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Aprilia scooter (manual) - part 12

1. 1. CARBURETTOR SPECIFICATIONS

      
       

      COMPONENTS		SPECIFICATIONS
      		125 cc	250 cc
      Type	CVK 7 30 KEHIN		WVF 7 0 29 WALBRO
      Throttle port (Venturi)	0 29		0 29
      Engine-side fitting	0 40		0 40
      Float	5.9 g (0.035 oz)		-
      Float valve - needle seat	1.5		1.2
      Start air inlet hole	200		150
      Starter jet	50		42
      Idling adj. hole	-		-
      Idle jet	36		38
      Mixture control screw open by (turns)	2 5/8		2 1/2
      Idle air hole	100		115
      Maximum rpm air hole	115		70
      Main jet	108		100
      Throttle valve slide	Standard		Standard
      Mixing tube	0 2.7 mm (0.106 in)		0 2.8 mm (0.110 in)
      Nozzle needle	51C		NDWA
      Notch	2°		-

      
       

      
       

      

   2. CHECKING AND TOPPING UP TRANSMISSION OIL LEVEL

NOTE Use the recommended oil only, see 9.1.4 (LUBRICANT CHART).

• Ride until covering several kilometres to warm up engine up to operating temperature and then stop the engine.

  
   

  

  CHECKING LEVEL

• Place the vehicle on firm and level ground.

• Put the vehicle on the centre stand.

  
   

   WARNING

  Allow several minutes for the engine and

  exhaust system to cool down.

  
   

• Unscrew and extract the plug/dipstick (1).

• Clean the part in contact with the oil with a clean cloth.

• Tighten the plug/dipstick (1) fully into the filler opening (2).

• Extract the plug/dipstick (1) again and check oil level on the dipstick.

  
   

  

• Correct level is achieved when the oil reaches approximately the first mark over the dot.

• Top up if needed.

  
   

  TOPPING UP

• Pour a small quantity of oil into the filler opening (2). Allow one minute for oil to flow into the crankcase.

• Check level and top up if needed.

• Top up with small quantities of oil until obtaining the correct level.

• When finished, tighten the plug/dipstick (1).

NOTE Do not use the vehicle when lubricant levels are low or lubricant has become contaminated. Use specified lubricants only. Improper lubrication will lead to moving parts fretting, resulting in irreparable damage.

500 SPRINT UPDATES 10

SUMMARY

1. UPDATES 3

   1. REFERENCE MANUALS 3

   2. SPECIFICATIONS 4

   3. SCHEDULED MAINTENANCE CHART 7

   4. TIGHTENING TORQUE SETTINGS 8

2. COOLING SYSTEM 13

   1. DIAGRAM 13

   2. REMOVING THE EXPANSION TANK 14

3. THROTTLE BODY 15

   1. REMOVING THE THROTTLE BODY. 15

4. ENGINE 17

   1. REMOVING THE ENGINE 17

   2. REASSEMBLING THE ENGINE ON THE FRAME 24

5. CHASSIS 29

   1. REMOVING THE BATTERY COVER 29

   2. REMOVING THE TAIL GUARD 30

   3. REMOVING THE HELMET COMPARTMENT 32

   4. REMOVING THE SHOCK ABSORBER 34

6. ELECTRIC SYSTEM 35

   1. WIRING DIAGRAM 35

1. UPDATES

   1. REFERENCE MANUALS

      
       

      SPARE PARTS CATALOGUES

      aprilia part# (description)
      6824

      
       

      SPECIAL TOOLS MANUAL

      
       

      aprilia part# (description)
      001H

      
       

      OWNER'S MANUALS

      
       

      aprilia part# (description)
      8104859
      8104867
      8104868

      
       

      CHASSIS WORKSHOP MANUAL

      
       

      aprilia part# (description)
      8140862
      8140863
      8140864
      8140865
      8140866
      8140867
      8CM0080
      8CM0081

      
       

      ENGINE WORKSHOP MANUAL

      
       

      aprilia part# (description)
      8140868
      8140869
      8140870
      8140871
      8140872
      8140873
      8CM0082
      8CM0083

      

   2. SPECIFICATIONS

      DIMENSIONS

      Max. length 2085 mm (82.086 in)

      Max. length 2200 mm (86.614 in)

      Max. width 785 mm (30.905 in)

      Max. width 815 mm (32.086 in)

      Max. height (to the headlight fairing) 1370 mm (53.937 in)

      Seat height 790 mm (31.102 in)

      Wheelbase 1460 mm (57.480 in)

      Wheelbase 1480 mm (58.267 in)

      Wheelbase 1550 mm (61.023 in)

      Minimum ground clearance 190 mm (7.480 in)

      Loadless weight (in running order) 162 kg (357.148 lb)

      Loadless weight (in running order) 170 kg (374.785 lb)

      Loadless weight (in running order) 210 kg (642.970 lb) ENGINE

      Type M 245 M

      Type M 237 M

      Type M 273 M

      Type One cylinder, 4 stroke engine with 4 valves, forced lubrication with wet sump, one overhead camshaft.

