'officina di riparazione.
Naturalmente ciò non può accadere quando viene a mancare il segnale di giri-fase oppure quando
l'anomalia interessa i circuiti di comando:
- Pompa benzina
- Bobine A.T.
- Iniettori
The control unit is provided with a self-diagnosis

system connected to an indicator light in the in-
strument panel.
Failures are detected and restored by the diagnostic tester.

In any case, when the fault is no longer present, the data storage is automatically cleared after 16 cycles
of use (cold start, running at regular engine temperature, stop).
The diagnostic tester is also required to adjust the idle mixture.
Specific tooling
The EMS injection-ignition system has a control

function over the rpm indicator and the radiator
cooling electric fan.
The EMS is connected to the anti-theft immobilizer
system decoder.
In turn, the decoder is connected to a flashing di-
agnostic LED that also serves as deterrent.
INJEC - 241
Injection SRV 850
The EMS control unit power supply is further con-

trolled by the emergency switch, side stand switch
and the stop buttons; that is to provide further
safety for the scooter.
Precautions
1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not
disconnect the battery before checking for faults.
2. The fuel supply system is pressurised at 300 kPa (3 BAR). Before disconnecting the quick coupler
of a pipe in the fuel supply system, check that there are no naked flames. Do not smoke. Act with caution
to prevent spraying in the eyes.
3. When fixing electric components, operate with the battery connected only when actually required.
4. When functional checks are performed, check that the battery voltage is over 12V.
5. Before trying to start up, check to make sure there is at least two litres of fuel in the tank. Failure to
respect this norm will damage the fuel pump.
6. If the scooter is expected to remain unused for a long time, refill the tank up to a little over half the
level. This will ensure the pump will be covered by fuel.
7. When washing the vehicle, be careful with the electric components and wiring.
8. When an ignition fault is detected, start the checks from the battery and the injection system con-
nections.
9. Before disconnecting the EMS control unit connector, perform the following operations in the following
order:
- Set the switch to «OFF»
- Disconnect the battery
Failure to respect this norm may damage the control unit.
10. Do not invert the polarity when fitting the battery.
11. In order to prevent damages, disconnect and reconnect the EMS connectors only if actually required.
Before reconnecting, check that the connectors are dry.
12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not
take measurements not specifically foreseen by the manual.
13. At the end of every check performed with the diagnostic tester, protect the system connector with
its cap. Failure to respect this norm may damage the EMS control unit.
14. Before reconnecting the quick couplers of the power supply system, check that the terminals are
perfectly clean.
INJEC - 242
SRV 850 Injection
Troubleshooting tips
1 An EMS failure is more likely to be due to the connections than to the components.
Before searching the EMS system for failures, perform the following checks:
A: Electrical power supply
a. Battery voltage b. Blown fuse c. Remote control switches d. Connectors
B: Chassis earthing
C: Fuel supply
a. Faulty fuel pump b. Dirty fuel filter
D: Ignition system
a. Faulty spark plug
b. Broken coil
c. Broken shielded cap
E: Intake circuit
a. Dirty air filter
b. Dirty by-pass circuit
c. Faulty Stepper motor
F: Other
a. Incorrect distribution timing b. Incorrect idle mixture c. Incorrect reset of the throttle valve position
sensor
2 Failures in the EMS system may be caused by loosened connectors. Make sure that all connections
are properly implemented.
Check the connectors taking into consideration the following point:
A - Check that the terminals are not bent.
B - Check that the connectors have been properly connected.
C - Check whether the malfunction can be fixed by shaking the connector slightly.
3 Check the entire system before replacing the EMS control unit. If the fault is fixed by replacing the
EMS control unit, install the original control unit again and check whether the fault occurs again.
4 Use a multimeter with an internal resistance of over 10kW/V when troubleshooting. Instruments that
are not suitable might damage the EMS control unit. Instruments must be used with definitions over
0.1V and 0.5W; precision must be greater than 2%.
INJEC - 243
Injection SRV 850
Terminals setup
VEHICLE CONTROL UNIT CONNECTOR

1. Start-up remote control switch relay (Orange-
White)
6. Injection loads relay (Black-Purple)
7. Immobilizer Decoder (Orange)
8. Low beam relay (Yellow-Grey)
9. Rpm indicator (Brown)
13. Injection warning light (Brown-White)
14. Electric fan relay (Blue-Yellow)
16. Diagnostic socket (Purple-White)
low)
21. Oxygen sensor signal No. 2 (Purple)
22. Oxygen sensor ground No. 1 (White-Green)
23. Stop lights (Grey-Green)
27. Engine stop switch (Green)
28. Starter button (Grey-White)
31. Oxygen sensor ground No. 2 (Black-Green)
32.Oxygen sensor signal No. 1 (Grey-Red)
35. Overturn sensor (Yellow)
38. Stand switch (White-Blue)
ENGINE CONTROL UNIT CONNECTOR

3.Throttle potentiometer (Orange-Light Blue)
5. Engine temperature (Grey-Green)
9. Idle adjusting motor (Light Blue-Yellow)
10. HV coil Cylinder 2 (Light Blue)
14. Air temperature sensor (White-Grey)
17. Idle adjusting motor (Light Blue-Red)
18. Idle adjusting motor (Light Blue-Black)
19. Idle adjusting motor (Orange-Red)
20. Negative sensors (Light Blue-Green)
22. Positive sensors (Red-Blue)
INJEC - 244
SRV 850 Injection
25. Engine speed sensor (White)

28. Injector Cylinder 1 (Red-Yellow)
29. Throttle potentiometer (Grey-Black)
32. Throttle potentiometer (Brown-Yellow)
34. Engine speed sensor screen (Black)
35. Engine speed sensor (Red)
37. Injector Cylinder 2 (Blue)
38. HV coil cylinder 1 (Pink-Black)
EMS circuit diagram
KEY:
1. Battery 12V 14Ah
3. Chassis ground
6. Fuses No. 02 - 15A
7. Fuses No. 04 - 15A
8. Fuses No. 05 - 15A
9. Fuses No. 06 - 7.5A
10. Fuses No. 07 - 5A
13. Key switch
INJEC - 245
Injection SRV 850
17. Fuses No. 11 - 7.5A

18. Fuses No. 12 - 7.5A
33. Fuses No. 10 - 7.5A
36. C.D.I.
55. Diagnostics socket
57. Oxygen sensor No.1
58. Oxygen sensor No.2
65. Speed sensor
69. Injection load relay
71. Fuel pump
Troubleshooting procedure
Engine does not start
ENGINE DOES NOT START IF ONLY PULLED

Immobiliser enabling signal System not encoded
System not efficient, repair according to the indications of the
self-diagnosis
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Fuel system Fuel in the tank
Fuel pump activation
Fuel pressure (low)
Injector capacity (low)
Power to the spark plug Shielded spark plug cap HV coil (secondary insulation)
Parameter reliability Coolant temperature
Distribution timing - injection ignition
Intake air temperature
End of compression pressure End of compression pressure
Starting difficulties
ENGINE STARTER PROBLEMS

HV coil
Injector
Air temperature
Coolant temperature
Starter speed Starter motor and solenoid
Battery
Ground connections
End of compression pressure End of compression pressure
Power to the spark plug Spark plug
Shielded cap
HV coil
INJEC - 246
SRV 850 Injection

Speed-timing sensor
Ignition advance
Fuel system Fuel pressure (low)
Injector capacity (low)
Injector sealing (poor)
Correctness of the parameters Coolant temperature
Stepper throttle valve position intake air temperature (steps
and actual opening)
Cleaning of the auxiliary air pipe and throttle valve; air filter ef-
ficiency
Engine stops at idle
ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOW

HV coil
Injector
Air temperature
Coolant temperature
Ignition efficiency Spark plug
Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system cleaning Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel system (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Engine does not rev down
ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGH

HV coil
Injector
Air temperature
Coolant temperature
Ignition efficiency Ignition timing
Stepper
Intake sleeve
Filter box
Pressure regulator
Fuel filter
Injector capacity
INJEC - 247
Injection SRV 850
Exhaust backfires in deceleration
EXHAUST BACKFIRES WHEN DECELERATING

HV coil
Injector
Air temperature
Coolant temperature
Lambda probe
Stepper
Intake sleeve
Filter box
Pressure regulator
Fuel filter
Injector capacity
Exhaust system sealing (infiltrations) Manifold - head
Manifold - silencer
silencer welding
Engine revs irregularly
ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN

Intake system cleaning Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake system sealing Intake sleeve
Filter box
Ignition system Spark plug wear check
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
TPS reset successful TPS reset successful
HV coil
Injector
Air temperature
Coolant temperature
Lambda probe
Poor performance at full throttle
POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM-

ANCE ON PICKUP
HV coil
Injector
INJEC - 248
SRV 850 Injection

Air temperature
Coolant temperature
Lambda probe
Spark plug power supply Spark plug
Shielded cap
HV cable
HV coil
Intake system Air filter
Filter box (sealing)
Intake sleeve (sealing)
Ignition advance
Fuel system Fuel level in the tank
Fuel pressure
Fuel filter
Injector capacity
Engine knocking
PRESENCE OF KNOCKING (COMBUSTION SHOCKS)

HV coil
Injector
Air temperature
Coolant temperature
Lambda probe
Ignition efficiency Spark plug
Ignition advance
Intake system sealing Intake sleeve
Filter box
TPS reset successful TPS reset successful
Fuel system Fuel pressure
Fuel filter
Injector capacity
Fuel quality
Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness
Fuel supply system
Fuel is fed to the injectors by a pump, a filter and a pressure regulator.
The fuel supply circuit includes the electric pump, the filter, the pressure regulator, injectors and the
fuel delivery and reverse pipes.
The electric pump is located in the tank from which the fuel is pumped and sent to the injectors through
the filter.
Pressure is controlled by the pressure regulator located in the pump assembly in the tank on the fuel
reverse circuit.
The pump unit is connected to the injectors by:

