Single-cylinder, four-stroke with four valves,
wet forced lubrication, overhead camshaft.
Number of cylinders
1
Total displacement
124 cu. cm
Total displacement (200)
197.75 cu. cm
Bore/stroke
57 mm /48.6 mm
Bore/stroke (200)
72 mm /48.6 mm
Intake valve clearance
0.10
Exhaust valve clearance
0.15
Compression ratio
12.5 ± 0.5: 1
Compression ratio (200)
11.5 ± 0.5: 1
Starting
Electric
Engine idling rpm
1750 ± 100 rpm
Clutch
Centrifugal type
Gearbox
Automatic
Cooling system
Liquid-type (50% water + 50% coolant), with
forced circulation
CAPACITY
Fuel (with reserve)
10.5 liters
Fuel reserve
1.5 liters
Engine oil
- changing engine oil only
1000 cu. cm
- changing engine oil and engine oil filter
1100 cu. cm
- changing for engine overhaul
1150 cu. cm
Transmission oil
250 cu. cm
Coolant
1.2 liters
Seats
2
Vehicle max. load (rider + passenger + luggage)
210 kg
TRANSMISSION
Variator
Continuous automatic
Primary
With V-belt
Secondary
Gear-type
Engine/wheel total ratio (125)
- short
1:28.03
- long
1:8.41
Total wheel/engine ratio (200)
- short
1:21.05
- long
1:7.37
CARBURETOR
Model (125)
WVF 7C* ø29 WALBRO
Model (200)
CVK 7C* 30 KEIHIN
Model (200)
WVF 7D* ø29 WALBRO
FUEL SUPPLY
Type
Vacuum pump
Fuel
Premium-grade petrol, min. O.N. 95 (N.O.R.M.)
and 85 (N.O.M.M.)
FRAME
Type
Single-beam with twin overlapped cradle
Steering inclination angle
27°
Trail
104 mm
SUSPENSIONS
Front
telescopic fork with hydraulic operation
Stroke
110 mm
Rear
n. 1 Hydraulic monoshock
Stroke
105 mm
BRAKES
Front
Hydraulic disc brake -240
mm
Rear
Hydraulic disc brake -190
mm (combined with front brake)
WHEELS
Rims
Front
E – 13 x 3.00 DOT - D
Rear
E – 13 x 3.50 DOT - D
TYRES
Front
110/90 – 13" 56P
Rear
130/70 – 13" 63P
STANDARD INFLATING PRESSURE
Front
210 kPa
Rear
220 kPa
INFLATING PRESSURE WITH PASSENGER
Front
220 kPa
Rear
240 kPa
STARTING
Type
Magneti Marelli capacity-discharge type with
variable advance
Ignition advance
15° ± 1 – 2000 rpm 10° ± 1 – 2000 rpm
Ignition advance (200)
34° ± 1 – 6000 rpm 32° ± 1 – 6500 rpm
Standard spark plug
NGKCR8EB
Spark plug gap
0.7 0.8 mm
ELECTRIC SYSTEM
Battery
12 V – 12 Ah
Fuses
20 – 15 – 7.5 A
Generator (with permanent magnet)
12 V – 180 W
BULBS
Low beam
12 V – 55 W
High beam (F)
12 V – 55 W
Parking light
12 V – 16 W
Direction indicators
12 V – 10 W
Tail lights/Number plate light/ Stop light
12 V – 5 W / 21 W
WARNING LIGHTS
Instrument panel lights
12 V – 1.2 W
Direction indicators
12 V – 1.2 W
Engine oil pressure
12 V – 1.2 W
Low beam
12 V – 1.2 W
High beam
12 V – 1.2 W
Fuel reserve
12 V – 1.2 W
DECALS INSTRUCTIONS
Should some frame parts be removed:
NOTE
Plastic and painted parts shall be handled
with care. Do not score or damage them. Operate with care.
Do not damage keys and/or keyways.
When sticking decals, carefully follow the instructions listed below.
Recommended tools:
- Medium-strength spatule (1);
NOTESoft
spatules, such as those used on windshield wipers, do not usually
sufficiently remove the water under the decal.
sponge or sprayer (2) with water.
NOTEAdd
some detergent (1-3%) to water and then shake it to produce foam
bubbles.
To apply decals, proceed as follows:
Position the decal (3) in upside-down position on the work bench.
Keep the decal flat and pressed on the work bench and remove the
protective film (4) completely.
NOTEThe
use of a sprayer (2) is recommended.
