Академический Документы
Профессиональный Документы
Культура Документы
00/2004-10
www.serviceaprilia.com
workshopmanual
UK
8140811
INTRODUCTION
Sportcity 125 - 200
INTRODUCTION 0
0-1
INTRODUCTION
Sportcity 125 - 200
SUMMARY
0.1. FOREWORD..................................................................................................................................................... 3
0.1.1. FOREWORD ............................................................................................................................................. 3
0.1.2. REFERENCE MANUALS .......................................................................................................................... 4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ........................................................................................ 5
0-2
INTRODUCTION
Sportcity 125 - 200
0.1. FOREWORD
0.1.1. FOREWORD
- This manual provides the information required for normal servicing.
- This publication is intended for use by aprilia Dealers and their qualified mechanics; many concepts have been
omitted on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been
included in this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair
procedures. Without such familiarity, repairs and checks could be ineffective and even hazardous. Since not all
vehicle inspection and repair procedures are described in details, pay utmost attention to avoid damages to
components or people. aprilia s.p.a. undertakes to constantly improve the design of its products and their literature
to ensure that the customer is satisfied of the product. The main technical modifications and changes in repair
procedures are communicated to all aprilia dealers and agencies worldwide. These changes will be applied to the
next issues of this manual. Should you need assistance or clarifications about the inspection and repair procedures,
please contact the aprilia SERVICE DEPT., they will be glad to give you any information on the matter, or supply
you with any detail on updates and technical changes applied to the vehicle.
aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the
essential features of a product as specified in the relevant manual.
All rights of electronic storage, reproduction and total or partial adaptation with any means reserved for all Countries.
Third parties' products are only mentioned for information purposes, and constitute no engagement.
aprilia s.p.a. is not liable in any way for the performance or use of these products.
DECA S.r.l.
via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail:deca@decaweb.it
www.decaweb.it
On behalf of:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - Italy
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 29 190
www.aprilia.com
www.serviceaprilia.com
0-3
INTRODUCTION
Sportcity 125 - 200
OWNER'S MANUALS
0-4
INTRODUCTION
Sportcity 125 - 200
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS
# = number
< = less than
> = greater than
≤ = equal or less than
≥ = equal or greater than
~ = approximately
∞ = infinite
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = more or less
a.c = alternating current
A = Ampere
Ah = Ampere per hour
API = American Petroleum Institute
AT = high voltage
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement (1 bar = 100 kPa)
d.c. = direct current
cc = cubic centimetres
CO = carbon monoxide
CPU = Central Processing Unit
DIN = German industrial standards (Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Electronic Control Unit
rpm = revolutions per minute
HC = unburnt hydrocarbons
ISC = Idle Speed Control
ISO = International Standardisation Organisation
kg = kilograms
kgm = kilogram metre (1 kgm = 10 Nm)
km = kilometres
km/h = kilometres per hour
kΩ = kilo Ohm
kPa = kiloPascal (1 kPa = 0.01 bar)
KS = clutch side (from the German "Kupplungseite")
kW = kilowatt
l = litres
LAP = racetrack lap
LED = Light Emitting Diode
LEFT SIDE = left side
m/s = metres per second
max = maximum
mbar = millibar (1 mbar = 0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German "Magnetoseite")
MΩ = MegaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton metre (1 Nm = 0.1 kgm)
Ω = ohm
PICK-UP = pick-up
BDC = Bottom Dead Centre
TDC = Top Dead Centre
PPC = Pneumatic Power Clutch
RIGHT SIDE = right side
SAE = Society of Automotive Engineers
SAS = Secondary Air System
TEST = diagnostic check
0-5
INTRODUCTION
Sportcity 125 - 200
0-6
GENERAL INFORMATION
Sportcity 125 - 200
GENERAL INFORMATION 1
1-1
GENERAL INFORMATION
Sportcity 125 - 200
SUMMARY
1.1. STRUCTURE OF THE MANUAL...................................................................................................................... 3
1.1.1. CONVENTIONS USED IN THE MANUAL ................................................................................................. 3
1.1.2. SAFETY WARNINGS ................................................................................................................................ 4
1.2. GENERAL RULES............................................................................................................................................ 5
1.2.1. BASIC SAFETY RULES ............................................................................................................................ 5
1.3. DANGEROUS ELEMENTS............................................................................................................................... 8
1.3.1. WARNINGS ............................................................................................................................................... 8
1.4. RUNNING-IN .................................................................................................................................................. 12
1.4.1. RUNNING-IN ........................................................................................................................................... 12
1.5. VEHICLE IDENTIFICATION ........................................................................................................................... 13
1.5.1. POSITION OF THE SERIAL NUMBERS ................................................................................................. 13
1-2
GENERAL INFORMATION
Sportcity 125 - 200
optional
catalytic version
- all versions
11kw derated version 11 kw
80km speed 80km/h
f.p full-power version
MP national certification
SF European certification (EURO 1 limits)
VERSION:
1-3
GENERAL INFORMATION
Sportcity 125 - 200
Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a
personal injury hazard. Non-compliance with the indications given in the messages preceded by this
symbol may result in serious risks for you and other people's safety and for the vehicle!
DANGER
Indicates a potential hazard which may result in serious injury or even death.
WARNING
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
CAUTION The word "CAUTION" in this manual identifies important information or instructions.
1-4
GENERAL INFORMATION
Sportcity 125 - 200
DANGER
Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of
consciousness or even lead to death.
FUEL
DANGER
The fuel used in internal combustion engines is highly flammable and can become explosive under
particular conditions.
Refuelling and engine service should take place in a well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and
any element that could ignite fuel or provoke explosions.
HIGH-TEMPERATURE COMPONENTS
The engine and the components of the exhaust system become very hot and remain hot for some time after the engine
has been stopped.
Before handling these components, wear insulating gloves or wait until the engine and the exhaust system have cooled
down.
DANGER
Wear latex gloves when servicing.
Gear fluid may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after handling engine oil.
Take it to the filling station where you usually buy it or to an oil salvage centre.
Wear latex gloves when servicing.
BRAKE FLUID
WARNING
When handling the brake fluid, take care not to spill it on the plastic, rubber or painted parts, since it
can damage them. When carrying out the maintenance operations on the braking system, use a clean
cloth to cover these parts.
Always wear safety goggles when working on the braking system.
The brake fluid is highly irritant. Avoid contact with your eyes.
If the brake fluid gets in contact with your eyes, carefully wash them with fresh water and immediately
seek medical advice.
1-5
GENERAL INFORMATION
Sportcity 125 - 200
HYDROGEN AND BATTERY FLUID
DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact with the skin.
Always wear tight gloves and protective clothes when handling this fluid.
In case of contact with skin, rinse with plenty of fresh water.
Always use a protection for your eyes since even a very small amount of the battery fluid can cause
blindness. In the event of contact with your eyes, carefully wash them with water for fifteen minutes
and then consult immediately an eye specialist.
Should you accidentally drink some fluid, drink abundant water or milk, then drink magnesia milk or
vegetable oil and immediately seek medical advice.
The battery gives off explosive gases and must be kept away from flames and sources of ignition or
heat; do not smoke near the battery.
Make sure the room is well-aerated when servicing or recharging the battery.
DANGER
Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or
inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the
engine and exhaust system to cool down; where possible, lift the motorcycle using adequate
equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system
which may still be hot to the touch to avoid scalds or burns.
Never put any mechanical parts or other vehicle components in your mouth when you have both
hands busy. None of the motorcycle components is edible. Some components are harmful to the
human body or toxic.
Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling
procedure. Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly
to avoid disturbing any parts unless strictly necessary. Do not polish matt-painted surfaces with
polishing paste.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean any rubber or plastic parts or the seat with alcohol, petrol or solvents. Clean with water
and mild detergent.
