APRILIA MOJITO 50 125 150 Workshop Repair Manual All Models Covered

www.serviceaprilia.com workshopmanual MOJITO 50 - 125 - 150 1149 3 00/2003-11 8140754 UK

INTRODUCTION 0 - 1 MOJITO 50 - 125 - 150 INTRODUCTION 0

INTRODUCTION 0 - 2 MOJITO 50 - 125 - 150 CONTENTS 0.1. FOREWORD ................................................................................................................................................... 3 0.1.1. FOREWORD............................................................................................................................................... 3 0.1.2. REFERENCE MANUALS............................................................................................................................ 4 0.1.3. ABBREVIATIONS AND SYMBOLS ............................................................................................................ 5

INTRODUCTION 0 - 3 MOJITO 50 - 125 - 150 0.1. FOREWORD 0.1.1. FOREWORD - This manual provides all the most important information on the normal tasks involved in working on this vehicle. - This publication is intended for aprilia dealers and their trained mechanics. Many topics have been intentionally omitted as they have been judged to be superfluous. As not all the mechanical topics could be covered in this publication, those using this manual must have undergone basic mechanical training, and must have a minimum knowledge of the procedures involved in repairing motorcycles. Without this knowledge, repairing and checking the motorcycle could be inefficient or dangerous. As not all the procedures involved in repairing and checking the motorcycle are described in detail, particular care must be taken to avoid harming components or people. To afford the customer greater satisfaction in using their motorcycle aprilia s.p.a. is constantly committed to improving their products and the related documentation. The major technical modifications and changes to the procedures for repairing the motorcycle are forwarded to all aprilia Points of Sale and Branches around the World. These changes will be made to subsequent editions of this manual. When necessary, or when in any doubt as to repair and checking procedures, contact the aprilia ASSISTANCE DEPARTMENT, who will be able to provide any information you require in this regard, as well as providing information on updates and technical modifications to the motorcycle. The aprilia s.p.a. Company reserves the right to make changes to its models at any time, without prejudice to the essential characteristics described and illustrated in this manual. The right to store this information electronically, reproduce it, or adapt it in its entirety or in part by any means, is reserved in all countries around the world. The mentioning of products or services provided by third parties is for information purposes only and does not imply any kind of commitment. aprilia s.p.a. does not accept any responsibility in relation to the performance or use of these products. First edition: November 2003 Compiled and Printed by: 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

INTRODUCTION 0 - 4 MOJITO 50 – 125 - 150 0.1.2. REFERENCE MANUALS 50 cc VERSION WORKSHOP ENGINE MANUALS aprilia part # (description) 8140433 8140436 8140434 8140435 8140437 SPARE PART CATALOGUES aprilia part # (description) 550X 551X USE AND MAINTENANCE HANDBOOKS aprilia part # (description) 8104690 8104784 CYCLE CHARACTERISTICS WORKSHOP MANUALS aprilia part # (description) 8140750 8140751 8140752 8140753 8140754 125-150 cc VERSION WORKSHOP ENGINE MANUALS aprilia part # (description) 8140680 8140681 8140682 8140683 8140684 SPARE PART CATALOGUES aprilia part # (description) 6693 USE AND MAINTENANCE HANDBOOKS aprilia part # (description) 8104690 8104784 CYCLE CHARACTERISTICS WORKSHOP MANUALS aprilia part # (description) 8140750 8140751 8140752 8140753 8140754

INTRODUCTION 0 - 5 MOJITO 50 - 125 - 150 0.1.3. ABBREVIATIONS AND SYMBOLS # = number < = less than > = greater than = = equal to or less than = = equal to or greater than ~ = approximately ∞ = infinite °C = degrees Celsius (centigrade) °F = degrees Fahrenheit ± = plus/minus a.c = alternating current A = amperes Ah = amperes per hour API = American Petroleum Institute HV = high voltage AV/DC = Anti-Vibration Double Countershaft bar = unit of pressure (1 bar =100 kPa) d.c. = direct current cm³ = 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 = revs per minute HC = unburnt hydrocarbons ISC = Idle Speed Control ISO = International Standardisation Organisation kg = kilograms kgm = kilograms per metre (1 kgm =10 Nm) km = kilometres km/h = kilometres per hour kΩ = kiloOhm kPa = kiloPascal (1 kPa =0,01 bar) KS = clutch side (Kupplungseite) kW = kiloWatt l = litres LAP = lap (race track) LED = Light Emitting Diode LEFT SIDE = left side m/s = metres per second max = maximum mbar = millibar (1 mbar =0,1 kPa) mi = mile MIN = minimum MPH = miles per hour MS = flywheel side (Kupplungseite) MΩ = megaOhm N.A. = Not Available N.O.M.M. = octane rating “motor” method N.O.R.M. = octane rating “research” method Nm = Newton per metre (1 Nm =0,1 kgm) Ω = ohm PICK-UP = pick-up PMI = bottom dead centre (BDC) PMS = top dead centre (TDC) PPC = Pneumatic Power Clutch

INTRODUCTION 0 - 6 MOJITO 50 - 125 - 150 RIGHT SIDE = right side SAE = Society of Automotive Engineers TEST = diagnostic test T.B.E.I. = crowned head with flush-mounted hexagonal bolt T.C.E.I. = cylinder head with flush-mounted hexagonal bolt T.E. = hexagonal head T.P. = flat head TSI = Twin Spark Ignition UPSIDE- DOWN = upside-down sleeves V = Volt W = Watt Ø = diameter

GENERAL INFORMATION 1 - 1 MOJITO 50 - 125 - 150 GENERAL INFORMATION 1

GENERAL INFORMATION 1 - 2 MOJITO 50 - 125 - 150 CONTENTS 1.1. STRUCTURE OF THIS MANUAL..................................................................................................3 1.1.1. HOW TO CONSULT THIS MANUAL.......................................................................................3 1.1.2. SAFETY MESSAGES .............................................................................................................4 1.2. GENERAL INSTRUCTIONS..........................................................................................................5 1.2.1. GENERAL SAFETY RULES ...................................................................................................5 1.3. DANGEROUS ELEMENTS ...........................................................................................................8 1.3.1. WARNINGS............................................................................................................................8 1.4. RUNNING IN .............................................................................................................................. 11 1.4.1. RUNNING IN ........................................................................................................................ 11 1.5. VEHICLE IDENTIFICATION........................................................................................................ 12 1.5.1. POSITION OF SERIAL NUMBERS ....................................................................................... 12

GENERAL INFORMATION 1 - 3 MOJITO 50 - 125 - 150 1.1. STRUCTURE OF THIS MANUAL 1.1.1. HOW TO CONSULT THIS MANUAL • This manual is broken down into sections and chapters, each of which corresponds to a major category of components. To consult the manual, see the contents indicating the sections. Per . • Unless otherwise stated, reassembly of units is to take place in the opposite order to that used to disassemble the same unit. • The terms “right” and “left” refer to the driver's position when seated in the normal driving position. • Consult the “USE AND MAINTENANCE HANDBOOK” for instructions on how to use the vehicle and routine maintenance operations. Variables in this manual are indicated using the following symbols: optional catalytic version - all versions MP national type approval SF European type approval (EURO 1 limits) VERSION: Italy Greece Malaysia United Kingdom Holland Chile Austria Switzerland Croatia Portugal Denmark Australia Finland Japan United Sta- tes of Amer- ica Belgium Singapore Brazil Germany Slovenia Republic of South Africa France Israel New Zealand Spain South Ko- rea Canada

APRILIA MOJITO 50 125 150 Workshop Repair Manual All Models Covered

You're Reading a Preview

Recently Viewed