3 semi-flexible pipes
6 fast-release couplings
INJEC - 249
Injection SRV 850
NOTE
BEFORE WORKING ON THE FUEL SUPPLY SYSTEM, CAREFULLY CLEAN THE PARTS TO
PREVENT DAMAGING THE FAST-RELEASE COUPLING SEAL OR TO PREVENT DIRT GETTING
INTO THE DUCTS.
CAUTION
THE SYSTEM IS UNDER PRESSURE.
DO NOT SMOKE DURING ANY OPERATION.
PREVENT ANY FUEL SPRAYING.
WARNING
- BEFORE STARTING THE ENGINE, CHECK WHETHER THERE IS FUEL IN THE TANK.
- DO NOT USE THE SCOOTER IN RESERVE FOR A LONG TIME, UP TO THE POSSIBILITY OF
RUNNING OUT OF FUEL.
- IF THE SCOOTER IS EXPECTED TO REMAIN UNUSED FOR A LONG TIME, REFILL THE TANK
AT LEAST TO HALF THE LEVEL.
FAILURE TO OBSERVE THESE RULES CAN DAMAGE THE PUMP.
Pump supply circuit
INJEC - 250
SRV 850 Injection
FUEL PUMP CONNECTOR

FUEL PUMP UNIT

Mechanical type pressure regulator operating at a
pressure of 3 BAR
Pump winding resistance: ~ 1,5 Ohm
Verificare, commutando in «ON», la presenza di tensione batteria, per circa 2 secondi, tra il pin 5 del
connettore pompa e massa con connettore pompa staccato. Altrimenti verificare la continuità del cav-
etto tra pin 5 connettore pompa e zoccolo del teleruttore carichi iniezione.
Verificare l'efficienza della linea di massa della pompa carburante misurando la continuità tra pin 2
connettore pompa e massa.
Circuit leak test
Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.
INJEC - 251
Injection SRV 850
Check during regular operation by placing the ap-

propriate tool between the pump and the injector.
With battery voltage > 12 V check that the fuel
pressure is 3 BAR and that the input current is ~2.8
A
With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe
equipped with the pressure gauge of the appropriate tool. Get a graded burette with a flow rate of
approximately 1 L. Rotate the pump using the active diagnoses of the palm top computer. Using a pair
of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 2.9 ÷ 3 BAR.
Pay attention not to choke the pipe too much, as the pressure remains equal to 3 BAR while the flow
diminishes. Check that within 15 seconds the pump has a flow rate of approx. 300 cm³.
Specific tooling
020480Y Petrol pressure check kit
Inspecting the injector circuit
INJEC - 252
SRV 850 Injection
REAR CYLINDER INJECTOR CONNECTOR

1. Control unit (Red-Yellow)
FRONT CYLINDER INJECTOR CONNECTOR

1. Control unit (Blue)
FUEL INJECTOR
Type: 4 holes
Conicity of the nozzle: 24°
Resistance at terminals: 13.7 ÷ 15.2 Ohm
Scollegare il connettore dell'iniettore.

Commutare in "ON".
Eseguire la diagnosi attiva iniettore tramite palmare.
Verificare la presenza di tensione 12V ai capi del connettore durante le attivazioni.
In caso contrario verificare la linea di massa tra pin 37 connettore centralina motore e il pin 1 del con-
nettore iniettore cilindro anteriore e tra pin 28 connettore centralina e il pin 1 del connettore iniettore
cilindro posteriore.
Verificare la linea +12V tra teleruttore carichi iniezione e pin 2 connettore iniettore.
INJEC - 253
Injection SRV 850
Immobiliser circuit
The EMS system is independent from the immo-

bilizer antitheft device.
Its functions are:
- Start-up enabled by key recognition.
- Deterrent flashing.
The system consists of:

-EMS system control unit
- Decoder
- Aerial
- master key
- service key
- Deterrent and diagnosis LED
Virgin circuit
When control unit (ECU) and decoder are not pro-

grammed, the following conditions occur:
- Key switch set to «OFF»:
Deterrent flashing inactive.
- Key switch set to «ON»:
Ignition and injection disabled and LED on with
solid light.
When the key switch is set to "ON", the LED
switches on as shown in the figure.
The LED is turned on by the decoder.
Specific tooling
INJEC - 254
SRV 850 Injection
To connect the diagnostic tester, open the battery

inspection port and pull out the EMS diagnosis
socket. Remove the protection cap and connect
the tester terminal.
Power the diagnostic tester by connecting the ter-

minals to the battery poles, or the specific connec-
tor to the socket inside the helmet compartment.
Set the switch to "ON" and select the diagnostic tester menu to the immobiliser function.
Scroll the pages to display the control unit data.
NOTE
AN UNPROGRAMMED SYSTEM CANNOT BE DETECTED UPON FIRST FITTING, OR IN CASE
THE DECODER AND THE CONTROL UNIT ARE REPLACED CONCURRENTLY.
The information will be as follows:
Unprogrammed control unit «ON»
Start-up disabled «ON»
Key number Zero › 250
1 Replacing the small cylinder

- Remove the original master key transponder and install it on the master key of the new cylinder.
- Program the system again as described in the injection chapter.
2 Decoder replacement
When the decoder is replaced it is necessary to program the system again.
Programming is indispensable for the engine start-up. (see injection chapter).
3 Control unit replacement

Programming is indispensable when the control unit is replaced to enable the engine start-up.
In this case it is sufficient to switch to "ON" using the master key.
NOTE
THE SERVICE KEY IS NOT USED FOR PROGRAMMING.
- WHEN NOT PROGRAMMED, THE CONTROL UNIT ALLOWS NO FUNCTIONAL DIAGNOSIS ON
THE ENGINE.
4 Replacing or duplicating service keys
INJEC - 255
Injection SRV 850
Keys can be duplicated using the blank keys and the original master key.
WITH MASTER KEY

When the key switch is set to "ON" and program-
ming is performed normally, the LED switches on
"ON", a number of flashes are emitted, equal to the
number of keys used for programming.
WITH SERVICE KEYS

«ON», the LED remains off.
Switching from «ON» to «OFF» with programmed

system causes the intermittent switching on of the
LED, with an antitheft effect.
This occurs with any key used for programming.
If the scooter is not used, the deterrent light stops automatically after 48 hours to prevent discharging
the battery. A new 48-h cycle starts by switching from "OFF" to "ON" and "OFF" again.
Diagnostic codes
The LED indication is divided into 3 steps:

1st step: A flash: "ON" switching recognition
2nd step: Series of flashes: diagnosis code indication
3rd step: Steady light on or off:
on = start-up disabled off = start-up enabled
INJEC - 256
SRV 850 Injection
Code 1
Code 1 indicates a non-programmed system.

If the code is still displayed after having carried out
the programming procedure, repeat the procedure
carefully observing the "ON" times of each key.
If the code is still displayed, proceed as follows:

- Disconnect the battery negative.
- Remove the control unit connector.
- Remove the main decoder connector.
NOTE
TO ACCESS THE COMPONENTS, SEE THE COMPONENTS LAYOUT CHAPTER.
1- With a multimeter, check the continuity between
pin 7 of the vehicle side connector control unit and
pin 6 of the decoder connector.
2 - Repair or replace the wiring.

3 - Check the connections carefully
4 - Restore
5 - Replace the decoder. Connect the battery. Repeat the programming. YES go to 7 NO go to 6
6 - Disconnect the battery, replace the control unit, connect the battery. Repeat the programming.
7 - The system is OK
INJEC - 257
Injection SRV 850
Code 2

does not perceive the transponder signal.
- Start-up disabled
In this case, proceed as follows:
1 - Check whether the code is repeated using the

second key.
2 - Failure detected with the service key Replace
and program again. Failure detected with the mas-
ter key.
Replace the transponder using one from the new
cylinder kit.
Replace decoder and control unit.
Program again.
3 - Check the proper connection of the aerial con-
nector.
4 - Restore the connection and check the presence

of the code
5 - Disconnect the aerial connector and check con-
tinuity (8 ± 2 W).
6 - Replace the aerial.