Always disconnect the battery negative (-) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.
For further warnings, see (DANGEROUS ELEMENTS)
1-6
GENERAL INFORMATION
Sportcity 125 - 200
BEFORE REMOVING THE COMPONENTS
• Clean off all dirt, mud, and dust and clear any foreign objects from the vehicle before disassembling any
components.
• Use the model-specific special tools where specified.
DANGER
Never reuse a circlip or snap ring. These parts must always be renewed once they have been
disturbed.
When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow
fitment to the shaft.
Make it a rule to check that a newly-fitted circlip or snap ring has located fully into its groove.
Never clean a bearing with compressed air.
CAUTION All bearings must rotate freely with no hard spots or noise. Replace any bearings that do not meet these
requirements.
- Use ORIGINAL aprilia SPARE PARTS only.
- Use the specified lubricants and consumables.
- Where possible, lubricate a part before assembly.
- When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten
evenly, in subsequent steps until achieving the specified torque.
- Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have
a damaged thread.
- Lubricate the bearings abundantly before assembly.
- Make it a rule to check that all components you have fitted are correctly in place.
- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then operate
the motorcycle in a private estate area or in a safe area away from traffic.
- Clean all mating surfaces, oil seal edges and gaskets before assembly. Apply a thin layer of lithium grease along the
edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).
ELECTRICAL CONNECTORS
To disconnect the electrical connectors, follow the procedures below. Failure to comply with these procedures may lead
to irreparable damage to the connector and the wiring as well.
If present, press the special safety hooks.
WARNING
Do not pull cables to disconnect the two connectors.
• Grasp the two connectors and disconnect them by pulling them in the two opposite directions.
• In case of dirt, rust, moisture, etc.., thoroughly clean the inside of the connectors with compressed air.
• Make sure that the cables are correctly fitted inside the connector terminals.
CAUTION The two connectors have just one correct positioning. Make sure to position them in the right direction.
• Then fit the two connectors. Make sure they are correctly coupled (a click will be heard if hooks are present).
DANGER
Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other
suspension parts play a fundamental role to ensure vehicle safety. Make sure that these values are
always within the specified limits.
Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a
torque wrench.
Failure to comply with these recommendations could lead to the loosening and detachment of one of
these parts with a consequent locking of the wheel or other serious troubles affecting the vehicle
manoeuvrability, and thus the risk of falls and serious injuries or death.
1-7
GENERAL INFORMATION
Sportcity 125 - 200
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
Refuelling and engine servicing should take place in a well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and
any element that could ignite fuel or provoke explosions.
Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts.
In the event of accidental fuel spillage, make sure the affected area is fully dry before starting the
engine. Fuel expands from heat and when left under direct sunlight.
Never fill the fuel tank up to the brim. Tighten the filler cap securely after each refuelling.
Avoid contact with skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between
different containers using a hose.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only unleaded petrol with 95 RON and 85 MON octane rating minimum.
LUBRICANTS
DANGER
A good lubrication ensures the vehicle safety.
Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean
type of lubricant can lead to the engine or gearbox seizure, thus causing serious accidents, personal
injury or even death.
Gear fluid may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil in the environment.
Take it to the filling station where you usually buy it or to an oil salvage centre.
WARNING
When filling the vehicle with this oil, take care not to spill it out. Immediately clean spilt oil, or it might
damage the vehicle paintwork.
In case of contact with oil, the tyre surface will become very slippery, thus becoming a serious danger
for your safety.
In case of leaks, do not use the vehicle. Check and trace the cause of leaks and proceed to repair.
Engine oil
DANGER
Engine oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil in the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves when servicing.
DANGER
Front suspension response can be modified to a certain extent by changing damping settings and/or
selecting a particular grade of oil. Standard oil grade is: SAE 20 W. Choose suitable viscosity grades
according to the desired set-up (SAE 5W softer, 20W less soft).
The two grades can also be mixed in varying solutions to obtain the desired response.
1-8
GENERAL INFORMATION
Sportcity 125 - 200
BRAKE FLUID
CAUTION This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent
hydraulic circuit. The information provided below applies to both braking systems.
DANGER
Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts
that most ensure your safety and for this reason they must always be perfectly working. Failure to
comply with these recommendations will probably lead to a crash or an accident, with a consequent
risk of personal injury or death.
A wet surface reduces brakes efficiency.
DANGER
In case of wet ground the braking distance will be doubled, since both brakes and tyre grip on the
road surface are extremely reduced by the water present on the road surface.
Any water on brakes, after washing the vehicle or driving on a wet road surface or crossing puddles
or gips, can wet brakes so as to greatly reduce their efficiency.
Failure to comply with these recommendations may lead to serious accidents, with a consequent risk
of severe personal injuries or death.
Brakes are critical safety components. Do not ride the vehicle in case brakes are not working at their
best.
Check for brakes proper operation before every trip.
Brake fluid is an irritant. Avoid contact with eyes or skin.
In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental
contact with eyes, contact an eye specialist or seek medical advice.
DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will
damage.
DANGER
Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up
level, as this will damage the braking system.
Do not use brake fluid from containers which have been kept open or in storage for long periods.
Any sudden changes in play or hardness in the brake levers are warning signs of problems with the
hydraulic circuits.
Ensure that the brake discs and brake linings have not become contaminated with oil or grease. This
is particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Prevent accidental ingress of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.
DISC BRAKES
DANGER
The brakes are the parts that most ensure your safety
and for this reason they must always be perfectly working; check them before every trip.
A dirty disc soils the pads.
Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser.
Perform the maintenance operations with half the indicated frequency if the vehicle is used in rainy or
dusty areas, on uneven surfaces or for racing.
Check brake pads for wear.
When the brake pads wear out, the level of the fluid decreases to automatically compensate for their
wear.
The front brake fluid reservoir is located on the right handlebar, near the front brake lever.
The rear brake fluid reservoir is located under the right fairing.
Do not use the vehicle if the braking system leaks fluid.
1-9
GENERAL INFORMATION
Sportcity 125 - 200
COOLANT
DANGER
Coolant is toxic when ingested and is an irritant, contact with eyes or skin may cause irritation.
In the event of contact with your skin or eyes, rinse repeatedly with abundant water and seek medical
advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and
seek medical advice immediately.
DO NOT RELEASE INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
DANGER
Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear
latex gloves when servicing.
Do not ride when coolant is below the minimum level.
Coolant mixture is a 50% solution of water and antifreeze. This is the ideal solution for most operating temperatures and
provides good corrosion protection.
This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce the need for top-
ups.
In addition, less water evaporation means fewer minerals salts depositing in the radiator, which helps preserve the
efficiency of the cooling system.
When the temperature drops below zero degrees centigrade, check the cooling system frequently and add more
antifreeze (up to 60% maximum) to the solution, if needed.
Use distilled water in the coolant mixture. Tap water will damage the engine.
Refer to the chart given below and add water with the quantity of antifreeze to obtain a solution with the desired freezing
point:
1 - 10
GENERAL INFORMATION
Sportcity 125 - 200
TYRES
WARNING
If tyres are excessively inflated, the vehicle will be hard, difficult and uncomfortable to ride.
In addition, the roadworthiness, mainly on wet surfaces and during cornering, will be impaired.
Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle.
In this case too, both vehicle roadworthiness, manoeuvrability and brake efficiency will be impaired.
Tyres changing, repair, maintenance and balancing must be carried out by specialized technicians
using suitable equipment.
When new, tyres can have a thin slippery protective coating. Drive carefully for the first kilometres
(miles).
Never use rubber treating substances on tyres.
In particular, avoid contact with fluid fuels, leading to a rapid wear.
In case of contact with oil or fuel, do not clean but change the tyres.