      Number of cylinders 1

      Total displacement 124 cu. cm (7.567 cu. in).

      Total displacement 244 cu. cm (14.890 cu. in).

      Total displacement 459 cu. cm (28.010 cu. in).

      Bore I stroke 57 x 48.6 mm (2.244 x 1.913 in)

      Bore I stroke 72 x 60 mm (2.835 x 2.362 in)

      Bore I stroke 92 x 69 mm (3.622 x 2.716 in)

      Compression ratio 12.0 ± 0.5 : 1

      Compression ratio 11.0 ± 0.5 : 1

      Compression ratio 10.5 ± 0.5 : 1

      Starting Electric

      Engine idling rpm 1600 ± 100 rpm

      Engine idling rpm 1450 ± 100 rpm

      Clutch Automatic dry centrifugal clutch

      Gearbox Automatic

      Cooling Liquid cooling (50% water + 50% coolant) with forced circulation

      Valve clearance Intake 0.10 I Exhaust 0.15

      CARBURETTOR

      Type CVK 7 30 KEIHIN

      Type WVF 7 0 29 WALBRO

      FUEL SUPPLY

      Type Vacuum pump

      Fuel Premium grade unleaded petrol, minimum octane rating 95 (ROM) and 85 (MON).

      CAPACITY

      Fuel (reserve included) 9.5 litres (17.25 pt)

      Fuel (reserve included) 14.5 litres (26.33 pt)

      Fuel reserve 1.5 litres (2.72 pt)

      Engine oil

      • engine oil change only 1000 cu. cm (61.024 cu. in).

      • changing engine oil and oil filter 1100 cu. cm (67.126 cu. in).

      • changing engine oil and oil filter 1500 cu. cm (91.535 cu. in).

      • change for engine overhaul 1150 cu. cm (70.177 cu. in).

      • change for engine overhaul 1700 cu. cm (103.74 cu. in).

      Transmission fluid 150 cu. cm (9.154 cu. in).

      Transmission fluid 250 cu. cm (15.256 cu. in).

      Cooling system 1200 cu. cm (73.228 cu. in).

      Cooling system 1500 cu. cm (91.535 cu. in).

      Seats 2

      Max. carrying load (rider + passenger + luggage)

      210 kg (462.970 lb)

      Max. carrying load (rider + passenger + luggage) 200 kg (440.924 lb)

      

      TRANSMISSION

      Converter Automatic, stepless

      Primary V belt

      Final gears

      Total engineIwheel ratio

      • minimum 1:29.40

      • maximum 1:8.78

        Total engineIwheel ratio

      • minimum 1:19.30

      • maximum 1:6.80

        Total engineIwheel ratio

      • minimum 1:12.72

      • maximum 1:4.88

      FRAME

      Type Single beam, superimposed double cradle

      Steering head angle 28°

      Trail 104 mm (4.094 in)

      SUSPENSIONS

      Front Hydraulically operated telescopic fork

      Stroke 105 mm (4.134 in)

      Rear Hydraulic shock absorber

      Stroke 105 mm (4.134 in)

      Stroke 90 mm (3.543 in)

      BRAKES

      Front Disc 0 240 mm (9.449 in) with hydraulic transmission.

      Front Disc 0 260 mm (10.236 in) with hydraulic transmission.

      Rear Disc 0 190 mm (7.480 in) with hydraulic transmission combined with front brake

      Rear Disc 0 220 mm (8.661 in) with hydraulic transmission combined with front brake

      WHEEL RIMS

      Front E 13 x 3.00 DOT D

      Front E 14 x 3.00 DOT D

      Rear E 13 x 3.50 DOT D

      Rear E 14 x 3.75 DOT D

      TYRES

      Type Tubeless

      Front 110 I 90 - 13" 56 P

      Front 120 I 70 - 14" 55 R

      Rear 130 I 70 - 13" 63 P

      Rear 140 I 60 - 14" 64 P

      STANDARD INFLATION PRESSURE

      Front 200 kPa (2.0 bar)

      Front 230 kPa (2.3 bar)