7 - Check the proper position of the aerial.
8 - Place it in proper position
9 - Replace the decoder and check the presence of the code
INJEC - 258
SRV 850 Injection
Code 3

perceives a transponder not provided for by pro-
gramming.
- Start-up disabled
1- Check whether the code is still displayed using the master key
2 - Program again using all service keys
3 - Check that all components (keys - decoder - control unit) are properly matched.
4 - Restore
5 - Replace decoders and control unit. Program the components again.
Tachometer
INJEC - 259
Injection SRV 850
ENGINE RPM SENSOR CONNECTOR

1. Control unit (White)
2. Control unit (Red)
3. Sensor screen (Black)
REVOLUTION TIMING SENSOR

Resistance between "+ and -" = 890 ± Ohm (pins 35 - 25 , engine-side wiring)
Insulation between "+ and S" and between "- and S" (pins 35 - 34 and 25 - 34, engine-side wiring)
Check the continuity between pin 1 of the revolution timing sensor connector and pin 25 of the engine
connector control unit. Check the continuity between pin 2 of the revolution timing sensor connector
and pin 35 of the engine connector control unit. Check insulation between them and the ground lead of
pin 1 and 2 of the connector and shielding. Check the continuity between pin 3 of the connector and
pin 34 of the engine connector control unit.
HT coil
INJEC - 260
SRV 850 Injection
REAR CYLINDER HV COIL CONNECTOR

2. Control unit (Red-Black)
FRONT CYLINDER HV COIL CONNECTOR

2. Control unit (Light Blue)
INJEC - 261
Injection SRV 850
H.V. COIL
Primary winding resistance: 520 ÷ 620 mOhm
Secondary resistance: 6830 ÷ 7830 Ohm
Check if there is voltage for 2 seconds, switching to "ON" between pin 1 of the coil connectors and
ground lead.
Check the continuity between pin 2 of the cylinder 1 coil connector and pin 38 of the engine connector
control unit.
Check the continuity between pin 2 of the cylinder 2 coil connector and pin 10 of the engine connector
control unit.
Inspecting the spark plug shielded cap
Measure the shielded cap resistance.
Resistance:
5 KΩ
If different values are measured (<1; >20KΩ), replace the shielded cap.
NOTE
A SHIELDLESS CAP OR SPARK PLUG CAN ADVERSELY AFFECT THE INJECTION SYSTEM.
FOR INFORMATION ON THE SPARK PLUG, SEE THE «SPECIFICATIONS» AND «MAINTE-
NANCE» CHAPTERS.
Spark advance
The ignition advance is determined electronically on the basis of parameters known by the control unit.
For this reason it is not possible to interpret the reference values based on the engine rpm.
The ignition advance value is detectable at any time using the diagnostic tester.
It is possible to check whether the ignition advance determined by the injection system matches the
value actually activated on the engine, by means of the stroboscopic light.
Specific tooling
020330Y Stroboscopic light to check timing
INJEC - 262
SRV 850 Injection
- Unscrew the TDC reference inspection cap.

- Connect the stroboscopic light.
- Connect the diagnostic tester.

- Start the engine.
- Select the «parameters» function in this menu.
- Set the stroboscopic light control to the traditional four-stroke engine position (1 spark, 2 revs).
- Check that the real values of rpm and ignition advance match those measured using the diagnostic
tester.
- Refit the inspection cap on the flywheel side.
Specific tooling
If the values do not match, check:

- distribution timing
- revolution timing sensor
- injection control unit
INJEC - 263
Injection SRV 850
WATER TEMPERATURE SENSOR CONNEC-

TOR
1. Control unit (Grey-Green)
2. Instrument panel (Green-Yellow)
4. Instrument panel (Brown-Black)
ENGINE TEMPERATURE SENSOR

0° = 5900 Ohm
+10° = 3800 Ohm
+20° = 2500 Ohm
+30° = 1700 Ohm
+80° = 300 Ohm
With the switch set to "ON", check if there is 5V voltage between pin 1 and 3 of the sensor connector.
Check the continuity between pin 1 of the sensor connector and pin 5 of the engine connector control
unit.
unit.
Check the ground insulation of the lines.
Repeat checks between pin 2 of the connector and pins 3/20 of the instrument panel, also between pin
4 of the connector and pins 4/20 of the instrument panel
INJEC - 264
SRV 850 Injection
AIR TEMPERATURE SENSOR CONNECTOR

1. Control unit (White-Grey)
INTAKE AIR TEMPERATURE SENSOR

-10° = 9600 Ohm
0° = 5900 Ohm
+10° = 3800 Ohm
+20° = 2500 Ohm
-30° = 1700 Ohm
With the switch set to "ON", check if there is 5V voltage between pins 1 and 2 of the sensor connector
unit.
INJEC - 265
Injection SRV 850
With the sensor connector disconnected, check that pin 2 of the sensor connector is earthed with the
key set to "ON".
unit.
With the palm top computer, compare the value shown with the ambient temperature value.
Throttle valve opening sensor
THROTTLE SENSOR CONNECTOR

1. Control unit (Grey-Black)
2. Control unit (Brown-Yellow)
3. Control unit (Orange-Light Blue)
INJEC - 266
SRV 850 Injection
THROTTLE POSITION SENSOR

With the switch set to "ON" at a variable voltage
between 0.7V and > 4V between pins 32 - 3 on
engine-side wiring.
Ground insulation of pins 29 - 32 - 3 on engine-side
wiring
Pins 1(A) - 3(C): Throttle valve closed: approximately 2.5 kOhm; throttle valve open: approximately 1.5
kOhm
Pins 1(A) - 2(B): approximately 1.1 kOhm
unit.
unit.
unit.
Check that the three lines are ground insulated.
Zeroing the throttle

Resetting the throttle valve position signal (TPS reset)
The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated.
Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of
air under pre-set reference conditions.
Pre-calibration ensures optimal air flow to control idling.
This regulation must not be tampered with in any way whatsoever.
The injection system will complete the management of the idling through the Stepper motor and the
variation of the ignition advance.
The throttle body after the pre-calibration has an opened valve with an angle that can vary depending
on the tolerances of the machining of the pipe and the valve itself.
The valve position sensor can also assume various fitting positions. For these reasons the mV of the
sensor with the valve at idle can vary from one throttle body to another.
To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to
match the throttle body with the control unit following the procedure known as TPS resetting.
With this operation we inform the control unit, as the starting point, of the mV value corresponding to
the pre-calibrated position.
To reset, proceed as follows.
Connect the diagnostic tester.
INJEC - 267
Injection SRV 850
Switch to «ON».
Select the functions of the diagnostic tester on «TPS RESET».
Specific tooling
Make sure that the throttle valve with the control is

supporting the stop screw.
Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure.
Reset should be performed in the following cases:

- on first fitting.
- if the injection control unit is replaced.
NOTE
THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY
BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE
AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
Step motor
INJEC - 268
SRV 850 Injection
IDLE ADJUSTMENT MOTOR CONNECTOR

1. Control unit (Light Blue-Red)
2. Control unit (Orange-Red)
3. Control unit (Light Blue-Yellow)
4. Control unit (Light Blue-Black)
STEPPER MOTOR
Resistance engine-side connector between pins
19 - 9 ~ 51 Ohm
Resistance engine-side connector between pins
18 - 17 ~ 51 Ohm
With the palm top computer, while the engine is running and with at least one electric ventilation trip,
perform the Stepper motor active diagnosis. Slight rpm variations must be detected.
Check the continuity of the 4 Stepper motor control lines.
Check the ground insulation of the 4 lines.
INJEC - 269
INDEX OF TOPICS
SUSPENSIONS SUSP
SRV 850 Suspensions
This section is dedicated to operations that can be carried out on the suspensions.
Front
Removing the front wheel
- Support the scooter adequately.

- Undo the screws indicated from both sides and
release the front brake callipers from the discs.
- Unscrew the wheel pin fixing nut.
- Loosen the two screws indicated on the right fork

leg.
SUSP - 271
Suspensions SRV 850
- Slide off the front wheel pin and remove the

wheel.
Front wheel hub overhaul
- Remove the protection cap and the spacer from

both sides by hitting with a mallet at several points.
- Visually inspect whether the components are in

good conditions and that they exhibit no signs of
abnormal wear.
- Acting on the specific tool, pull out one bearing.
Specific tooling
001467Y001 Pliers to extract Ø 25-mm bear-
ings
SUSP - 272
SRV 850 Suspensions
- Remove the internal spacer.

- Repeat the previously described procedure to pull out the other bearing from the opposite side.
- Visually inspect that the internal spacer and the bearing seats exhibit no signs of abnormal wear.
Upon refitting the bearings, insert bearing "A", wheel LH side, riding direction (inflation valve to the left
as highlighted by the red circle) as far as it will go; insert spacer "B" and afterwards insert bearing "C"
as far as it will go.
SUSP - 273
Suspensions SRV 850
SUSP - 274
SRV 850 Suspensions
- Heat the seat of one bearing with the specific tool.
Specific tooling
020151Y Air heater
- Use the specific tool to insert a new bearing as

far as it will go.
Specific tooling
020364Y 25-mm Guide
- Fit the internal spacer from the opposite side.

- Repeat the previously described procedure to fit
the other bearing.
- Insert the assembled protection cap and spacer

as far as they will go as described.
Refitting the front wheel
- To refit, carry out the removal operations but in reverse order and tighten to the prescribed torques.
SUSP - 275
Suspensions SRV 850
Screw fixing wheel pin on right fork leg 6 ÷ 7 Front wheel pin nut 60 ÷ 70 Screws fixing front
brake calliper to fork 20 ÷ 25
Handlebar
Removal
- Remove the Gilera clip-on badge, undo the screw

indicated and remove the handlebar cover.
- The half-handlebar comprises two parts: undo

the indicated screw to remove the handlebar in-
sert.
- Undo the five screws indicated to remove both

half-handlebars.
SUSP - 276
SRV 850 Suspensions
- Undo the four screws indicated, remove the

frame by passing the inserts through to the inside.
CAUTION
BE CAREFUL WITH THE SWITCH STOP CONNECTORS.
- Undo the two screws indicated.
SUSP - 277
Suspensions SRV 850
- Remove the supporting plate.
Refitting
- Fit the supporting plate on the steering tube.

- Align the plate following the indicated reference
so as to allow the upper fixing screw to fit into the
hole on the steering tube.
- Tighten the two screws indicated to the prescri-

bed torque.

Screws fixing handlebar supporting plate -
steering tube 50 ÷ 55
SUSP - 278
SRV 850 Suspensions
- Fit both handlebar inserts inside the frame as in-

dicated in the photograph.
- Assemble the frame on the supporting plate .

- Fit the four fixing screws and tighten to the pre-
scribed torque.

Screws fixing frame - supporting plate 4.5 ÷ 7
- Assemble the half-handlebars to the supporting

plate and tighten the five screws indicated to the
prescribed torque using the recommended prod-
uct.