DANGER
Some of the factory-assembled tyres of this vehicle are provided with wear indicators.
There are several kinds of wear indicators.
For more information on how to check the wear, contact your Dealer.
Visually check if the tyres are worn and in this case have them changed.
If a tyre deflates while driving, stop immediately.
Avoid hard brakings or moves and do not close throttles too abruptly.
Slowly close the throttle grip, move to the edge of the road and use the engine brake to slow down
until coming to a halt.
Failure to comply with these recommendations may lead to accidents, with a consequent risk of
personal injuries or death.
Do not install tyres with air tube on rims for tubeless tyres and vice versa.
1 - 11
GENERAL INFORMATION
Sportcity 125 - 200
1.4. RUNNING-IN
1.4.1. RUNNING-IN
Correct engine running-is essential to ensuring proper performance and durability.
Twisty, hilly roads are ideal for an effective running-in of engine, suspension and brakes.
Vary speed frequently during the running-in period.
This will allow engine parts to be alternately loaded and unloaded, allowing them to cool down when unloaded.
While it is important to put some stress on engine components during running-in, it is equally important to avoid extreme
load conditions.
WARNING
Only after the first 500 km (312 mi) of running-in is it possible to obtain the best acceleration
performance from the vehicle.
WARNING
After the first 1000 km (625 mi), carry out the checking operations indicated in the column "After
running-in", see REGULAR SERVICE INTERVALS CHART, in order to avoid hurting yourself or other
people and/or damaging the vehicle.
1 - 12
GENERAL INFORMATION
Sportcity 125 - 200
ENGINE NUMBER
1 - 13
PERIODIC MAINTENANCE
Sportcity 125 - 200
PERIODIC MAINTENANCE 2
2-1
PERIODIC MAINTENANCE
Sportcity 125 - 200
SUMMARY
2.1. TECHNICAL INFORMATION............................................................................................................................ 3
2.1.1. TECHNICAL DATA.................................................................................................................................... 3
2.1.2. SCHEDULED MAINTENANCE CHART .................................................................................................... 5
2.1.3. LUBRICANT CHART ................................................................................................................................. 6
2.1.4. TIGHTENING TORQUE SETTINGS ......................................................................................................... 7
2.1.5. ARRANGEMENT OF THE MAIN ELEMENTS......................................................................................... 11
2.1.6. INSTRUMENT PANEL OPERATION....................................................................................................... 13
2.2. SCHEDULED MAINTENANCE....................................................................................................................... 18
2.2.1. BRAKING SYSTEM................................................................................................................................. 18
2.2.2. AIR FILTER ............................................................................................................................................. 22
2.2.3. COOLANT ............................................................................................................................................... 23
2.2.4. CHECKING AND TOPPING UP TRANSMISSION OIL LEVEL ............................................................... 24
2.2.5. CHANGING TRANSMISSION OIL .......................................................................................................... 25
2.2.6. ENGINE OIL ............................................................................................................................................ 26
2-2
PERIODIC MAINTENANCE
Sportcity 125 - 200
DIMENSIONS
Max. length 1965 mm (77.36 in.)
Max. width 730 mm (28.74 in.)
Max. height (to the headlight fairing) 1130 mm (44.49 in.)
Seat height 790 mm (31.10 in.)
Wheelbase 1360 mm (53.54 in.)
Minimum ground clearance 130 mm (5.11 in.)
Weight in running order 148 kg (328.28 lb)
ENGINE
Model M281M
Model M282M
Type One-cylinder, 4-stroke engine with 4 valves, forced
lubrication with wet sump, one overhead camshaft.
Total displacement 124 cu. cm (7.57 cu in).
Total displacement 198 cu. cm (12.08 cu in).
Bore / stroke 57 mm /48.6 mm (2.24 in /1.91 in).
Bore / stroke 72 mm /48.6 mm (2.83 in /1.91 in).
Compression ratio 12.5 ± 0.5: 1
Compression ratio 11.5 ± 0.5 : 1
Starting Electric starter
Engine idling speed 1600 ± 100 rpm
Clutch Automatic dry centrifugal clutch
Gearbox Automatic
Cooling Liquid cooling, forced circulation with centrifugal pump.
Intake valve clearance 0.10
Exhaust valve clearance 0.15
CAPACITY
Fuel (reserve included) 8.6 litres (2.27 gal)
Fuel reserve 1.4 litres (0.37 gal)
Engine oil
- changing engine oil and oil filter 1100 cu. cm (67.12 cu in).
- change for engine overhaul 1150 cu. cm (70.18 cu in).
Transmission fluid 250 cu. cm (15.25 cu in).
Front fork fluid 135 ± 1 cu cm ( 8.24 ± 0.06 cu in) per leg
Coolant 1.5 litres (0.39 gal) (50% water + 50% antifreeze with
ethylene glycol)
Seats 2
Vehicle max. load (rider + passenger + luggage) 210 kg (463 lb)
TRANSMISSION SYSTEM
Converter Stepless automatic converter
Primary V-belt
Final Gear-type
Total engine/wheel ratio
- minimum 36.5
- maximum 10.95
Total engine/wheel ratio
- minimum 22.36
- maximum 7.88
CARBURETTOR
Model CVK7 30 Keihin
FUEL SYSTEM
Type Vacuum pump
Fuel Premium grade leaded petrol (4 Stars ) or unleaded
petrol with 95 RON and 85 MON octane rating minimum.
FRAME
Type One beam at the front, split in two overlapping cradles at
the rear, in steel tubes with high yield point
Steering head angle 26.5°
2-3
PERIODIC MAINTENANCE
Sportcity 125 - 200
SUSPENSIONS
Front hydraulically operated telescopic fork
Stroke 100 mm (3.94 in.)
Rear no. 1 hydraulic, double-effect shock absorber with preload
adjustment
Stroke 80 mm (3.15 in.)
BRAKES
Front Disc - Ø 260 mm (10.24 in) with hydraulic transmission.
Rear Disc - Ø 220 mm (8.66 in) with hydraulic transmission.
WHEEL RIMS
Type in light alloy
Front 2.75 x 15"
Rear 3.00 x 15"
TYRES
Type tubeless
Front 120/70 - 15" 56 P
Rear 130/80 – 15" 63P
STANDARD INFLATION PRESSURE
Front 200 kPa (2.0 bar)
Rear 230 kPa (2.3 bar)
INFLATION PRESSURE WITH PASSENGER
Front 200 kPa (2.0 bar)
Rear 230 kPa (2.3 bar)
IGNITION
Type Capacity discharge ignition with variable advance
Spark advance Variable, managed by ECU. 5° minimum – 24°> 4000 rpm.
Spark advance Variable, managed by ECU. 5° minimum – 15°>
6000/8000 rpm.
SPARK PLUG
Standard spark plug NGK CR7EB
As an alternative NGK CR8EB – NGK CR9EB - CHAMPION RG6YG -
CHAMPION RG4HC
Spark plug gap 0.7 mm /0.8 mm (0.027 in /0.031 in).
ELECTRIC SYSTEM
Battery 12 V - 12 Ah
Fuses 20 - 15 - 7.5 A
Generator (with permanent magnet) 12 V – 180 W
LAMPS
Low/high beam 12 V - 55 W - H7
Parking light 12 V – 3 W
Turn indicator light 12 V – 10 W
Rear parking light/stoplight 12 V – 5 W / 21 W
Number plate light 12 V – 5 W
Instrument panel lighting LED
WARNING LIGHTS
Turn indicators LED
High beam LED
Fuel reserve LED
Alarm light LED
2-4
PERIODIC MAINTENANCE
Sportcity 125 - 200
1 = check and clean, adjust, lubricate or change, if necessary; 2 = clean; 3= change; 4= adjust.
Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas or on uneven
ground.
2-5
PERIODIC MAINTENANCE
Sportcity 125 - 200
2-6
PERIODIC MAINTENANCE
Sportcity 125 - 200
SCREW / NUT
TIGHTENING
QUANTITY
SETTINGS
TORQUE
( Nm )
Notes
DESCRIPTION
HANDLEBAR
Handlebar to fork fastener 1 10x70 48±20%
Safety screw 1 8x50 20±20%
Adjust
Steering adjuster nut 1 M36x1 15±20%
steering play
2-7
PERIODIC MAINTENANCE
Sportcity 125 - 200
REAR BODYWORK
Cat's eye to number plate holder fastener 2 NUT M4 1.5±20%
Number plate to number plate holder fastener 1 4.2x16 1±20%
Tail light fastener to right and left tail guards 4 3.9x14 1±20%
Right and left tail guards to helmet compartment fastener 2 5x16 4±20%
Tail light cover to number plate holder fastener 1 4.2x16 1±20%
Number plate holder to right and left tail guards fastener 2 5x16 3±20%
Number plate holder to rear mudguard frame fastener 1 6x16 5±20%
Luggage rack cover to luggage rack fastener 4 3.9x14 1±20%
Right and left tail guards to helmet compartment fastener 2 3.9x14 1±20%
Fuel sensor door fastener onto helmet compartment 1 3.9x14 1±20%
Right and left tail guards lower cover fastener to right and left tail
6 5x16 3±20%
guards
CENTRE BODYWORK
Central inspection cover fastener onto helmet compartment 2 3.9x14 1±20%
Central inspection cover fastener onto right and left side body
2 5x16 3±20%
panels
Left side inspection cover fastener 3 5x16 3±20%
Right side inspection cover fastener 3 5x16 3±20%
Battery cover fastener 2 5x16 3±20%
Footpeg platform fastener 4 5x16 3±20%
Right to left lower shield fastener 3 5x16 3±20%
Glove compartment door fastener to inner front shield 4 3.9x14 1±20%
Inner front shield fastener to outer front shield 6 3.9x14 1±20%
Inner front shield fastener to outer front shield 2 4.2x25 1±20%
Multipurpose net fastener to inner front shield 4 3.9x14 1±20%
Glove compartment door reinforcement fastener 4 3.9x14 1±20%
Bag hook fastener 2 4.2x25 1±20%
Air vent fastener onto inner front shield 2 3.9x14 1±20%
FRONT AND REAR BRAKE
Calliper fastener onto fork 2 8x30 25±20% with grease
Calliper fastener onto muffler plate 1 8x20 25±20% with grease
Cable guide tube fastener onto connecting rod 1 6x16 10±20%
Cable guide tube fastener onto conveyor 1 6x16 5±20%
Right and left master cylinder fasteners onto handlebar 4 M6 10±20%
Rear calliper support fastener to muffler plate 2 8x60 25±20%
Rear calliper support fastener to muffler plate 1 8x60 25±20% with grease
Cable guide tube fastener onto fork 1 6x16 10±20%
2-8
PERIODIC MAINTENANCE
Sportcity 125 - 200
FRONT BODYWORK
Right and left air vents fasteners onto inner front shield 2 3.9x14 1±20%
Right and left turn indicator fasteners onto outer front shield 4 3.9x14 1±20%
2-9
PERIODIC MAINTENANCE
Sportcity 125 - 200
REAR WHEEL
Rear wheel fastener 1 - 110±20%
Speed sensor screw fastener 2 6x12 10±20%
Speed sensor fastener onto muffler plate 1 6x16 10±20%
STAND
Stand fastener onto engine 1 M10 27±20% -
ENGINE
Muffler plate fastener onto engine 2 8x45 25±20% -
Fuel breather hose cable guide onto casing 1 6x25 10±20% -
REAR SUSPENSION
Right and left shock absorbers fastener to frame 2 M10x40 40±20%
Shock absorber fastener onto engine bracket 1 M10x45 40±20%
Shock absorber fastener onto muffler plate 1 NUT M10 40±20%
Shock absorber bracket fastener onto engine 2 2x50 25±20%
REAR SUSPENSION
Sensor to tank fastener 4 NUT M4 1.5±20%
Fuel coupling clamp fastener 1 tie 1±20%
5x20 self-
Fuel tank fastener onto helmet compartment 2 2±20%
tapping
Fuel pump fastener onto helmet compartment 2 M2x50 2±20%
2 - 10
PERIODIC MAINTENANCE
Sportcity 125 - 200
Key:
1. Expansion tank
2. Coolant expansion tank plug
3. Rear brake fluid reservoir
4. Left rear-view mirror
5. Bag hook
6. Air filter
7. Centre stand
8. Engine oil filler plug
9. Left passenger footpeg
10. Battery
11. Fuse carrier
12. Frame number
13. Front cover
2 - 11
PERIODIC MAINTENANCE
Sportcity 125 - 200
Key:
2 - 12
PERIODIC MAINTENANCE
Sportcity 125 - 200
Key:
2 - USER'S INTERFACE
Using the Mode button (2), located on the handlebar right-side, it is possible to choose many functions: clock setting,
odometer function (ODO), trip meter (TRIP), battery voltage measurement and resetting the trip meter.
Odometer (ODO)
When the instrument panel is switched on, the multifunction display (1) shows the odometer function (ODO).
TRIP function (TRIP)
With the odometer display (ODO), press the Mode button (2) once to display the function (TRIP).
Hold down the Mode button (2) for at least three seconds to reset stored trip value.
Battery voltage
With the odometer display, press the Mode button (2) twice to display the battery function.
When battery voltage is displayed on multifunction display (1), hold down the Mode button (2) for more than ten seconds
to change the unit of measurement from kilometres (Km) to miles (Mi).
While pressing the button, the current unit of measurement is flashing.
Should the button be pressed for less than ten seconds, the conversion will not take place.
CAUTION For safety reasons, it is possible to set this function when vehicle is stopped only.
• Hold down the Mode button (2) for at least three seconds. The column dividing hours and minutes will start
flashing.
• Set the hour value, it will increase by one unit every time you press the Mode button (2).
• Hold down the Mode button (2) again for at least three seconds to shift to minute setting. The indicated value will
increase by one unit every time the Mode button (2) is pressed.
Hold down the Mode button (2) for at least three seconds to go back to hour setting.
If no key has been touched for three seconds, the display will automatically quit the clock setting function.
2 - 13
PERIODIC MAINTENANCE
Sportcity 125 - 200
3 – PINOUT
The numbers are printed on the plastic element of the pins and on the connector body.
4 – SERVICE
Upon vehicle start-up, just after the ignition check sum, if there are less than 300 km (200 mi) to go before next Service,
the relevant icon will flash for 5 seconds.
Once the mileage for Service has been reached, the icon is kept on until Service reset is carried out.
It is possible to reset the light even if the mileage is lower, up to 300 km (200 mi), than the mileage for Service. During
the 300 km (200 mi) before the Service warning light comes on, the light flashes for 5 times at every key-ON.
The warning should first come on at 1000 km (625 mi). Then it is preset to come on at 6000 km (3750 mi), 12000 km
(7500 mi), and so on.
5 – SERVICE RESET
2 - 14
PERIODIC MAINTENANCE
Sportcity 125 - 200
Turn the key to ON, and allow 10 seconds.
1) Every time the battery is connected, the fuel indicator indicates full tank regardless of the quantity of fuel inside the
tank and it takes it about 80 seconds to refresh. After the refresh, the indicator indicates the correct value.
2) If the fuel tank is emptied with engine off and using an external pump, when the vehicle is being started, the
instrument will display the fuel quantity that was in the tank before emptying. Even in this case, allow 80 seconds to read
the correct fuel level.
