Aprilia Sportcity One 125 2008 2009 Repair Service Manual

SERVICE STATION MANUAL 854184 SPORTCITY ONE 125

SERVICE STATION MANUAL SPORTCITY ONE 125 The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this manual remain unchanged, aprilia 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 shown in this publication are available in all countries. The availability of individual models should be confirmed with the official aprilia sales network. © Copyright 2008 aprilia. All rights reserved. Reproduction of this publication in whole or in part is prohibited. aprilia - After-sales service. aprilia trademark is property of Piaggio & C. S.p.A.

SERVICE STATION MANUAL SPORTCITY ONE 125 - 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, aprilia 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 ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS CHASSIS CHAS PRE-DELIVERY PRE DE

INDEX OF TOPICS CHARACTERISTICS CHAR

Safety rules CARBON MONOXIDE If you need to keep the engine running in order to carry out any procedure, please ensure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a smoke-extraction system. CAUTION EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH. FUEL FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND CAN BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE OPERATIONS IN A WELL VENTILATED AREA WITH THE ENGINE OFF. DO NOT SMOKE WHILE REFUELLING OR WHEN CLOSE TO FUEL VAPOURS, AVOID CONTACT WITH NAKED FLAMES, SPARKS OR ANY OTHER SOURCE THAT MAY CAUSE FUEL TO CATCH FIRE OR EXPLODE. CAUTION DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT. CAUTION KEEP OUT OF THE REACH OF CHILDREN. HIGH-TEMPERATURE COMPONENTS The engine and the components of the exhaust system can get very hot and remain hot for some time even after the engine has been switched off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down. TRANSMISSION OIL AND USED FORK OIL CAUTION IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK. THE TRANSMISSION OIL MAY CAUSE SKIN DAMAGE IF HANDLED FREQUENTLY AND FOR LONG PERIODS. WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL. HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER. IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK. CAUTION Characteristics SPORTCITY ONE 125 CHAR - 6

DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. CAUTION KEEP OUT OF THE REACH OF CHILDREN. BRAKE FLUID CAUTION THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING THE BRAKE SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKE SYSTEM. THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE. CAUTION KEEP OUT OF THE REACH OF CHILDREN. COOLANT The coolant contains ethylene glycol which, under certain conditions, can become flammable. When it burns, ethylene glycol produces invisible flames which, however, can cause burns. CAUTION MAKE SURE NOT TO POUR THE COOLANT ON HOT ENGINE OR EXHAUST SYSTEM COMPO- NENTS; IT MAY CATCH FIRE PRODUCING INVISIBLE FLAMES. WHEN CARRYING OUT MAIN- TENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN IF IT IS TOXIC, THE COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS THEY MAY DRINK IT. CAUTION KEEP OUT OF THE REACH OF CHILDREN. CAUTION DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. HYDROGEN GAS AND BATTERY ELECTROLYTE CAUTION HYDROGEN GAS AND BATTERY ELECTROLYTE THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID, IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING THE BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PRO- TECTIVE APPAREL. SPORTCITY ONE 125 Characteristics CHAR - 7

IF THE ELECTROLYTIC FLUID GETS INTO CONTACT WITH THE SKIN, WASH WITH ABUNDANT COOL WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF IT COMES INTO CONTACT WITH THE EYES, RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIAL- IST AS SOON AS POSSIBLE. IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOL- LOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATE- LY. THE BATTERY RELEASES EXPLOSIVE GASES. KEEP IT AWAY OF FLAMES, SPARKS, CIGA- RETTES OR ANY OTHER HEAT SOURCE. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY. CAUTION KEEP OUT OF THE REACH OF CHILDREN. CAUTION THE BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTI- VATED. GENERAL PRECAUTIONS AND INFORMATION When repairing, dismantling and reassembling the vehicle follow the recommendations reported below carefully. CAUTION THE USE OF NAKED FLAMES IS FORBIDDEN FOR ANY KIND OF OPERATION. BEFORE START- ING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THE ENGINE AND REMOVE THE KEY. WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD, IF POSSIBLE, RAISE THE VEHICLE USING A SUITABLE TOOL ON FIRM AND LEVEL GROUND. TO AVOID BURNS PAY SPECIAL CARE WITH HOT ENGINE AND EXHAUST SYSTEM PARTS. DO NOT HOLD ANY MECHANICAL OR ANY OTHER SCOOTER PARTS WITH YOUR MOUTH: SCOOTER COMPONENTS ARE NOT EDIBLE, ON THE CONTRARY SOME OF THEM ARE HARMFUL AND EVEN TOXIC. UNLESS OTHERWISE INDICATED, REFIT THE UNITS FOL- LOWING REMOVAL OPERATIONS BUT IN REVERSE ORDER. THE POSSIBLE OVERLAPPING OF OPERATIONS REFERRED TO IN THE OTHER CHAPTERS MUST BE CARRIED OUT LOGI- CALLY, AVOIDING ANY UNNECESSARY REMOVAL OF COMPONENTS. DO NOT POLISH MATT- PAINTED SURFACES WITH POLISHING PASTE. NEVER USE FUEL AS SOLVENT FOR CLEANING THE SCOOTER. DO NOT USE ALCOHOL, PETROL OR SOLVENTS TO CLEAN RUB- BER AND PLASTIC PARTS AND THE SADDLE. USE ONLY WATER AND NEUTRAL SOAP INSTEAD. DISCONNECT THE BATTERY NEGATIVE LEAD (-) IF YOU INTEND TO CARRY OUT ELECTRICAL WELDING WORK. WHEN TWO OR MORE PEOPLE WORK AT THE SAME TIME, MAKE SURE ALL SAFETY MEASURES ARE OBSERVED EACH OF THEM. BEFORE REMOVING COMPONENTS • Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle. • Use the special tools designed for this scooter, as required. REASSEMBLING COMPONENTS CAUTION Characteristics SPORTCITY ONE 125 CHAR - 8