Screws fixing half-handlebars - supporting
plate 20 ÷ 25*
- Fit both handlebar inserts on the half-handlebars
and tighten the screw indicated to the prescribed
torque using the recommended product.
(°) Loctite 243 Medium strength threadlock
Apply LOCTITE 243 medium-strength threadlock

Screw fixing half-handlebar insert - half-han-
dlebar 20 ÷ 25*
SUSP - 279
Suspensions SRV 850
- Fit the handlebar cover, tighten the screw indi-

cated to the prescribed torque and fit the Gilera
clip-on badge.

Handlebar cover fixing screw 2.5 ÷ 4
Front fork
Removal
See also
Removal
Overhaul
- Support the fork in a vice.

- Loosen the three screws tightening the stem sup-
porting clamp.
- Unscrew the stem closing cap and slide off the
fork leg together with the stem from the relevant
support.
CAUTION
THE STEM CLOSING CAP KEEPS THE MAIN SPRING PRE-
LOADED. KEEP THE CAP PROPERLY FITTED DURING
THE REMOVAL FINAL STAGE TO AVOID ACCIDENTS.
- Support the fork leg properly, remove the main

spring and drain off the fork leg oil.
SUSP - 280
SRV 850 Suspensions
- Remove the hydraulic rod fixing screw with the

corresponding sealing gasket:
- Lock hydraulic rod rotation using the specific tool.
- Undo the fixing screw and collect the copper
washer.
Specific tooling
- Remove the stem dust guard with a screwdriver.
- Remove the circlip retaining the oil seal.
SUSP - 281
Suspensions SRV 850
- Pull out the stem with force to the end of stroke.

NOTE
THE STEM HAS A SLIDING BUSHING LOCATED IN THE
UPPER PART. WHEN THE STEM IS BEING REMOVED, THE
LOWER BUSHING WORKS AS AN EXTRACTOR AGAINST
THE UPPER BUSHING, THE WASHER AND THE OIL SEAL
ON THE FORK LEG.
- Remove the hydraulic rod with the corresponding

sealing gasket, the spring and the stop bushing.
COMPONENT CHECK
CAUTION
CLEAN ALL THE COMPONENTS THOROUGHLY.
- Check that the fork leg is not cracked or broken
in the attachments.
- Visually inspect that the upper sliding bushing
exhibits no signs of abnormal wear on the internal
surface.
SUSP - 282
SRV 850 Suspensions
- Check that the stem is not scored, dented or dis-

torted.
- Check that the stop bushing for the hydraulic rod
is properly fixed through caulking.
- Visually inspect that the lower sliding bushing ex-
hibits no signs of abnormal wear on the external
surface.
- Check that hydraulic rod caulkings, the return

spring to the unloaded the end of stroke and the
hydraulic rod sealing ring are in good conditions.
- Check that the main spring exhibits no signs of

yielding or abnormal wear.
SUSP - 283
Suspensions SRV 850
- Check that the closing cap O-ring of the stem is

in good conditions.
Refitting
- Preassemble the stem with the lower sliding

bushing, the hydraulic rod with the spring and the
stop bushing.
- Fit the pre-assembled components inside the fork
leg.
- Fit the hydraulic rod fixing screw with the copper

sealing washer and tighten to the prescribed tor-
que using the recommended product.
CAUTION
ALWAYS USE NEW COPPER WASHER.

Hydraulic rod fixing screw 25 ÷ 35*
(°) Apply LOCTITE 243 threadlock
- Lock hydraulic rod rotation using the specific tool.
Specific tooling
SUSP - 284
SRV 850 Suspensions
- Fit the upper sliding bushing and the bushing stop

washer inside the fork leg.
- First grease the splitting chamber of the two seal-

ing lips of a new oil seal.
- Fit the sealing ring on the stem and keep the
identification words facing upwards.
- Fit the specific tool in the sealing ring in the initial

driving position.
Specific tooling
020633Y Clamp for sealing ring driving of
Kayaba 41-mm and Marzocchi 40-mm forks
- Fix the specific tool in a vice with the stem placed

at approximately halfway.
SUSP - 285
Suspensions SRV 850
- Drive the sealing ring to the end of stroke acting

on the fork leg with a mallet.
- Fit the oil seal retaining circlip.
- Grease and fit a new dust guard.
- Fit the fork leg together with the stem on the fork
supporting clamp until it stops.
- Tighten the three screws to the prescribed torque
in the sequence indicated in the photograph.

Stem support clamp tightening screws 20 to 25
SUSP - 286
SRV 850 Suspensions
- Refill the fork leg with the recommended product

to the prescribed amount.
AGIP FORK 7.5 W Oil for fork.
-
Characteristic
Oil quantity per stem
243 ± 3 cm³
- Bleed the hydraulic rod by actuating the stem re-

peatedly.
- Fit the spring into the stem.
- Lubricate the closing cap O-ring of the stem.

- Preload the spring; fit the closing cap and tighten
to the prescribed torque.

Fork locking screws cap 35 - 55
- Repeat the procedure for the other fork leg.

NOTE
IF BOTH FORK LEGS ARE SERVICED AT THE SAME TIME, BE CAREFUL NOT TO INVERT THE
RIGHT FORK LEG WITH THE LEFT ONE.
SUSP - 287
Suspensions SRV 850
Steering column
Removal
- Remove the front wheel.

- Undo the screw indicated and remove the brake-
force distribution mechanism from the fork.
- Remove the half-handlebar supporting plate.

- Unscrew the steering ring nuts with the specific
tool.
Specific tooling
- Remove the upper steering fifth wheel and rele-

vant components; the fork is now free.
CAUTION
HOLD IT SO THAT IT DOES NOT COME OFF SUDDENLY.
- Slide off the complete front fork, remove the lower

steering fifth wheel.
SUSP - 288
SRV 850 Suspensions
Overhaul
- Clean thoroughly and visually inspect if the com-

ponents are in good conditions.
- Check the upper steering bearing for wear.
- Check the lower steering bearing for wear.
- Visually inspect that the steering fifth wheel

tracks, the headstock and the steering tube exhibit
no scores or abnormal wear. Otherwise, replace
them.
STEERING FIFTH WHEEL TRACK REMOVAL
- Remove the steering fifth wheel tracks on the
chassis with the specific tool, following the indica-
ted procedure.
- Fit the specific tool from the lower part of the
headstock until it makes contact with the upper
track.
- Hit with force the specific tool, placing it at differ-
ent points diametrically opposed so as to remove
the upper track.
Specific tooling
from headstock
SUSP - 289
Suspensions SRV 850
- From the upper part, fit the specific tool in the two
millings on the headstock (indicated in the figure)
so as to make contact with the lower track.
- Hit with force the specific tool, placing it properly
at both points so as to remove the lower track.
Specific tooling
from headstock
- Remove the lower steering bearing seat on the

steering tube using the specific tool.
Specific tooling
from headstock
STEERING FIFTH WHEEL TRACK FITTING

- Thoroughly clean the track seats on the headstock and the steering tube.
- Fit the new tracks of the headstock with the specific tool.
- Screw the nut until the tracks are fully inserted.
NOTE
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH RECOMMENDED GREASE BEFORE
USE.
Specific tooling
001330Y Tool for fitting steering seats
AGIP GREASE PV2 Ivory smooth-textured, slightly-stringy anhydrous calcium-base grease.
SUSP - 290
SRV 850 Suspensions
- Fit the lower fifth wheel seat on the steering tube.

- With a tube of the indicated sizes, fit the lower
seat until it stops. Inside Ø: 40.5 mm; Outside Ø:
48 mm; Length: 350 mm.
NOTE
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.
grease.
Refitting
- Fit the lower steering bearing on the steering

tube.
- Fit the fork together with the lower steering bear-
ing on the headstock and hold it so that it does not
fall.
NOTE
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.
grease.
- Fit the upper steering fifth wheel.
SUSP - 291
Suspensions SRV 850
- Fit the steering bearing upper seat.
- Fit the cover plate.
- Fit the lower tightening ring nut with the cham-

fered side facing down, screw it until it stops and
with the specific tool, tighten to the indicated tor-
que.
Specific tooling

Steering tube lower ring nut 20 ÷ 22
SUSP - 292
SRV 850 Suspensions
- Fit the spacer between the two ring nuts on the

steering tube in the position indicated.
- Fit the upper tightening ring nut with the cham-

fered side facing up, screw it until it stops and with
the specific tool, tighten to the indicated torque.
Specific tooling

Steering tube upper ring nut 48 ÷ 54
- Fix the three-way union to the fork head.

Screw fixing three-way union to fork head 10 ÷
12
- Fit the front wheel.
Rear
SUSP - 293
Suspensions SRV 850
Removing the rear wheel
- Unscrew the wheel pin fixing nut.
- Remove the wheel pin and collect the spacer in-

dicated.
- Move the wheel to the front part of the vehicle so

as to obtain chain clearance to remove it from the
sprocket.
- Release the calliper holding plate from the disc.

- Remove the wheel.
SUSP - 294
SRV 850 Suspensions
REAR WHEEL HUB SERVICE

- Remove the protection sleeve and the spacer
from both sides using a flat blade screwdriver as a
lever.
- Visually inspect if the components are in good
conditions and that they exhibit no signs of abnor-
mal wear.
- Acting on the specific tool, pull out one bearing.
Specific tooling
- Remove the internal spacer.

- Repeat the previously described procedure to
pull out the other bearing from the opposite side.
- Visually inspect that the internal spacer and the
bearing seats exhibit no signs of abnormal wear.
- Heat the seat of one bearing with the specific tool.
Specific tooling
020151Y Air heater
SUSP - 295
Suspensions SRV 850
- Insert a new bearing until it stops with the specific

tool.
Specific tooling
020483Y 30 mm guide
- Fit the internal spacer from the opposite side.