In fact, the multifunction digital computer keeps in the memory the fuel available when turning the key to OFF; when the
battery connection is restored, the computer does not have any valid value in memory and it is therefore not able to
detect if the tank is emptied with an external pump.
7 – DIAGNOSTICS
2 - 15
PERIODIC MAINTENANCE
Sportcity 125 - 200
Battery fault
Fuel sensor
Temperature sensor
2 - 16
PERIODIC MAINTENANCE
Sportcity 125 - 200
Should the instrument panel detect an infinite resistance
(broken circuit), the general alarm light comes on and the
relevant icon flashes on the display.
Summary table
AFFECTED
GENERAL ALARM INDICATION
ELECTRIC FAULT ICON Notes
LIGHT ON SEGMENTS
CIRCUIT
Engine oil is really
OIL PRESSURE YES on
low oil pressure - missing
It is recommended
broken circuit NO off to periodically check
- for correct operation
Useful indication
mainly in case of
voltage below about
BATTERY voltage regulator
10 V or above about NO flashing -
VOLTAGE outputting excessive
16 V
voltage to the
battery
It indicates full tank
FUEL LEVEL short-circuit NO normal
all on even if tank is empty
The orange reserve
YES flashing light does not turn
broken circuit off on
WATER temperature above
YES normal
TEMPERATURE 115 °C all on
short-circuit (or
YES flashing
above 140 °C) all on
broken circuit YES flashing off
2 - 17
PERIODIC MAINTENANCE
Sportcity 125 - 200
Check
CAUTION Place the vehicle on a firm and flat surface.
• Position the vehicle on the centre stand.
• Make sure that the fluid in the reservoir is above the
"MIN" level mark.
If the fluid does not reach at least the "MIN" mark, proceed
as follows:
WARNING
Brake fluid level decreases as the brake pads
wear down.
TOPPING UP
WARNING
Danger: brake fluid could leak out. Do not
operate the front brake lever if the screws are
loose or, most important, if the brake fluid
reservoir cover has been removed. Use a cloth
under the brake fluid reservoir.
2 - 18
PERIODIC MAINTENANCE
Sportcity 125 - 200
WARNING
Avoid long exposure of brake fluid to air. Brake
fluid is hygroscopic and will absorb moisture
from the air. Keep the brake fluid reservoir
open JUST LONG ENOUGH to top up level.
WARNING
Never top up to maximum level, just top up
until level is above “MIN” mark. It is advisable
to top up until reaching the "MAX" level only
with new pads. Brake fluid level decreases as
the brake pads wear down. Do not reach the
"MAX" level with worn out pads, since this will
cause a fluid outflow when the pads are
changed.
2 - 19
PERIODIC MAINTENANCE
Sportcity 125 - 200
2 - 20
PERIODIC MAINTENANCE
Sportcity 125 - 200
BLEEDING THE BRAKING SYSTEM
The air, if any, present inside the hydraulic circuit will serve
as "pad" by absorbing most of the pressure coming from the
brake master cylinder and thus reducing the calliper
efficiency during braking. If some air is present inside the
circuit, the brake control is "spongy" and the braking
efficiency is reduced.
DANGER
It is fundamental that air is bled off the
hydraulic circuit after the brakes have been
refitted and the braking system has been
restored to its standard operating conditions,
since it would be very dangerous for the
vehicle and the rider not to do so.
WARNING
Do not soil brake pads or disc with brake fluid.
WARNING
Tighten bleed valve (4-5) before releasing the
lever in order to prevent air from getting in the
brake circuit.
WARNING
After reassembly, repeatedly pull the brake
lever and check the braking system for correct
operation.
2 - 21
PERIODIC MAINTENANCE
Sportcity 125 - 200
WARNING
The partial cleaning of the filter does not
exclude or postpone the replacement of the
filter itself. Do not start the engine when the air
filter is not in place. Do not clean the filtering
element with petrol or solvents, since they may
cause a fire in the fuel supply system, with
serious danger for the persons in the vicinity
and for the vehicle.
CLEANING
WARNING
The partial cleaning of the filter does not
exclude or postpone the replacement of the
filter itself.
Do not start the engine when the air filter is not
in place.
Do not clean the filtering element with petrol or
solvents, since they may cause a fire in the fuel
supply system, with serious danger for the
persons in the vicinity and for the vehicle.
WARNING
Do not use filters that have already been used.
• Change the air filter with a new one of the same type.
2 - 22
PERIODIC MAINTENANCE
Sportcity 125 - 200
2.2.3. COOLANT
CHECKING AND TOPPING UP THE COOLANT LEVEL
WARNING
Wait for the engine to cool down before
checking or topping up coolant level.
If not so:
• Loosen the filler plug (2) (by turning it anticlockwise by
two turns), without removing it.
• Wait a few seconds in order to release any residual
pressure.
• Unscrew and remove the plug.
WARNING
Do not put additives or other substances into
the fluid.
WARNING
In case of excessive consumption of coolant
and in case the expansion reservoir remains
empty, make sure that there are no leaks in the
circuit.
2 - 23
PERIODIC MAINTENANCE
Sportcity 125 - 200
Check
WARNING
Allow several minutes for the engine and
exhaust system to cool down.
TOPPING UP
2 - 24
PERIODIC MAINTENANCE
Sportcity 125 - 200
WARNING
Allow several minutes for the engine and
exhaust system to cool down.
WARNING
Used oil contains substances that are very
dangerous for the environment. Dispose of
used oil in accordance with applicable
regulations.
2 - 25
PERIODIC MAINTENANCE
Sportcity 125 - 200
2.2.6. ENGINE OIL
CHECKING AND TOPPING UP
Check
WARNING
Allow several minutes for the engine and
exhaust system to cool down.
Stop the engine and let it cool down, in order to allow the oil
to flow into the crankcase and to cool down.
CAUTION Failure to perform the operations described above
may result in the incorrect measurement of the engine oil
level.
• Unscrew and extract the plug/dipstick (1).
• Clean the part in contact with the oil with a clean cloth.
• Tighten the plug/dipstick (1) completely, screwing it into
the filling hole (2).
• Withdraw the plug/dipstick (1) again and read the oil
level on the dipstick itself:
DANGER
Never exceed the "MAX" mark or let oil level
drop below the "MIN" mark, as this may lead to
severe engine damage.
TOPPING UP
2 - 26
PERIODIC MAINTENANCE
Sportcity 125 - 200
WARNING
Allow several minutes for the engine and
exhaust system to cool down.
WARNING
Used oil contains substances that are very
dangerous for the environment. Dispose of
used oil in accordance with applicable
regulations.
• Loosen and remove the oil drain plug (3) and let engine
oil fully drain inside the container.
• Smear with oil the filter O-rings and install a new
cartridge filter (4).
• Tighten oil drain plug (3).