      Rear 220 kPa (2.2 bar)

      Rear 240 kPa (2.4 bar)

      INFLATION PRESSURE WITH PASSENGER

      Front 220 kPa (2.2 bar)

      Front 230 kPa (2.3 bar)

      Rear 240 kPa (2.4 bar)

      Rear 260 kPa (2.6 bar)

      IGNITION

      Type Capacity discharge ignition with variable advance

      Spark advance Variable, controlled by the ECU 5°Iminimum 24°I>4000 rpm

      Spark advance Variable, controlled by the ECU 4°Iminimum 15°I4000 6000 rpm

      Spark advance Variable, controlled by the ECU 20°I3100 rpm 33°I6200 rpm

      

      SPARK PLUG

      Standard

      
       

      As an alternative

      
       

      • NGK CR8EB CHAMPION RG6YC CHAMPION RG4HC

      • NGK CR7EB

      • NGK CR9EB

      • CHAMPION RG6YC

      • CHAMPION RG4HC NGK CR7EKB

      NGK CR8EKB

      Spark plug gap 0.7 - 0.8 mm (0.028 - 0.031 in) ELECTRIC SYSTEM

      Battery 12 V 12 Ah

      Fuses 20 15 7.5 A

      Fuses 3 15 30 A

      Generator (with permanent magnet) 12 V - 180 W

      Generator (with permanent magnet) 12 V 235 W

      Generator (with permanent magnet) 12 V - 380 W BULBS

      Low beam 12 V - 55 W

      High beam 12 V - 55 W

      Parking light 12 V - 16 W

      Direction indicator light 12 V - 10 W

      Tail light I brake light 12 V - 5 W I 21 W

      WARNING LIGHTS

      Instrument panel lighting 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

      

   3. SCHEDULED MAINTENANCE CHART

      
       

      Component

      
       

      After running-in [1000 km (621 mi)]

      
       

      Every 6000 km

      (3728 mi)

      or 8 months

      
       

      Every 12000 km

      (7456 mi)

      or 16 months

      Idle mixture (CO) 1

      Belt, converter rollers and plastic guides 1 3

      Converter belt 1 3

      Steering tube bearings 1 1

      Wheel bearings 1

      Converter cover air filter 2

      Secondary air scoop filter 2

      Clutch jaws 1

      Valve clearance 1

      Brake fluid 1 1 every 2 years:3

      Front suspension fluid 1 1 3

      Engine oil filter screen and magnetic screw 1 1

      Converter rollers and converter plastic guides 1 3

      Wheels I tyres 1

      Nut, bolt, screw tightening 1 1

      Cylinder head nut tightening 1

      Battery terminals tightening 1

      Draining brake fluid 1

      Fuel hose 1 every 2 years:3

      Rear shock absorber 1 1

      Battery I Electrolyte level 1 1

      Spark plug 1 1 3

      Carburettor idling 4 1

      Air filter 2

      Engine oil filter 3 3

      Throttle operation 1 1

      Brake locking operation 1 1

      Converter grease 3

      Stop light switches 1

      Coolant 1 every 1000 km (621 mi): 1 I

      every 16 months: 3

      Engine oil 3 every 1000 km (621 mi): 1 I

      every 6000 months: 3

      Transmission fluid 3 every 6000 km (3728 mi): 1 I

      every 24000 km (14913 mi): 3

      Headlight beam direction operation 1 Tyres I inflation pressure Every month: 1

      Battery terminals tightening 1

      Front suspension 1 1

      Brake pad wear 1 every 2000 km (1250 mi): 1

      
       

      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, on uneven ground or for racing.

      
       

      

      ( ) = OPERATIONS THAT CAN BE CARRIED OUT BY THE USER

   4. TIGHTENING TORQUE SETTINGS

1. COOLING SYSTEM

   1. DIAGRAM

      
       

      

      Key:

      1. Expansion tank

      2. Breather hose

      3. Cylinder pump hose

      4. Water pump cover

      5. By pass hose

      6. Thermostat

      7. Thermostat head hose

      8. Radiator head hose

      9. Radiator

      10. Pump radiator hose

      11. Fan

   2. REMOVING THE EXPANSION TANK

      

      • Remove left side body panel, see (ATLANTIC 125 200 WORKSHOP MANUAL).

      • Drain the cooling system, see (REMOVING THE ENGINE FROM THE FRAME).

      • Loosen and remove the two screws securing the expansion tank.

        
         

        

      • Loosen both clamps of cooling system hoses to remove them.

      • Remove the expansion tank.

        
         

        
         

        

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