- Repeat the previously described procedure to fit
the other bearing.
- Insert the assembled protection cap and spacer

until they stop on both sides as described.
Refitting the rear wheel
- Follow the removal steps but in reverse order and tighten to the prescribed torque.

Rear wheel pin nut 70
Swing-arm
SUSP - 296
SRV 850 Suspensions
Removal
Remove the left side panel.

- Undo the two screws indicated and collect the
washers thus releasing the rear brake pipe retain-
er.
- Release the rear shock absorber front retainer.

- Undo the screw indicated and collect the washer.
NOTE
THE SWINGARM, FREE, TURNS DOWNWARDS.
- Undo the fork pin tightening nut and collect the

washer.
- Slide off the fork pin.
SUSP - 297
Suspensions SRV 850
- Remove the fork paying attention to the shock

absorber.
Overhaul
- Slide off the internal spacer from the right side

and remove the stop bushing from the left side.
- Thoroughly wipe off any lubricating grease on the

spacer.
- Check that the roller casing work surfaces exhibit
no signs of scratches or abnormal wear.
Characteristic
Standard diameter
30.0 mm -0.02 -0.041
SUSP - 298
SRV 850 Suspensions
- Remove the Seeger ring.
- Take out the bearing using the specific tool.
Specific tooling
001467Y001 Pliers to extract Ø 25-mm bear-
ings
001467Y035 Bell for OD 47-mm bearings
- Fit the adaptor handle from the left side, then

prepare the adaptor and the guide.
- Pull out the two ball bearing cages with the spe-
cific tool.
- Visually inspect if the surfaces are in good con-
ditions and that they exhibit no signs of scratches
or abnormal wear.
Specific tooling
020483Y 30 mm guide
SUSP - 299
Suspensions SRV 850
- Fit the adaptor handle from the right side, then

prepare the adaptor and the guide. - Pull out the
ball bearing cage with the specific tool. - Visually
inspect if the surfaces are in good conditions and
that they exhibit no signs of scratches or abnormal
wear.
Specific tooling
020483Y 30 mm guide
SUSP - 300
SRV 850 Suspensions
- Drive the new ball bearing cages with the specific

tool and a hydraulic press.
- Grease with the recommended product.
Specific tooling
020669Y Roller bearing assembly punch
AGIP GREASE PV2 Ivory coloured, smooth-
textured, slightly stringy anhydrous calcium
grease@
TL 9150 066, NATO G 460 symbol
- Drive a new bearing with the specific tool and a

hydraulic press.
Specific tooling
020364Y 25-mm Guide
- Fit the Seeger ring.
SUSP - 301
Suspensions SRV 850
- Pull out the rear shock absorber silent-block with

a hydraulic press
- Similarly to the removal operations, drive a new
silent-block after heating with the specific tool.
Specific tooling
020151Y Air heater
- Undo the three fixing screws to replace the chain

stop slider.
- Upon fitting, tighten the three screws to the pre-
scribed torque.

Chain stop pad fixing screw - swinging arm 5 ÷
7
- Undo the two fixing screws and collect the wash-

ers to replace the stand stop buffer.
- Upon fitting, tighten the two screws to the pre-
scribed torque.

Centre stand stop buffer fixing screw - swing-
ing arm 5 ÷ 7
SUSP - 302
SRV 850 Suspensions
- Fit the pin and the stop bushing.
Refitting
NOTE
CLEAN ALL THE SURFACES AND THREADS THOROUGHLY BEFORE FITTING.
LUBRICATE ALL THE FRICTION AREAS THOROUGHLY.
- Fit the fork together with the rear shock absorber.
- Tighten the screw fixing it to the chassis to the
prescribed torque.

Shock absorber fixing screw - swinging arm 38
- 46
- Fit the fork together with the rear shock absorber.

- Tighten the screw fixing it to the chassis to the
prescribed torque.

Swinging arm pin adjuster screw 0.5
SUSP - 303
Suspensions SRV 850
CAUTION
WHILE TIGHTENING, LIGHTLY SWING THE SWINGARM

SO AS TO ACHIEVE PROPER COUPLING ON THE SWING-
ING ARM AXIS.
NOTE
PLACE THE WRENCH AT 90° REGARDING THE SPECIFIC
TOOL. FAILURE TO OBSERVE THIS POSITIONING MAY
ALTER THE PROPER LOCKING TORQUE.
- Using the specific tool tighten the set screw lock-

ing ring nut to the prescribed torque while keeping
the set screw locked.
Specific tooling
020667Y Wrench for fork pin adjustment ring
nut

Swinging arm lock ring nut 60 ± 3
- Lock the pin from the vehicle right side, tighten

the fork pin locking nut to the prescribed torque.

Swinging arm pin nut 90 ± 5
SUSP - 304
SRV 850 Suspensions
- Tighten the two screws together with the wash-

ers, thus fixing the rear brake pipes.
CAUTION
UPON FITTING, BE PARTICULARLY CAREFUL WHEN IN-

SERTING THE BREATHER PIPE IN THE FORK SLOT.
Shock absorbers
Removal
- Remove the fork.

- Unscrew the nut indicated to remove the pin.
See also
SUSP - 305
Suspensions SRV 850
Refitting
- Fix the fork to the shock absorber with a pin.

- Tighten the nut indicated to the prescribed tor-
que.

Nut fixing shock absorber - fork 38 - 46
- Following the operations indicated in the relevant

section, fit the rear fork on the vehicle thus fixing
the shock absorber to the chassis to the prescribed
torque.

Vite fissaggio ammortizzatore - forcellone 38 ÷
46
Removal
See also
Refitting
See also
Centre-stand
See also
SUSP - 306
SRV 850 Suspensions
Side stand
REMOVAL
- Remove the left footrest.
- Remove the two return screws and unscrew the
nut indicated.
- Slide off the pin and remove the side stand.
- Should the side stand button be replaced, undo

the two screws indicated and remove the footrest
support.
- Disconnect the connector, remove the two

clamps, undo the two connecting screws to the
chassis and remove the button.
FITTING
- Follow the removal steps but in reverse order and tighten to the prescribed torques.

Screws fixing side stand button 6 Side stand bolt nut 37
- Grease with the recommended product.
AGIP GP 330 Water repellent springy calcium spray grease.
R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 - I.A.T.A. 2 - I.M.D.G. class 2 UN 1950 Pag. 9022 EM 25-89
SUSP - 307
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

SRV 850 Braking system
This section è is dedicated to the description of the brake system components.
Rear brake calliper
Removal
- Remove the two retainers fixing the brake calliper

to the bracket.
- Remove the pads.
Refitting
To refit, carry out the removal operations but in reverse order. Once these operations are completed,
purge the braking system.

Screws fixing the calliper to the supporting plate 20 ÷ 25
Front brake calliper
Removal
- Remove the two retainers fixing the brake calliper

to the fork.
NOTE
SHOULD THE BRAKE CALLIPER BE REPLACED, BEFORE
REMOVING THE FITTINGS FIXING THE CALLIPER TO THE
SUPPORTING BRACKET, FIRST LOOSEN THE OIL HOSE
FITTING AFTER HAVING EMPTIED THE SYSTEM OF THE
CIRCUIT BEING INSPECTED.
BRAK SYS - 309

Braking system SRV 850
Refitting
- Fasten the brake calliper to the fork with the two

screws.

- Fix the brake pipe coupling to the calliper.

Brake pipes / front brake calliper coupling 16 ÷
20
- Purge the system.
Rear brake disc
Removal

- Undo the five screws fixing the disc to the rim.
BRAK SYS - 310

Refitting
- Place the disc on the rim so that the words face

the vehicle external side.
- Fasten the disc with the five screws and apply
specific product on them.

Screws fixing rear brake disc to rim 25
Disc Inspection
Checking the disc is important; it must be perfectly

clean, with no sign of rust, oil or grease or other
dirt and must not show signs of deep scoring.
Characteristic
New rear disc thickness
5 mm
Disc thickness at wear limit (rear)
4.5 mm
- Remove the wheel and check using the appro-

priate tools that the axial run-out of the brake
surface is within the prescribed limits.
- If this is not the case, replace the disc and repeat
the test.
WHEN INSTALLING, THOROUGHLY CLEAN THE DISC
AND ITS SEAT ON THE HUB.
Characteristic
Max. axial run-out
0.1 mm
Front brake disc
BRAK SYS - 311

Removal
- Remove the front wheel.

- Undo the five screws fixing the disc.
Refitting
- Place the disc on the rim so that the words face the vehicle external side.
- Fasten the disc with the five screws.

Screws fixing front brake disc to rim 25
BRAK SYS - 312

Disc Inspection
Checking the disc is important; it must be perfectly

clean, with no sign of rust, oil or grease or other
dirt and must not show signs of deep scoring.
Characteristic
Thickness of a new front disc
5 mm
Disc thickness at wear limit (front)
4.5 mm
- Remove the wheel and check using the appro-

priate tools that the axial run-out of the brake
surface is within the prescribed limits.
- If this is not the case, replace the disc and repeat
the test.
WHEN INSTALLING, THOROUGHLY CLEAN THE DISC
AND ITS SEAT ON THE HUB.
Characteristic
Max. axial run-out
0.1 mm
Front brake pads
BRAK SYS - 313

Removal
- Remove the brake calliper.

- Remove the two stop clips and slide off the pin.
- Remove the two pads.
- Check the thickness of the friction material. Re-

place the pads if the thickness is below the mini-
mum value.
Characteristic
Minimum friction material thickness
1.5 mm
- In case of uneven wear, replace the pads when

the thickness difference in the friction material is
0.5 mm.
BRAK SYS - 314

Refitting
- Insert the two pads in the callipers.
- Lock the pads using the pin and fit the clips.
- Fit the calliper on the fork stem.