2 - 27
FUEL SYSTEM
Sportcity 125 - 200
FUEL SYSTEM 3
3-1
FUEL SYSTEM
Sportcity 125 - 200
SUMMARY
3.1. FUEL TANK ...................................................................................................................................................... 3
3.1.1. FUEL SUPPLY SYSTEM DIAGRAM ......................................................................................................... 3
3.1.2. REMOVING THE FUEL TANK .................................................................................................................. 4
3.1.3. REMOVING THE FUEL SENSOR............................................................................................................. 8
3.2. AIR FILTER..................................................................................................................................................... 10
3.2.1. REMOVING THE AIR BOX...................................................................................................................... 10
3.2.2. REMOVING THE AIR FILTER................................................................................................................. 12
3.3. CARBURETTOR............................................................................................................................................. 13
3.3.1. CARBURETTOR DIAGRAM.................................................................................................................... 13
3.3.2. REMOVING THE CARBURETTOR......................................................................................................... 14
3-2
FUEL SYSTEM
Sportcity 125 - 200
Key:
1. Fuel tank;
2. Fuel level sensor;
3. Fuel collection rubber element;
4. Fuel hose;
5. Hose;
6. Valve preventing downflow;
7. Fuel filter;
8. Fuel pump;
9. Vacuum hose;
10. Complete coupling;
11. SAS valve cut-off;
12. Vacuum pick-up point;
13. Carburettor delivery
3-3
FUEL SYSTEM
Sportcity 125 - 200
3-4
FUEL SYSTEM
Sportcity 125 - 200
3-5
FUEL SYSTEM
Sportcity 125 - 200
3-6
FUEL SYSTEM
Sportcity 125 - 200
3-7
FUEL SYSTEM
Sportcity 125 - 200
WARNING
Pay attention to the tabs and their housings.
3-8
FUEL SYSTEM
Sportcity 125 - 200
WARNING
Ensure that the tank is not full since the sensor
housing is lower than the tank overflow level.
WARNING
Remove the sensor and immediately plug the
sensor inlet opening with a rag so to avoid
breathing fuel vapours.
3-9
FUEL SYSTEM
Sportcity 125 - 200
3 - 10
FUEL SYSTEM
Sportcity 125 - 200
• Loosen and remove the two screws and remove the air
box front cover.
3 - 11
FUEL SYSTEM
Sportcity 125 - 200
3 - 12
FUEL SYSTEM
Sportcity 125 - 200
3.3. CARBURETTOR
3.3.1. CARBURETTOR DIAGRAM
Key:
SPECIFICATIONS
Component
125 cc 200 cc
Model Kehin CVK7 30 Kehin CVK 7 30
Throttle Ø 29 mm Ø 29 mm
Engine-side fitment Ø 40 mm
Ø 40 mm
Float - -
Fuel inlet valve - pin housing 1.2 1.2
Starter air inlet hole 150 150
Starter nozzle 42 42
Minimum jet 35 38
Idle screw - choke on - rpm 2 2½
Minimum air hole 130 115
Maximum air hole 70 70
Maximum jet 105 100
Throttle valve Standard Standard
Atomiser Ø 2.8 mm Ø 2.8 mm
Tapered needle NDVA NDVA
Notch - -
3 - 13
FUEL SYSTEM
Sportcity 125 - 200
• Remove the clamp and slide out the heater hose (1).
• Plug the heater hose (1) to prevent coolant from
spilling.
WARNING
Proceed with care.
While removing, do not damage the tabs.
3 - 14
FUEL SYSTEM
Sportcity 125 - 200
3 - 15
ENGINE
Sportcity 125 - 200
ENGINE 4
4-1
ENGINE
Sportcity 125 - 200
SUMMARY
4.1. ENGINE ............................................................................................................................................................ 3
4.1.1. REMOVING THE ENGINE FROM THE FRAME ....................................................................................... 3
4.1.2. INSTALLING THE ENGINE ....................................................................................................................... 8
4.2. SECONDARY AIR SYSTEM........................................................................................................................... 13
4.2.1. SECONDARY AIR SYSTEM GENERAL INFORMATION ....................................................................... 13
4.2.2. TROUBLESHOOTING............................................................................................................................. 15
4-2
ENGINE
Sportcity 125 - 200
4.1. ENGINE
4.1.1. REMOVING THE ENGINE FROM THE FRAME
• Before removing the crankcase, remove all outer
structures, the fuel tank, the air box, the exhaust
silencer.
• Pull up the platform lower protection and turn it to
remove it.
4-3
ENGINE
Sportcity 125 - 200
4-4
ENGINE
Sportcity 125 - 200
4-5
ENGINE
Sportcity 125 - 200
4-6
ENGINE
Sportcity 125 - 200
• Slide out the pin from the left side and collect washer
and spacer.
• Remove the engine from behind.
4-7
ENGINE
Sportcity 125 - 200
• Working on the right side, tighten the nut onto the pin.
4-8
ENGINE
Sportcity 125 - 200
4-9
ENGINE
Sportcity 125 - 200
4 - 10
ENGINE
Sportcity 125 - 200
• Fit the rear brake calliper plate with rear brake calliper
and speed sensor, tighten the two screws.
• Fit the rear brake line and the speed sensor cable and
secure them to the frame by fitting the cable guide.
4 - 11
ENGINE
Sportcity 125 - 200
4 - 12
ENGINE
Sportcity 125 - 200
4 - 13
ENGINE
Sportcity 125 - 200
4 - 14
ENGINE
Sportcity 125 - 200
4.2.2. TROUBLESHOOTING
4 - 15
CYCLE PARTS
Sportcity 125 - 200
CYCLE PARTS 5
5-1
CYCLE PARTS
Sportcity 125 - 200
SUMMARY
5.1. OUTER STRUCTURES.................................................................................................................................... 3
5.1.1. REMOVING THE SEAT............................................................................................................................. 3
5.1.2. REMOVING THE PASSENGER GRAB HANDLE ..................................................................................... 4
5.1.3. REMOVING THE TAIL GUARD................................................................................................................. 5
5.1.4. REMOVING THE CENTRAL INSPECTION COVER ................................................................................. 8
5.1.5. REMOVING THE PASSENGER FOOTREST ........................................................................................... 9
5.1.6. REMOVING THE RIGHT AND LEFT SIDE BODY PANELS ................................................................... 10
5.1.7. REMOVING THE RIGHT INSPECTION COVER .................................................................................... 12
5.1.8. REMOVING THE FOOTREST................................................................................................................. 13
5.1.9. REMOVING THE LOWER SHIELD ......................................................................................................... 14
5.1.10. REMOVING THE INNER FRONT SHIELD .......................................................................................... 16
5.1.11. REMOVING THE INSTRUMENT PANEL ............................................................................................ 18
5.1.12. REMOVING THE FRONT COVER ...................................................................................................... 21
5.1.13. REMOVING THE EXTERNAL FRONT SHIELD .................................................................................. 22
5.1.14. REMOVING AND DISASSEMBLING THE HEADLIGHT FAIRING ...................................................... 24
5.1.15. REMOVING THE FRONT MUDGUARD .............................................................................................. 26
5.1.16. REMOVING THE REAR MUDGUARD................................................................................................. 27
5.2. EXHAUST SYSTEM ....................................................................................................................................... 29
5.2.1. REMOVING THE EXHAUST SILENCER ................................................................................................ 29
5.2.2. REMOVING THE EXHAUST SYSTEM.................................................................................................... 30
5.3. FRAME ........................................................................................................................................................... 31
5.3.1. REMOVING THE HANDLEBAR .............................................................................................................. 31
5.4. FRONT WHEEL.............................................................................................................................................. 34
5.4.1. FRONT WHEEL DIAGRAM ..................................................................................................................... 34
5.4.2. REMOVING THE FRONT WHEEL .......................................................................................................... 35
5.4.3. DISASSEMBLING THE FRONT WHEEL ................................................................................................ 36
5.4.4. CHECKING THE FRONT WHEEL COMPONENTS ................................................................................ 37
5.5. REAR WHEEL ................................................................................................................................................ 38
5.5.1. REAR WHEEL DIAGRAM ....................................................................................................................... 38
5.5.2. REMOVING THE REAR WHEEL ............................................................................................................ 39
5.6. BRAKING SYSTEM ........................................................................................................................................ 40
5.6.1. BRAKING SYSTEM DIAGRAM ............................................................................................................... 40
5.6.2. CHANGING THE PADS........................................................................................................................... 41
5.6.3. CHECKING THE BRAKE DISC ............................................................................................................... 43
5.6.4. REMOVING THE BRAKE DISC .............................................................................................................. 44
5.7. STEERING...................................................................................................................................................... 45
5.7.1. STEERING DIAGRAM............................................................................................................................. 45
5.7.2. CHECKING THE COMPONENTS ........................................................................................................... 46
5.8. FRONT FORK................................................................................................................................................. 47
5.8.1. FRONT FORK DIAGRAM........................................................................................................................ 47
5.8.2. REMOVING THE FORK LEGS................................................................................................................ 49
5.8.3. DISASSEMBLING THE STANCHION TUBES AND SLIDERS................................................................ 50
5.8.4. DRAINING THE FRONT FORK............................................................................................................... 53
5.8.5. FILLING THE FORK ................................................................................................................................ 55
5.8.6. CHECKING THE COMPONENTS ........................................................................................................... 57
5.8.7. REFITTING THE STANCHION TUBES AND SLIDERS .......................................................................... 58
5.9. REAR SUSPENSION ..................................................................................................................................... 60
5.9.1. REMOVING THE SHOCK ABSORBER................................................................................................... 60
5-2
CYCLE PARTS
Sportcity 125 - 200
5-3
CYCLE PARTS
Sportcity 125 - 200
5-4
CYCLE PARTS
Sportcity 125 - 200
5-5
CYCLE PARTS
Sportcity 125 - 200
5-6
CYCLE PARTS
Sportcity 125 - 200
5-7
CYCLE PARTS
Sportcity 125 - 200
5-8
CYCLE PARTS
Sportcity 125 - 200
5-9
CYCLE PARTS
Sportcity 125 - 200
5 - 10
CYCLE PARTS
Sportcity 125 - 200
5 - 11
CYCLE PARTS
Sportcity 125 - 200
5 - 12
CYCLE PARTS
Sportcity 125 - 200
5 - 13
CYCLE PARTS
Sportcity 125 - 200
5 - 14
CYCLE PARTS
Sportcity 125 - 200
Proceed as follows:
5 - 15
CYCLE PARTS
Sportcity 125 - 200
5 - 16
CYCLE PARTS
Sportcity 125 - 200
5 - 17
CYCLE PARTS
Sportcity 125 - 200
WARNING
The right mirror can be released by turning
clockwise.