NEVER REUSE A CIRCLIP; IF A CIRCLIP HAS BEEN REMOVED, IT MUST BE REPLACED WITH A NEW ONE. WHEN INSTALLING A CIRCLIP, ENSURE THAT ITS ENDS ARE NOT STRETCHED MORE THAN IS NECESSARY TO FIT IT ONTO THE SHAFT. AFTER INSTALLING THE CIRCLIP, CHECK THAT IT IS FULLY AND CLEANLY INSTALLED IN ITS SEAT. DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS. NOTE BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH- ERWISE THEY NEED REPLACING. • Use only ORIGINAL aprilia SPARE PARTS. • Comply with lubricant and consumables usage guidelines. • Lubricate parts (whenever possible) before reassembling them. • When tightening nuts and screws, start from the ones with the largest section or from the internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap- plying the tightening torque. • Always replace self-locking nuts, washers, sealing rings, circlips, O-rings, split pins and screws with new ones if their tread is damaged. • When fitting bearings, make sure to lubricate them well. • Check that each component is fitted correctly. • After a repair or routine maintenance procedure, carry out pre-ride checks and test the vehicle on private grounds or in an area with low traffic density. • Clean all junction surfaces, oil guard rims and washers before refitting them. Smear a light layer of lithium-based grease on the oil guard rims. Reassemble the oil guards and the bearings with the brand or lot number facing outward (visible side). ELECTRIC CONNECTORS Electric connectors must be disconnected as described below as non-compliance with the procedure so described causes irreparable damage to both the connector and the cable harness: Press the relevant safety hooks, if any. CAUTION TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES. • Grip the two connectors and disconnect them by pulling them in opposite directions. • In presence of dirt, rust, humidity etc., clean the connector's internal parts carefully, using a pressurised air jet. • Make sure that the cables are correctly linked to the connector's internal terminal ends. NOTE THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAY ROUND. SPORTCITY ONE 125 Characteristics CHAR - 9

• Then fit the two connectors making sure that they couple correctly (if the relevant hooks are provided, you will hear them "click" into place). CAUTION TIGHTENING TORQUE DO NOT FORGET THAT TIGHTENING TORQUES FOR ALL FIXING ELEMENTS ON WHEELS, BRAKES, WHEEL BOLTS AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REFIT THESE COMPONENTS. IF THESE RECOMMENDATIONS ARE NOT COMPLIED WITH, ONE OF THE COMPONENTS MAY BECOME LOOSE AND EVEN DE- TACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISING THE VEHICLE'S MA- NOEUVRABILITY. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH. Vehicle identification Quote the chassis number when purchasing spare parts. NOTE DO NOT OBLITERATE OR ALTER THE VEHICLE IDENTIFICATION NUMBERS. DOING SO IS CONSIDERED AN OFFENCE IN ALL COUNTRIES. FURTHERMORE, ALTERING THE IDENTIFI- CATION NUMBERS INVALIDATES THE WARRANTY. Chassis number The chassis number is marked on the chassis cen- tral steel tube. Remove the cover «1» to read it. Engine number The engine number «2» is marked near the lower support of the rear shock absorber. Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc./Quantity Max. length 1.950 mm Characteristics SPORTCITY ONE 125 CHAR - 10

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Aprilia Sportcity One 125 2008 2009 Repair Service Manual

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