In case you are using a sponge, apply it on the surface without
exerting any pressure in order not to damage the adhesive.
Wet the adhesive surface with suds.
Apply the decal (3) on the surface you wish to decorate and position
it correctly.
NOTEPress
the spatule with constant movements, working from the center towards
the edge of the decal.
Apply a moderate pressure on the decal surface with the spatule (1)
until all the excess soap and water under the decal itself have been
completely removed.
NOTEDo
not lift the decal corners and/or edges.
Using a cloth and working from inwards to outwards, dry the decal.
Use again the spatule. Press evenly as much as possible. Always work
starting from the center to the outside and take special care to the
corners and edges in order to ensure an even adhesion on the whole
surface.
NOTEIf
present, remove the application tape (5) 20 to 30 minutes after
applying the decal.
Remove the application tape (5) from the decal surface.
To ensure a good adhesion, use the spatule again by taking special
care to the corners and edges.
NOTEWhen
using the wet method, the decal final adhesion level will be reached
around 48 hours after the application.
After having removed the application tape, make sure that no
blisters are present on the surface.
Should some blisters be present, proceed as follows:
Using a pin or a cutter (6) cut the blister (7).
Use the spatule (1) starting from the side opposite to the cut and
press the blister to make the air come out.
The application tape is used to make the makes and letters
application easier, namely to position them correctly on the surface
you wish to decorate and to reinforce the adhesive during
application.
As an alternative to the recommended oils,
it is possible to use select oils having
properties in compliance with or even above
A.P.I. SJ specifications.
As an alternative to the recommended oil,
use select oils having properties in
compliance with or even above A.P.I. GL3
specifications
Fork oil
RECOMMENDED: F.A. 5W or F.A. 20W, as an
alternativeFORK
5W or FORK 20W.
Should you wish to reach an average behavior
between those offered byF.A.
5W and byF.A.
20W or FORK 5W and by
FORK 20W, mix the products as follows:
SAE 10W =F.A.
5W 67% of the volume, +F.A.
20W 33% of the volume.
FORK
5W 67% of the volume +FORK
20W 33% of the volume.
SAE 15W =F.A.
5W 33% of the volume, +F.A.
20W 67% of the volume.
FORK
5W 33% of the volume +FORK
20W 67% of the volume.
Bearings and other lubrication points
RECOMMENDED: BIMOL GREASE 481 +GREASE
SM2.
As an alternative to the recommended
product, use select oil for rolling
bearings, useful temperature range
-30°C…+140°C, dripping point 150°C…230°C,
highly anticorrosive, water and oxidization
resistant.
Battery terminals
Neutral grease or vaseline.
Brake fluid
The braking system is filled with Autofluid
FR. DOT 4 (DOT 5 can be used as well) +BRAKE
5.1 DOT 4 (DOT 5 compatible).
NOTEBefore
mixing different makes or types of oil,
check their compatibility.
As an alternative to the recommended fluid,
use fluids having properties in compliance
with or even above SAE J1703, NHTSA 116 DOT
4, ISO 4925 specifications.
Engine coolant
RECOMMENDED: ECOBLU – 40° C +COOL.
As an alternative to the recommended fluid,
use fluids having properties in compliance
or even above basic ethylene glicol CUNA NC
956-16 specifications.
USE OF PRODUCTS
For all maintenance operations, use the product listed below only.
The listed materials have been tested for many years and are
suitable for all the applications specified by the manufacturer.
NOTEConsumer
goods with part numbers are available upon request (see table)
PRODUCT SPECIFICATIONS
Description
Use
Molykote 111 / N. ROTAX 897 161
LOCTITE ANTI-SEIZE 76710 N. ROTAX 297 431
Lubricate
- All ball bearings, sintered discs, gears, cylinder
walls, if not otherwise specified.
Grease
- Oil seals lips, if not otherwise specified.
Gearbox oil
- Engine oil SAE 30, 0.6 l
Engine oil
- Premium 2-stroke engine oil
LOCTITE 221 / N. ROTAX 899 785
LOCTITE 648 / N. ROTAX 899 788
Silastic 732 RTV / N. ROTAX 297386
Clearance between the two oil seals of the coolant pump.
Coupling gear stopper retaining socket head screw.
Electric starting device retaining socket head screws.
Oil pump retaining socket head screws.
All “Taptite” screws for casing and clutch cover reassembly.
Flywheel-to-crankshaft fixing hexagon nut.
Water tube into casing.
Electric starting device hole cover into casing (RX only)
Neutral indicator contact screw.