5 - 18
CYCLE PARTS
Sportcity 125 - 200
5 - 19
CYCLE PARTS
Sportcity 125 - 200
5 - 20
CYCLE PARTS
Sportcity 125 - 200
5 - 21
CYCLE PARTS
Sportcity 125 - 200
WARNING
Set a support under the frame so to keep the
front wheel raised from the ground.
5 - 22
CYCLE PARTS
Sportcity 125 - 200
5 - 23
CYCLE PARTS
Sportcity 125 - 200
5 - 24
CYCLE PARTS
Sportcity 125 - 200
5 - 25
CYCLE PARTS
Sportcity 125 - 200
5 - 26
CYCLE PARTS
Sportcity 125 - 200
5 - 27
CYCLE PARTS
Sportcity 125 - 200
5 - 28
CYCLE PARTS
Sportcity 125 - 200
DANGER
Allow for the engine and exhaust silencer to
cool down completely before proceeding.
5 - 29
CYCLE PARTS
Sportcity 125 - 200
5 - 30
CYCLE PARTS
Sportcity 125 - 200
5.3. FRAME
5.3.1. REMOVING THE HANDLEBAR
• Remove the front handlebar cover, see (REMOVING
THE HEADLIGHT FAIRING).
• Remove the rear handlebar cover, see (REMOVING
THE INSTRUMENT PANEL).
• Remove the inner front shield, see (REMOVING THE
INNER FRONT SHIELD).
• Remove the clamps.
CAUTION Take some new clamps to be used upon
reassembly.
5 - 31
CYCLE PARTS
Sportcity 125 - 200
5 - 32
CYCLE PARTS
Sportcity 125 - 200
5 - 33
CYCLE PARTS
Sportcity 125 - 200
Key:
5 - 34
CYCLE PARTS
Sportcity 125 - 200
WARNING
Do not operate the front brake lever when the
wheel is not in place or the calliper piston
might come off its housing, thus causing brake
fluid leakage.
5 - 35
CYCLE PARTS
Sportcity 125 - 200
WARNING
When reassembling, use a drift having the
same diameter as the bearing outer ring to seat
the bearings in place. Do not tap on the balls
and/or onto the inner ring. Ensure that the
following parts are fully home:
• the left bearing (4) on the hub;
• the spacer (5) on the left bearing (4);
• the right bearing (2) on the spacer (5).
5 - 36
CYCLE PARTS
Sportcity 125 - 200
BEARINGS
Manually turn the inner ring (1), it should turn smoothly with
no noise and/or hard spots.
No axial play should be noticed.
Faulty bearings should be changed.
SEALS
Check that all seals are intact; change them if they are
damaged or worn.
WHEEL SHAFT
Using a dial gauge, check shaft runout (2). If runout exceeds
the limit, change the shaft (2).
Maximum runout: 0.25 mm.
WHEEL RIM
Using a dial gauge, check that rim (3) radial (A) and axial
(B) runout does not exceed the specified values.
Excessive runout is usually due to worn or damaged
bearings.
If the value does not go back to specified values after
replacing the bearings, change the rim (3).
Maximum radial and axial runout: 2 mm.
Tyre
Check tyre condition.
WARNING
Inspect tyre surface condition and check for
wear, as worn tyres lead to poor road holding
and handling.
Change the tyre when worn or punctured, if the
puncture in the tread is larger than 5 mm.
Some of the tyres approved for this vehicle are
equipped with wear indicators.
Always check that the caps are in place on the
valves (1), or the tyres may deflate suddenly.
Have the wheel balanced after repairing a tyre.
5 - 37
CYCLE PARTS
Sportcity 125 - 200
Key:
5 - 38
CYCLE PARTS
Sportcity 125 - 200
WARNING
Do not operate the rear brake lever when the
wheel is not in place or the calliper piston
might come off its housing, thus causing brake
fluid leakage.
5 - 39
CYCLE PARTS
Sportcity 125 - 200
Key:
5 - 40
CYCLE PARTS
Sportcity 125 - 200
WARNING
Always change both pads and ensure they are
correctly in place inside the calliper. Do not
reverse fastener position upon reassembly.
WARNING
Do not operate the brake lever when the pads
are not in place or the calliper piston might
come off its housing, thus causing brake fluid
leakage.
5 - 41
CYCLE PARTS
Sportcity 125 - 200
REAR BRAKE
WARNING
On spring (3) is an arrow that should always
face the direction of rotation.
WARNING
Do not operate the brake lever when the pads
are not in place or the calliper piston might
come off its housing, thus causing brake fluid
leakage.
WARNING
Upon reassembly, ensure that the arrows on
the vibration dampers face the direction of
rotation.
WARNING
Always change both pads and ensure they are
correctly in place inside the calliper.
5 - 42
CYCLE PARTS
Sportcity 125 - 200
5 - 43
CYCLE PARTS
Sportcity 125 - 200
WARNING
Upon reassembly, smear LOCTITE® 243 on the
brake disc screw thread.
WARNING
Upon reassembly, smear LOCTITE® 243 on the
brake disc screw thread.
5 - 44
CYCLE PARTS
Sportcity 125 - 200
5.7. STEERING
5.7.1. STEERING DIAGRAM
Key:
1. Cap;
2. Lock nut;
3. Adjuster nut;
4. Top dust seal
5. Upper bearing
6. Spacer
7. Lower bearing
8. Bottom dust seal
5 - 45
CYCLE PARTS
Sportcity 125 - 200
WARNING
Smear grease on the surface mating with the
balls (2-3), see (LUBRICANTS CHART).