Rear brake pads
BRAK SYS - 315

Removal
Proceed as follows:
- Remove the rear brake calliper
- Loosen the two pins shown in the figure that lock
the two pads.
- Remove the pads, being careful with the pad
spring clamp.
- Check the thickness of the friction material of the
pads.
- Replace the pads if the thickness is below the
minimum value.
- The replacement must be made with greater re-
sidual thickness if the pad has not worn evenly. A
0.5 mm thickness difference in the residual friction
material is permitted.
Characteristic
Minimum value
1.5 mm
Refitting
To fit, proceed as follows:
- Insert the two pads in the callipers.
- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
NOTE
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT-
TING, GENTLY EXPAND THE PADS.
BRAK SYS - 316

Parking brake adjusting nut 10 Rear brake pad fixing pins 15 ÷ 20
Fill - Bleeding the braking system
Rear - combined
- Remove the rubber cap from the bleed screw and

insert a rubber pipe to collect the brake fluid.
- With the left-hand brake lever, load the system

and bring it up to the required pressure.
- Keeping the left-hand brake lever pulled, loosen
the bleed screw to permit the air in the system to
escape.
- Repeat the operation until only brake fluid comes
out of the rubber pipe.
- Tighten the bleed screw.
- Remove the fluid recovery pipe and refit the rub-
ber cap over the bleed screw.
- Top up the brake fluid to the right level in the res-
ervoir. If necessary, bleeding can be done using a
special vacuum pump
NOTE
DURING THE BLEEDING OPERATIONS, MAKE SURE THE
BRAKE FLUID DOES NOT COME INTO CONTACT WITH
THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHER-
MORE, DURING THE BLEEDING OPERATIONS REGARD-
ING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC
BRAKES AND WITH THE BRAKE PADS. FAILURE TO OB-
SERVE THIS PRECAUTION WILL ENDANGER THE PROP-
ER WORKING AND EFFICIENCY OF THE BRAKING SYS-
TEM
Specific tooling

Brake calliper bleed screws. 12 ÷ 16
BRAK SYS - 317

Front
- Remove the rubber cap from the bleed screw and

insert a rubber pipe to collect the brake fluid.
CAUTION
CARRY OUT THE FOLLOWING OPERATIONS ON BOTH
CALLIPERS
- With the right-hand brake lever, load the system

and bring it up to the required pressure.
- Keeping the right-hand brake lever pulled, loosen
the bleed screw to permit the air in the system to
escape.
- Repeat the operation until only brake fluid comes
out of the rubber pipe.
- Tighten the bleed screw.
- Remove the fluid recovery pipe and refit the rub-
ber cap over the bleed screw.
- Top up the brake fluid to the right level in the res-
ervoir. If necessary, bleeding can be done using a
special vacuum pump
NOTE
DURING THE BLEEDING OPERATIONS, MAKE SURE THE
BRAKE FLUID DOES NOT COME INTO CONTACT WITH
THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHER-
MORE, DURING THE BLEEDING OPERATIONS REGARD-
ING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC
BRAKES AND WITH THE BRAKE PADS. FAILURE TO OB-
SERVE THIS PRECAUTION WILL ENDANGER THE PROP-
ER WORKING AND EFFICIENCY OF THE BRAKING SYS-
TEM
Specific tooling

Brake calliper bleed screws. 12 ÷ 16
BRAK SYS - 318

Brake fluid level check
- Rest the vehicle onto the centre stand, with the

handlebar centred.
- Check the fluid level through the specific sight
glass.
- In the event that the level of one or all of the tanks
is less than the MIN indication, proceed with the
top-up.
Removal
- Remove the two contacts from the stop light

switch.
- Drain off the braking system corresponding to the

circuit being tested.
- Remove the oil pipe coupling.
BRAK SYS - 319

- Remove the two screws fixing the pump to the

handlebar.
Refitting
- To refit, carry out the removal operations but in reverse order.

CAUTION
ONCE REFITTING IS FINISHED, BLEED THE SYSTEM.
Screws fixing brake pump to handlebar 7 ÷ 10 Brake pipes / brake pump coupling 16 ÷ 20
Rear brake pump - combined
Removal
- Remove the two contacts from the stop light

switch.
- Drain off the braking system corresponding to the

circuit being tested.
- Remove the oil pipe coupling.
BRAK SYS - 320

- Remove the two screws fixing the pump to the

handlebar.
Refitting
- To refit, carry out the removal operations but in reverse order.

CAUTION
ONCE REFITTING IS FINISHED, BLEED THE SYSTEM.
Screws fixing brake pump to handlebar 7 ÷ 10 Brake pipes / brake pump coupling 16 ÷ 20
Brake pipes
FRONT BRAKE PIPE FITTING

- Fix the three-way union to the fork head.

Screw fixing three-way union to fork head 10 ÷
12
- Fit the front brake pipes to the right and the left.

Brake pipes / front brake calliper coupling 16 ÷
20
BRAK SYS - 321

- Remove the front shield.

- Thread the pipes through the right half-handlebar
and lay it to the vehicle left side.
- Fix the coupling to the brake pump.
- Fix the coupling to the three-way union.

Brake pipes / brake pump coupling 16 ÷ 20
REAR BRAKE PIPE FITTING

To reach the rear brake pipes, thread the pipes through the left half-handlebar and afterwards fix the
coupling to the brake pump.
- Thread the pipes through the left half-handlebar

and afterwards fix the coupling to the brake pump.
- Fasten the pipe to the clip.
BRAK SYS - 322

- Fasten the pipe to the clamp.
- Fasten the pipes to the chassis with a strap.
BRAK SYS - 323

- Fasten the pipe to the rear fork with the two clips.

Nut fixing rear brake pipe retaining clip 11 ÷ 13
- Fix the brake pipe coupling to the brake calliper.

Brake pipe / rear brake calliper coupling 20 ÷ 25
PARKING BRAKE TRANSMISSION FITTING

- Fit the transmission cable of the control lever and
thread the transmission sheath to the other side of
the vehicle as shown in the figure.
BRAK SYS - 324

- Fasten the sheath to the chassis with a strap.
- Fasten the pipe to the rear fork with the two clips.

Nut fixing rear brake pipe retaining clip 11 ÷ 13
BRAK SYS - 325

Parking brake
PARKING BRAKE CALLIPER REMOVAL

- Undo the two screws and remove the protection.
- Loosen the nut indicated and remove the trans-

mission.
- Undo the two screws and remove the calliper.
- To refit, carry out the previous operations but in reverse order. After adjustment, tighten the nut indi-
cated to the prescribed torque.

Screw fixing parking brake calliper to supporting plate 24 ÷ 27 Parking brake adjusting nut 10
BRAK SYS - 326

PARKING BRAKE CONTROL REMOVAL

- Remove the shield back plate.
- Undo the four fixing screws and remove the
transmission cable.
BRAKE PAD REPLACEMENT

- Remove the brake calliper.
- Unscrew the two retaining pins and slide off the
pads.
- To refit, carry out the previous operations but in
reverse order.

Pin fixing parking brake pads 15 ÷ 20
BRAK SYS - 327

INDEX OF TOPICS
COOLING SYSTEM COOL SYS

SRV 850 Cooling system
Circuit diagram
KEY:
1. Rear head outlet
2.To radiator
COOL SYS - 329

Cooling system SRV 850
3.Expansion tank
4.Radiator breather pipe
5. Circuit filling pipe
6. Thermostat
7. By-pass pipe
8. Intake from radiator
9. Coupling (T-joint)
10.Front head outlet
11. Delivery to the cylinders
12. Pump
13. Intake from radiator
The cooling system is a forced circulation type system, with continuous venting and air pressurisation.
Circulation takes place by means of a centrifugal pump.
The pump delivers the coolant to the thermal units.
The two-way thermostat support is connected to the head outlet. One way is connected to the pump
and the other to the radiator.
The radiator output is directly connected to the pump.
The expansion tank is connected in parallel to the radiator.
The radiator hot box is connected to the upper side of the expansion tank (in air).
The radiator cold box is connected to the lower side of the expansion tank (in the fluid).
When the engine is cold, the thermostat output to the radiator is closed, even though there is still a little
flow for de-aeration obtained by a hole into the closing plate.
In this case, the circulation into the thermal units is active to ensure an even heating.
Once the working temperature has been reached, the main circulation on radiator and expansion tank
starts.
With the small openings in the thermostat there is a flow overlapping (re-circulation and main one).
When the temperature is higher, the thermostat allows excluding the re-circulation to favour the main
circulation.
In this case, the flow is consistent in the expansion tank as well, and this ensures a continuous automatic
venting.
For the system venting during the circuit filling step, there is a special union at the top of the head (see
filling rules).
To ensure cooling in case of poor dynamic ventilation, there is an electric fan controlled by the injection
system.
Cooling system capacity 2.4 l
Recommended fluid AGIP PERMANENT SPEZIAL
Sealing pressure Cap calibrated at 0.9 bar
COOL SYS - 330

THERMOSTAT
Type Wax-type, with deviator
Starts opening at 85±2°C
ELECTRIC VENTILATION
Type With piston
Electric ventilation starts at 105°C
Electric ventilation stops at 100°C
WATER PUMP
Type Centrifugal
Control Gear on oil delivery pump
RADIATOR
Type Aluminium, with vertical circulation
EXPANSION TANK
Calibration Automatic bleeding, in parallel with the radiator
Electric fan check