Ignition cable seal.
TIGHTENING
GENERAL TIGHTENING TORQUE SETTINGS
The table shows the tightening toque settings for 8.8 class screws
made of steel/aluminum or other similar materials.
Screw or bolt thread
Wrench
Tightening torque
Nm
kgm
M 4
7
3
0.3
M 5
8
6
0.6
M 6
10
10
1.0
M 8
12
25
2.5
M 10
14
50
5.0
M 12
17
80
8.0
M 14
19
135
13.5
M 16
22
210
21.0
For special couplings on this vehicle, refer to2.3.2.
If not otherwise specified, the tightening torque settings refer to
clean, dry and ambient temperature threads.
NOTEIn
order to avoid any possible deformation and/or wrong coupling,
please tighten screws and bolts as follows:
Tighten all fasteners by hand.
Apply half of the recommended tightening torque value and tighten
the opposite parts: (A) and (B); (C) and (D).
Repeat the above operation by tightening to the specified torque
value.
NOTEThe
pressure on the fastening parts will be thus evenly distributed on the
coupling surface.
ROUTINE MAINTENANCE 2
SUMMARY
ROUTINE MAINTENANCE 3
INTRODUCTION 3
ROUTINE MAINTENANCE TABLE 4
POINTS TO BE LUBRICATED 5
POINTS TO BE LUBRICATED 5
TIGHTENING 6
NUT, BOLT, SCREW TIGHTENING 6
FASTENING ELEMENTS 7
BATTERY 9
BATTERY 9
CHECKING AND CLEANING THE TERMINALS 10
CHECKING THE BATTERY ELECTROLYTE LEVEL 11
RECHARGING THE BATTERY 12
LONG INACTIVITY OF THE BATTERY 13
ELECTRICAL PARTS 14
ELECTRICAL PARTS 14
SPARK PLUGS 15
SPARK PLUGS 15
AIR CLEANER 17
AIR CLEANER 17
TUBES 18
TUBES 18
COOLANT 19
CHECKING AND TOPPING UP THE COOLANT LEVEL 19
CLEANING THE RADIATOR. 20
BRAKE FLUID 21
CHECKING AND TOPPING UP THE BRAKE FLUID 21
CHANGING THE BRAKE FLUID 23
CHECKING THE BRAKE PAD WEAR 24
BLEEDING THE BRAKING SYSTEMS 25
ENGINE OIL 28
CHECKING THE ENGINE OIL LEVEL AND TOPPING UP 28
CHANGING THE ENGINE OIL AND THE OIL FILTER 29
TRANSMISSION OIL 30
CHECKING AND TOPPING UP THE TRANSMISSION OIL 30
CHANGING THE TRANSMISSION OIL 31
THROTTLE 32
THROTTLE 32
IDLING ADJUSTMENT 34
FRONT END 35
STEERING 35
FRONT SUSPENSION 36
REAR AXLE 37
CHECKING THE ENGINE AXLE 37
REAR SUSPENSION INSPECTION 38
WHEELS 39
WHEELS 39
TYRES 40
TYRES 40
EXHAUST SYSTEM 41
EXHAUST MANIFOLD NUTS 41
ROUTINE MAINTENANCE
INTRODUCTION
To keep your vehicle in top performance conditions,apriliastrongly
recommends to respect the routine maintenance schedule for
the different parts of the vehicle.
This section describes the routine maintenance operations
for vehicle main components.
DANGER
Before beginning any service operations or inspection of the
vehicle, switch off the engine and remove
the key, wait until the engine and the exhaust system have
cooled down and, if possible, lift the vehicle with the
proper equipment onto firm and flat ground. Keep away from
the red-hot parts of the engine and of the exhaust system,
in order to avoid burns. Do not hold any mechanical piece or
other parts of the vehicle with your mouth: the components
are not edible and some of them are harmful or even toxic.
If not expressly indicated otherwise, for the reassembly of
the units repeat the disassembly operations in reverse
order.
Every 2000 km (1243 mi): 1 – Every sixteen
months: 3
Engine oil
3
Every 3000 km (1864 mi): 1 – Every 6000
km (3728 mi): 3
Front suspension oil
1
1
3
Transmission oil
3
Every 6000 km (3728 mi): 1 – Every 24000
km (14913 mi): 3
Headlamp aim and operation
-
1
-
Tyres – Inflating pressure
every month: 1
Engine oil filter mesh and magnetic screw
1
1
-
Variator rollers and plastic slides 125-200
-
1
3
Wheels - Tyres
-
1
-
Nut, bolt, screw tightening
1
1
-
Head nuts tightening
1
-
-
Front suspension
1
1
-
Brake fluid bleeding
1
-
-
Fuel line
-
1
Every two years: 3
Brake pads wear
1
Every 2000 km (1243 mi): 1
Fuel filter
-
1
3
Cooler cleaning
-
2
-
1 = check and clean, adjust, lubricate or change, if
necessary; 2 = clean; 3 = change; 4 = adjust.