5 - 46
CYCLE PARTS
Sportcity 125 - 200
5 - 47
CYCLE PARTS
Sportcity 125 - 200
Key:
5 - 48
CYCLE PARTS
Sportcity 125 - 200
5 - 49
CYCLE PARTS
Sportcity 125 - 200
5 - 50
CYCLE PARTS
Sportcity 125 - 200
5 - 51
CYCLE PARTS
Sportcity 125 - 200
5 - 52
CYCLE PARTS
Sportcity 125 - 200
WARNING
The stanchion-and-slider assembly contains oil.
Do not turn it over or tilt it during removal.
5 - 53
CYCLE PARTS
Sportcity 125 - 200
• Drain oil into the container. Pump the slider back and
forth to facilitate draining.
5 - 54
CYCLE PARTS
Sportcity 125 - 200
WARNING
Never reuse the oil you have drained
previously.
5 - 55
CYCLE PARTS
Sportcity 125 - 200
5 - 56
CYCLE PARTS
Sportcity 125 - 200
DANGER
NEVER attempt to straighten a buckled
stanchion as this would weaken the overall
structure leading to a dangerous riding
condition.
SLIDER
5 - 57
CYCLE PARTS
Sportcity 125 - 200
WARNING
Make sure no dirt or objects fall into the slider
or the stanchion.
5 - 58
CYCLE PARTS
Sportcity 125 - 200
• Insert the centring bush (2) first and then the slider into
the stanchion.
5 - 59
CYCLE PARTS
Sportcity 125 - 200
5.9. REAR SUSPENSION
5.9.1. REMOVING THE SHOCK ABSORBER
• Loosen the top nut and remove the screw.
5 - 60
COOLING SYSTEM
Sportcity 125 - 200
COOLING SYSTEM 6
6-1
COOLING SYSTEM
Sportcity 125 - 200
SUMMARY
6.1. COOLING SYSTEM.......................................................................................................................................... 3
6.1.1. COOLING SYSTEM DIAGRAM................................................................................................................. 3
6.2. RADIATOR ....................................................................................................................................................... 4
6.2.1. EMPTYING THE COOLING SYSTEM....................................................................................................... 4
6.2.2. REMOVING THE RADIATOR.................................................................................................................... 5
6.2.3. REMOVING THE ELECTRIC FAN ............................................................................................................ 7
6.2.4. REMOVING THE COOLANT THERMAL SWITCH.................................................................................... 8
6.2.5. REMOVING THE COOLANT THERMISTOR ............................................................................................ 9
6.3. EXPANSION TANK ........................................................................................................................................ 10
6.3.1. REMOVING THE EXPANSION TANK..................................................................................................... 10
6-2
COOLING SYSTEM
Sportcity 125 - 200
Key:
6-3
COOLING SYSTEM
Sportcity 125 - 200
6.2. RADIATOR
6.2.1. EMPTYING THE COOLING SYSTEM
6-4
COOLING SYSTEM
Sportcity 125 - 200
6-5
COOLING SYSTEM
Sportcity 125 - 200
6-6
COOLING SYSTEM
Sportcity 125 - 200
6-7
COOLING SYSTEM
Sportcity 125 - 200
6-8
COOLING SYSTEM
Sportcity 125 - 200
WARNING
Upon reassembly, smear LOCTITE® 515 onto
thermistor thread (2).
6-9
COOLING SYSTEM
Sportcity 125 - 200
6 - 10
ELECTRICAL SYSTEM
Sportcity 125 - 200
ELECTRICAL SYSTEM 7
7- 1
ELECTRICAL SYSTEM
Sportcity 125 - 200
SUMMARY
7.1. CHECKING THE ELECTRICAL COMPONENTS ............................................................................................. 3
7.1.1. INTRODUCTION ....................................................................................................................................... 3
7.2. ELECTRIC SYSTEM ........................................................................................................................................ 4
7.2.1. CHECKING THE ELECTRICAL COMPONENTS ...................................................................................... 4
7.2.2. WIRING DIAGRAM.................................................................................................................................. 10
7- 2
ELECTRICAL SYSTEM
Sportcity 125 - 200
ELECTRICAL CONNECTORS
Disconnect two electric connectors as follows:
WARNING
Do not pull cables to disconnect the two
connectors.
7- 3
ELECTRICAL SYSTEM
Sportcity 125 - 200
7- 4
ELECTRICAL SYSTEM
Sportcity 125 - 200
1 Electric fan thermal switch
2 Electric fan
3 Instrument panel
4 Battery
12 V - 10 Ah
7- 5
ELECTRICAL SYSTEM
Sportcity 125 - 200
5 Coil
Primary resistance:
0.2±10% ohm at 20°C (68°F)
Secondary resistance:
2.9±10% kohm at 20°C (68°F)
6 Rear lights
7 Fuses
Main fuses:
15A fuse (2):
From the ignition switch to all light loads and horn.
20A fuse (1):
From the battery to ignition switch, voltage regulator, electric
fan.
Auxiliary fuses:
15A fuse (2):
From the ignition switch to all light loads and horn.
7.5A fuse (3):
From the ignition switch to ignition.
8 Spark plug
7- 6
ELECTRICAL SYSTEM
Sportcity 125 - 200
9 Fuel sensor
Float position R
Full tank 100 ± 10% ohm
Empty tank 1200 ± 10% ohm
10 Automatic choke
11 Voltage regulator
(SH640D)
Charging voltage:
- at the terminals, loadless: 13/15 V at 5000 RPM
12 Control unit
MARELLI
7- 7
ELECTRICAL SYSTEM
Sportcity 125 - 200
13 Start relay
12 V / 100 A
14 Horn
LEB 12V 4A
15 Headlight
Low/high beam: 12 V - 55 W - H7
Front parking light: 12 V - 5 W
7- 8
ELECTRICAL SYSTEM
Sportcity 125 - 200
17 Water Temperature Sensor
Temperature Resistance Ω
100 (°C) 212 (°F) 144
80 (°C) 176 (°F) 262
60 (°C) 140 (°F) 512
40 (°C) 104 (°F) 1090
18 Generator
19 Pick-up sensor
7- 9
ELECTRICAL SYSTEM
Sportcity 125 - 200
7- 10
ELECTRICAL SYSTEM
Sportcity 125 - 200
Key:
1. Multiple connectors
2. Fuel sensor
3. Instrument panel
4. Water thermistor
5. Speed sensor
6. Left dimmer switch
7. Horn
8. Key-operated switch
9. Front brake switch
10. Rear brake switch
11. Right dimmer switch
12. Rear left turn indicator
13. Parking light/brake light
14. Rear right turn indicator
15. Complete tail light
16. Number plate light
17. Stoplight relay/ignition enable
18. -
19. Starter relay
20. Starter motor
21. Main fuses
22. Auxiliary fuses
23. Power outlet
24. Battery
25. H.T. coil
26. Spark plug
27. Automatic choke
28. C.D.I. control unit
29. Oil sensor connector ( only)
30. Oil pressure sensor
31. Pick-up
32. Generator
33. Voltage regulator
34. Thermal switch
35. Fan
36. Case light
37. Case light switch
38. Front right turn indicator
39. Headlight parking light
40. High beam bulb
41. Low beam bulb
42. Front left turn indicator
43. Complete headlight
44. Flasher “det” ( only)
45. Kit for flasher “det” ( only)
Ar Orange
Az Light blue
B Blue
Bi White
G Yellow
Gr Grey
M Brown
N Black
R Red
V Green
Vi Violet
Ro Pink
7- 11
aprilia s.p.a.
via G.Galilei, 1
30033 Noale (VE) Italy
tel. +39 041.5829111
fax +39 041.5829190
www.aprilia.com
www.serviceaprilia.com