- Connect the injection diagnostic tester and select the «ERRORS» function in this menu.
- Check the electric fan control circuit for failures.
Specific tooling
- Select the «ACTIVE DIAGNOSIS» function in this menu and run a simulation of the electric fan op-
eration.
- If the electric fan is certainly efficient, check the ventilation start and stop temperatures.
- Select the «PARAMETERS» function in this menu to display the coolant temperature.
Electric fan starts: 105°C
Electric fan stops: 100°C
- If non-conforming values are detected, replace the injection ECU..
- If the analogue instrument temperature is close to the red zone, but the degrees indicated by the
diagnostic tester is below the electric ventilation temperature, check the temperature sensor on the
head and check the relevant injection circuit;
NOTE
THE ELECTRIC FAN TEMPERATURE AT 105° C CAN ONLY BE MANAGED BY A SYSTEM SUP-
PLIED WITH RECOMMENDED FLUID AND PRESSURISED AT 0.9 BAR.
AVOID STARTING THE ENGINE WITHOUT PRESSURISATION SINCE IT MAY REACH THE BOIL-
ING TEMPERATURE BEFORE THE ELECTRIC FAN STARTS WORKING.
IN CASE THE ELECTRIC VENTILATION TIME INCREASES, CHECK THE THERMOSTAT OPEN-
ING TEMPERATURE.
COOL SYS - 331

AGIP PERMANENT SPECIAL Ethylene glycol-based antifreeze fluid with organic inhibition ad-
ditives. Red, ready to use.
ASTM D 3306 - ASTM D 4656 - ASTM D 4985 - CUNA NC 956-16
System sealing check
- Check the proper circuit sealing when it is under

pressure and at the temperature.
- For a more accurate check, wait until the system
has cooled down since small leaks may not be
visible due to evaporation
- The water pump is provided with a drainage hole
in case of leaks from the cooling system mechan-
ical seal, or from the shaft sealing oil guard.
- If coolant leaks are detected, replace the pump (see «Engine» Chapter).
Coolant replacement
- Restore all the cooling system connections, re-

move the compartment cover giving access to the
expansion tank and unscrew the cap.
- Remove the front section of the helmet compart-
ment, remove the cap and undo the bleed screw
on the rear cylinder.
- Fill the expansion tank with the recommended

product up to the level indicated inside the expan-
sion tank filler.
NOTE
THE FLUID IS SUPPLIED READY FOR USE (ALREADY
MIXED).
AGIP PERMANENT SPECIAL Ethylene glycol-
based antifreeze fluid with organic inhibition
additives. Red, ready to use.
ASTM D 3306 - ASTM D 4656 - ASTM D 4985 -
CUNA NC 956-16
COOL SYS - 332

- Connect the bleed screw to the expansion tank,

using a transparent hose to be able to visually
check that air is escaping.
- Start the vehicle.

- Keep it running at idle speed up to 30 sec max.,
causing the air to escape.
- Shut off the engine, close the bleed screw and
screw the cap on the expansion tank.
- Restore the level in the expansion tank.
- Start the vehicle idle speed again and keep it running until the electric ventilation temperature is
obtained.
- Shut off the engine and wait until it cools down.
CAUTION
GIVEN REGULAR CONDITIONS OF USE, WITH ENGINE AT IDLE SPEED, THE TIME REQUIRED
TO TAKE THE TEMPERATURE BELOW THE ELECTRIC FAN ACTIVATION LEVEL IS ~ 35 SEC.
CHECK THAT THE ACTIVATION TIME AFTER BLEEDING THE SYSTEM DOES NOT DEVIATE
MUCH FROM THE TIME SPECIFIED.
OTHERWISE, REPEAT THE BLEEDING PROCEDURE.
- Once bleeding is complete, restore the level in the expansion tank.
COOL SYS - 333

Water pump - overhaul

If noise or leakage from the water pump drainage
hole is detected, it is necessary to revise the water
pump, as described in Engine Chapter.
Proceed to carry out a few preliminary operations

as described below:
- Place the vehicle on its centre stand and on flat
ground.
- Remove the bodywork components as described
in the Bodywork Chapter.
- Empty the cooling system by removing the cou-
plings on the pump cover and the filler plug on the
expansion tank.
CAUTION
THIS OPERATION MUST BE CARRIED OUT WHEN THE

ENGINE IS COLD.
Characteristic
Cooling system
2.4 l
Removing the water pump cover:
- Loosen the six fixing screws and remove the water pump cover.
- Check that the water pump cover is not deformed or dented.
- Check that the sealing O-ring is in good working order.
- Otherwise, replace the component.
- Adequately fit a new O-ring, be careful to lubricate it with petroleum jelly grease.
NOTE
DO NOT LUBRICATE THE O-RING WITH PETROLEUM GREASE TO AVOID DEFORMATION.

CAUTION
FAILURE TO OBSERVE THIS PRECAUTION WILL IRRETRIEVABLY DEFORM THE O-RING.

- Refit the water pump cover and tighten the 6 fixing screws to the prescribed torque.
COOL SYS - 334

NOTE
FOR CHANGING THE COOLANT AND BLEEDING THE SYSTEM, SEE THE "COOLANT CHANGE"
SECTION.
Water pump cover screws 3 - 4
diagnosis
Excessive system pressure
1 - Check the expansion tank cap efficiency.

NOTE
THE CAP IS EQUIPPED WITH A PRESSURE-RELIEF VALVE CALIBRATED AT 0.9 BAR.
There is also a valve that must allow air inlet during the cooling step.
2 - Check the head gasket seal (see «Thermal group and timing system» chapter)
3 - Replace the cap.
Cooling fluid consumption
1 - Check the system outer seals as described above.

- If water leaks are detected in the engine oil, inspect the pad on the head cooling circuit.
3 - Fix any damaged seals.
Oil in the fluid
1 - Presence of oil in the coolant.

YES go to 2
COOL SYS - 335

INDEX OF TOPICS
CHASSIS CHAS
SRV 850 Chassis
This section è is dedicated to the operations that

can be carried out on the vehicle's bodywork.
To remove the bodywork, follow this order:

Front part:
«A» Rearview mirrors - Windshield
«B» Front shield upper section
«C» Battery compartment cover - Expansion tank inspection compartment cover
«D» Headlight assembly
«E» Front central cover
«F» Handlebar
«G» Shield back plate
Central/rear part:
«H» Helmet compartment
«I» Chassis side cover- rear part
«L» Grab handles and upper side fairings - Rear light unit
«M» Spoiler
«N» Footrest
Seat
- Undo the four fixing screws and remove the sad-

dle.
CHAS - 337
Chassis SRV 850
Driving mirrors
- Unscrew from both sides the two fixing screws

- Disconnect the connectors of the turn indicators
and remove the rear view mirrors.
Instrument panel
- Remove the front shield.

- Disconnect the two connectors.
- Undo the six screws fixing it to the shield back

plate.
- Remove the instrument panel.
CHAS - 338
SRV 850 Chassis
Headlight assy.
- Remove the legshield.

- Unscrew the screws indicated and remove the
headlight assembly.
See also
Legshield
Legshield
- Remove the windshield.

- Remove the rear-view mirrors.
- Undo the six screws indicated to remove the up-
per part of the front legshield.
- Unscrew the screw indicated in the figure, one on

each side.
CHAS - 339
Chassis SRV 850
- Unscrew the five screws indicated located under

the front legshield.
- Undo from both sides the three screws indicated.
- Remove the screw indicated from both sides.

- Remove the side by pulling to though.
CHAS - 340
SRV 850 Chassis
- Undo from both sides the three screws indicated

and remove the part.
- Unscrew the screw indicated in the figure, one

per side.
- Unscrew the screw indicated in the figure, one

per side.
- Unscrew the two screws indicated at the back of
the front legshield.
CHAS - 341
Chassis SRV 850
- Unscrew the two screws indicated located under

the legshield.
- Release the connector and remove the lights by

pulling the fairing towards the front.
Knee-guard
- Remove the legshield.

- Disconnect the stop switches and unscrew the
retainers of the brake pumps U-bolts; release them
from the half-handlebars.
CAUTION
BE CAREFUL WITH THE SWITCH STOP CONNECTORS.
CHAS - 342
SRV 850 Chassis
- Remove the handlebar together with the sup-

porting plate.
- Remove the saddle opening command and un-
screw the screw underneath fixing to the frame.
- Remove the cover of the handlebar by unscrew-
ing the four screws indicated.
CHAS - 343
Chassis SRV 850
- Remove the key switch frame.

- Unscrew the expansion tank cap.
- Undo the screw fixing the expansion tank to the
shield back plate.
- Undo the two fixing screws to the front central

cover.
- Remove both fuse terminal blocks.

- Disconnect the instrument panel connectors.
- Remove the two screws indicated in the figure.
- Remove the handlebar support.
- Remove the leg shield back plate from the vehi-
cle, pushing it up.
CHAS - 344
SRV 850 Chassis
CHAS - 345
Chassis SRV 850
- Disconnect, one at a time, the brake pumps plus

the pipes and the half-handlebar plus the controls,
pass them through the central opening in the
shield back plate.
- Remove the leg shield back plate.
- Once the shield back plate has been removed,

remove the central frame by undoing the five
screws indicated from the rear part:
See also
Removal
CHAS - 346
SRV 850 Chassis
Front wheel housing
- Remove the fork

- Disconnect the ambient temperature sensor.

- Release the throttle control transmissions and
the oil bleed pipe of the air filter from the clamps.
- Undo the screw fixing the electrical cable harness
clamp.
- Remove the front wheel housing together with the radiator cover.
Taillight assy.
- Undo the two screws « A» and remove the cover.

- Undo the two screws «B» located in the license
plate holder.
CHAS - 347
Chassis SRV 850
- Undo the upper screw.

- Undo the screw «C», one per side.
- Undo the two screws «D» located behind the

headlight assembly.
- Undo the eight screws «E» located on the upper
side.
CHAS - 348
SRV 850 Chassis
- Remove the light assembly connector.