Perform the maintenance operations more often if the vehicle
is used in rainy or dusty areas, on uneven surfaces or on
racetracks.
()
= OPERATIONS TO BE MADE ALSO BY THE USER
(**) = Check every fifteen days or at the recommended
intervals.
POINTS TO BE LUBRICATED
POINTS TO BE LUBRICATED
A good lubrication ensures vehicle smooth operation and durability.
NOTEBefore
lubrication, clean all parts from any rust deposits, grease, dirt or
dust.
The points to be lubricated are specified in the “LUBRICATING CHART”.
LUBRICATING CHART
Steering bearings
Rear wheel shaft and bearing
Center stand spindle
Side stand spindle
Front wheel shaft and bearings
= Grease
= Oil
TIGHTENING
NUT, BOLT, SCREW TIGHTENING
Check all fastening parts with accuracy. Mainly check all
safety-related components and, in particular:
Handlebar-to-upper plate fastener;
Front brake control lever;
Clutch control lever;
Fuel delivery line;
Plate-to-front fork fastener;
Front wheel shaft fork clamps;
Front wheel;
Front brake line couplings;
Front brake disc;
Front brake calliper;
Engine;
Sprocket;
Rear brake control lever;
Rear swingarm;
Rear swingarm levers;
Rear shock absorber;
Rear wheel;
Rear brake disc;
Rear brake calliper;
Rear brake line couplings.
WARNING
The fastening elements shall be tightened to
the specified torque value. Apply LOCTITE ONLY where
indicated, see2.3.2.
Lubricate only the parts specified in the table
2.3.2.
FASTENING ELEMENTS
Check and, if necessary, tighten after the first 1000 km
(621 mi) and after every 6000 km (3728 mi) or 8 months.
WARNING
The fastening elements specified in the table must be
tightened to the specified torque value using a
torque wrench and, where recommended, applying LOCTITE®.
The highlighted parts ()
are safety components.
Notes:
L243 = tighten with Loctite®243
Lub = lubricate
FRAME
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Splitter-to-frame fitting
M6
10
1.0
Arc-to-frame fixing
M6
12
1.2
Locking ring nut
3
M25x1.5
45
4.5
Key-operated switch retaining tear screw
1
M6x25
Tearing
Tearing
Key-operated switch fastening screw
4
M6x25
8.5
0.85
STAND
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Centre stand-to-engine fastener
1
M10
27
2.7
Side stand-to-frame fastener
M10
20
2.0
CONNECTING RODS
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Con-rod-to frame fixing
M12 pin
60
6.0
Con-rod-to-engine fixing
M10 pin
40
4.0
Con-rod/con-rod fixing
M12 pin
60
6.0
Silencer fixing
M8
25
2.5
REAR SUSPENSION
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Rear shock absorber-to- frame fastener
M10
50
5.0
Rear shock absorber-to- engine fastener
M10
50
5.0
Rear shock absorber-to-frame fasteners
M8x50
25
2.5
FILTER BOX
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Filter box-to-engine fastener
1
M6x45
8
0.8
Filter box-to-engine fastener
1
M6x55
8
0.8
EXHAUST SYSTEM
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Manifold-to-head fixing
2
M7 nut
17
1.7
Plate-silencer fixing
3
M8x40
25
2.5
Manifold clamp fixing
1
10
1.0
Muffler mount fixing
2
M8x40
25
2.5
FRONT WHEEL
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Wheel shaft
1
M12
40
4.0
Safety screw
M6
12
1.2
REAR WHEEL
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Wheel nut
M16x1.5
110
11.0
FRONT AND REAR BRAKES
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Front calliper fixing
1
M8x40
25
2.5
Front calliper fixing
1
M8x45
25
2.5
Rear calliper fixing
2
M8x40
25
2.5
Rear brake cable retainer
1
M6x20
12
1.2
Front calliper fixing
2
M6x35
12
1.2
HANDLEBARS AND CONTROLS
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Clamp closing screw
1
M10
45
4.5
Safety screw
1
M8
20
2.0
FRONT BODY
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Mudguard-to-fork fixing
M5 collar
0.7
0.07
Mirrors-to-arc fixing
M6x30
10
1.0
CENTRAL BODY
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Self-tapping screw
4.2
0.3
0.03
Screw with collar
M5
REAR BODY
Description
Q.ty
Screw/Nut
Nm
Kgm
Notes
Handgrip-to-frame fixing
2
M8x60
24
2.4
Handgrip-to-frame fixing
2
M6x40
10
1.0
BATTERY
BATTERY Carefully read1.2.1.