- Remove the rear light assembly.
Footrest
- The operations are described only once, but are

valid for both footrests.
CHAS - 349
Chassis SRV 850
- Unscrew the two screws and collect the washers.

- Unscrew the screw at the rear of the footrest.
- Unscrew the screw on the front wheel compart-

ment.
- Unscrew the screw on the lower side of the foot-
rest.
CHAS - 350
SRV 850 Chassis
- Unscrew the screw on the back part of the foot-

rest.
- Remove the footrest.
PASSENGER FOOTRESTS
- Undo from both sides the three screws indicated
to remove the footrests.
When fitting, tighten the screws to the specified
torque.

Passenger footrest fixing screws 14 ÷ 17
CHAS - 351
Chassis SRV 850
Helmet bay
- Remove the two screws indicated in the figure

located in the rear part of the compartment.
- Remove the two screws indicated in the figure

located inside the compartment.
- Unscrew the two screws shown in the figure and

separate the locking catch of the saddle.
- Unscrew the fuel tank cap.
- Unplug the connector from the plug socket and

that of the light of the helmet compartment.
- Remove the helmet compartment.
CHAS - 352
SRV 850 Chassis
spoiler

to both spoilers.
- Remove the rubber mat.
- Undo the four screws indicated.
- Undo the lower connecting screw to the wheel

housing and the connecting screw to the chassis
side cover, rear part.
- Remove the spoiler.
CHAS - 353
Chassis SRV 850
Front mudguard
- Undo the two fixing screws on both sides.
- Once the mudguard has been removed, detach

the front part from the rear part by undoing the two
screws indicated on both sides.
Radiator fan
- Get a container of suitable capacity, disconnect

the pipes indicated and let the fluid drain off the
cooling system.
CHAS - 354
SRV 850 Chassis
- Disconnect the pipes indicated.
- Disconnect the connector of the electric fan.

- Undo the two screws indicated and collect the
washers.
- Remove the radiator by releasing it from its fit-

tings.
- To remove the electric fan, first remove the radi-
ator and afterwards undo the three screws indica-
ted.
Handles and top side fairings

to both vehicle fairings.
- Remove the upper centre cover by unscrewing
the two screws in the figure.
CHAS - 355
Chassis SRV 850
- Undo the screws indicated in the figure.

- Remove the side fairing.
CHAS - 356
SRV 850 Chassis
CHAS - 357
Chassis SRV 850
Front central cover
- Remove the battery compartment cover and ex-

pansion tank compartment cover.
- Unscrew the two screws indicated from the hel-

met compartment.
- Hold the front central cover as shown in the fig-

ure.
- Push the shield back plate and pull towards the
vehicle rear part to release the tongue.
CHAS - 358
SRV 850 Chassis
Flyscreen
- Undo the six screws indicated to remove the

windshield.
- Undo the six screws indicated to remove the leg-

shield.
Radiator cover
See also
Front wheel housing
Battery
- Undo the four screws indicated and remove the

battery compartment cover.
CHAS - 359
Chassis SRV 850
- Undo the screw and remove the battery fixing

bracket.
- Undo the battery negative and positive wires.
WARNING
IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYS-

TEM, NEVER DISCONNECT THE WIRING WHILE THE EN-
GINE IS RUNNING.
- To remove the battery from its housing, remove

the shield back plate.
- Disconnect the cable harnesses at the back of
the battery compartment.
- Undo the three screws indicated.
CHAS - 360
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Pre-delivery SRV 850
Carry out the listed tests before delivering the vehicle.

Warning - Handle fuel with care.
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection
- Visually check that there is a yellow mark on the following clamps:

HANDLEBAR
• Screws fixing half-handlebars - supporting plate

• Screws fixing brake pump to handlebar
• Brake pipes / brake pump couplings
• Brake pipes / front brake pump couplings
FRONT SUSPENSION
• Front wheel pin nut

• Screw fixing wheel pin on right fork leg
FRONT BRAKE
• Screws fixing front brake calliper to forks

• Brake pipes / front brake calliper couplings
REAR SUSPENSION
• Rear wheel pin nut

• Screws tightening the fork pin cam
REAR BRAKE
• Screws fixing parking brake calliper to supporting plate

• Parking brake adjusting nut
• Screws fixing rear brake calliper to supporting plate
• Brake pipe / rear brake calliper coupling
FORK
• Fork pin nut

• Fork locking ring nut
STAND
PRE DE - 362
SRV 850 Pre-delivery
• Centre stand bolt nuts

• Muffler support flange screw
Electrical system
• Battery
• Main switch
• Lights: high beam lights, low beam lights, taillights (front and rear) and relevant warning lights
- Headlight adjustment according to the regulations currently in force
• Front and rear stop light buttons and bulb
• Turn indicators and their warning lights
• Instrument lighting
• instruments: fuel and temperature indicator
•Instrument panel lights
• Horn
• Electric starter
• Engine stopping with emergency stop switch
• Electric opening of saddle with solenoid
• Tilting system locking - unlocking button
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR
ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES,
SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
Level check:
- Hydraulic brake system liquid level.
PRE DE - 363
Pre-delivery SRV 850
- Engine coolant level

- Engine oil level
Road test
Test ride
- Cold start
- Instrument operations
- Response to the gas command
- Stability on acceleration and braking
- Rear and front brake efficiency
- Parking brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
Static test
Static control after the test ride:

• Hot engine restart
• Minimum seal (turning the handlebar)
• Uniform steering rotation
• Possible losses
• electric radiator fan operation
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
Functional inspection
Functional check up:

• Hydraulic braking system: lever travel
• Clutch: proper functioning check
• Engine: proper general functioning and no abnormal noise check
• Other: paper check, frame and engine number check, tools and equipment, licence plate fitting, lock
check, tyre pressure check, rear-view mirrors and any accessory fitting
PRE DE - 364
A
Accessories: 83
Air filter: 41, 134
Air temperature sensor: 265
B
Battery: 80, 93, 110, 359
Brake: 309–311, 313, 315, 319–321, 326
Brake calliper: 309
Brake disc: 310, 311
Brake fluid: 319
Brake pads: 313, 315
Brake pump: 320
Bulbs:
C
Chain: 203
Clutch: 56, 143, 144, 149, 151
Coil: 260
Connectors: 112
coolant: 263, 332
Coolant: 263, 332
Crankcase: 205, 206, 211, 212, 235
Crankshaft: 205, 210, 211
Cylinder: 14, 17, 182, 185, 189, 193, 194
E
Electric fan: 331
Electrical system: 11, 60, 70, 363
Engine oil: 45
Exhaust: 122, 134, 248, 306
F
Fairings: 355
Fork: 280
Front wheel: 271, 272, 275, 347, 359
Fuel: 249
Fuses: 108
H
Handlebar: 276
Headlight: 50, 339
Horn: 101
I
Identification: 8
Instrument panel: 338
Intermediate gear: 178, 180
L
Light switch:
M
Maintenance: 7, 38
Maintenance Table:
Mirrors: 338
Mudguard: 354
O
Oil filter: 47
R
Radiator: 354, 359
Rear wheel: 294, 296
Recommended products:
S
Shock absorbers: 305
Side fairings: 355
Side stand: 307
Spark plug: 39, 91, 262
Stand: 307
Starter motor: 175, 181
T
Tank:
Transmission: 10, 56, 138, 164
Turn indicators: 84
Tyres: 12
V
Voltage regulator: 96
W
Water pump: 231, 334

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SERVICE STATION MANUAL

THE VALUE OF SERVICE

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

This section describes the general specifications of the vehicle.

Chassis prefix (A):

Engine prefix (B):

Dimensions and mass

WEIGHT AND DIMENSIONS

OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH

HEAD LUBRICATION CONTROL JET

PISTON COOLING NOZZLE

CRANKCASE VENTILATION CHECK

Frame and suspensions

FRAME AND SUSPENSIONS

Wheels and tyres

WHEELS AND TYRES

THERMAL GROUP AND TIMING SYSTEM

CRANKCASE AND CRANKSHAFT

Cylinder - piston assy.

HEIGHT TO MEASURE THE PISTON

THE ROTATION DIRECTION OF THE ENGINE IS OPPOSITE TO THE DIRECTION OF TRAVEL,

- Measure the diameter of the bearings on the pis-

- Calculate the pin - piston coupling clearance.

- Check that coating is free from flakes.

Check the size of the sealing ring opening:

Rings/slots coupling clearances:

Maximum clearances allowed after use: 0.10

- Using a trued bar and a thickness gauge, check

- In case of irregularities, replace the head.

- Fit the valves into the cylinder head.

Measure the camshaft seat bearings and rocking

- Measure the unloaded spring length.

- Remove any carbon deposits from the valve

VALVE STANDARD LENGTH

MINIMUM DIAMETER ALLOWED

- Calculate the clearance between the valve and

- Check the deviation of the valve stem by resting

- Check the concentricity of the valve head by

Measure the valve guides.

- After measuring the valve guide diameter and the

- Check that there are no signs of wear on the

- If no faults are found during the above checks,

MINIMUM DIAMETER ALLOWED

- Using a gauge, measure the height of the cams.

- Check the inside diameter of each rocking lever.

Slot packing system

BASE GASKET THICKNESS

RECOMMENDED PRODUCTS TABLE

UNIT OF MEASURE - CONVERSION - ENGLISH SYSTEM TO INTERNATIONAL SYSTEM (IS).

001330Y014 Tool for fitting steering seats

001330Y015 Tool for fitting steering seats

020004Y Punch for removing steering bearings

020668Y Steering ring nut wrench

020306Y Punch for assembling valve seal rings

020382Y012 bush (valve removing tool)

Stores code Description

020128Y Piston fitting band