Two different types of battery are available on the market:
battery needing to be maintained with plugs;
maintenance-free battery without plugs needing no
electrolyte level check and topping up.
After the first 1000 km (621 mi) and then every 6000 km
(3728 mi) or 8 months, check the electrolyte level and
the terminals correct tightening.
DANGER
The battery electrolyte is a toxic, caustic
substance containing sulphuric acid and thus able to
cause severe burns in case of contact. Always wear
protective clothes, a mask and/or eye protectors when
handling this fluid.
If the electrolyte gets in contact with the skin,
carefully wash the parts of your body that get in
contact with the fluid with abundant fresh water.
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 consult immediately a doctor.
Battery releases explosive gases.
Keep flames, sparks, cigarettes and any other heat
source away from the battery.
During recharging or use, make sure that the room is
properly ventilated and avoid inhaling the gases
released during recharging.
KEEP AWAY FROM CHILDREN.
Take care not to lean the vehicle to avoid dangerous
spills of the battery fluid.
WARNING
Never reverse connection of the battery cables.
Connect and disconnect the battery with the ignition
switch in position “”.
Connect first the positive cable (+) and then the
negative cable (-).
Disconnect following the reverse order.
CHECKING AND CLEANING THE TERMINALS
Carefully read2.4.1.
Make sure that the ignition switch is in position "".
Raise the seat.
Undo and remove the two screws (1).
Remove battery protection.
Make sure that the cable terminals (2) and the battery
terminals (3):
in good conditions (and not corroded or covered with
deposits);
covered with neutral grease or vaseline. If
necessary, proceed as follows:
Disconnect the negative cable (-) first and the positive
one (+).
Brush the wire with a wire brush, in order to eliminate
any trace of corrosion.
Reconnect the positive terminal (+) first and then the
negative one (-).
Cover the terminals of the cables and of the battery
with neutral grease or vaseline.
CHECKING THE BATTERY ELECTROLYTE LEVEL
Carefully read2.4.1.
To check battery electrolyte level, proceed as follows:
Raise the vehicle on center stand.
Raise the seat.
Undo and remove the two screws (1).
Remove battery protection.
Make sure that the fluid level is included between the
“MIN”and“MAX”marks,
etched on the battery side.
If this is not the case:
Remove the battery, see7.2.1.
Remove battery plugs.
WARNING
Top up the electrolyte using distilled water
only. Do not fill above the “MAX” mark as the level
increases during recharging.
Top up with distilled water.
RECHARGING THE BATTERY Carefully read2.4.1.
NOTEIf
the battery is almost fully flat, when the starting button ""
is pressed, the starting relay will issue a vibrating noise.
Do not remove the battery plugs: without plugs the battery
may be damaged.
Remove the battery, see7.2.1.
Remove plugs.
Check the battery electrolyte level, see2.4.3.
Connect the battery with a battery charger.
Recharge the battery with 1/10thof
its amperage.
Once finished, check the electrolyte level once again
and, if necessary, top up using distilled water.
Refit battery plugs.
WARNING
Reassemble the battery only 5 to 10 minutes
after disconnecting the recharge apparatus, since the
battery continues to produce gas for a short lapse of
time.
LONG INACTIVITY OF THE BATTERY Carefully read2.4.1.
WARNING
If the vehicle remains unused for more than
twenty days, disconnect the 20A fuses.
The removal of the 20A fuses requires the setting to zero of the
following functions: digital clock and red line setting.
To reset these functions.
If the vehicle remains unused for more than fifteen days, it is
necessary to recharge the battery, in order to prevent its
sulphation, see2.4.4.
Remove the battery, see7.2.1.,and
put it in a cool and dry place.
It is important to check the charge periodically (about once a month),
during the winter or when the vehicle remains unused, in order to
prevent the deterioration of the battery.
Recharge it completely with a normal charge, see
2.4.4.
NOTEIf
the battery remains on the vehicle, disconnect the cables from the
terminals.