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APRILIA CAPONORD Manual Download Page 155

extension and compression (semi-
active Aprilia Dynamic Damping
technology) on left stanchion; and
of spring preload on right
stanchion, manually adjustable

Travel

170 mm (6.69 in)

Rear (Caponord 1200)

Oscillating swingarm connected
with cantilever type link to a Sachs
single shock absorber, with
adjustment of hydraulic braking
during extension and spring
preload with knob.

Rear (Caponord 1200 Travel Pack) Oscillating swingarm connected

with cantilever type link to a Sachs
single shock absorber, with
adjustment of hydraulic braking
during extension and compression
(semi-active Aprilia Dynamic
Damping technology) with "piggy-
back" tank and automated
management (or manually on
instrument panel) of spring preload
via electro-hydraulic system.

Wheel travel

150 mm (5.90 in)

B

RAKES

Front

Double floating disc, Ø 320 mm
(12.60 in), radially-mounted

155

5 Technical data

Summary of Contents for CAPONORD

Page 1: ...ins information tips and precautions for using your vehicle It also describes features details and devices to assure you that you have made the right choice We believe that if you follow our suggestions you will soon get to know your new vehicle well and will use it for a long time at full satisfaction This booklet is an integral part of the vehicle and should the vehicle be sold it must be transf...

Page 2: ...ecks that should be carried out on the vehicle at an Aprilia Dealer or Authorised Workshop The booklet also contains instructions for simple repairs Any operations not specifically described in this booklet require the use of special tools and or particular technical knowledge for these operations please take your vehicle to an Aprilia Dealer or Authorised Workshop 2 ...

Page 3: ...arts of the booklet that should be read with particular care The different symbols are used to make each topic in the manual simple and quick to locate Before starting the engine read this booklet carefully particularly the SAFE RIDING section Your safety as well as other s does not only depend on the quickness of your reflexes and agility but also on how well you know your vehicle the state of ma...

Page 4: ...4 ...

Page 5: ...on 54 Engine stop switch 54 Button Cruise Control 54 System ABS 57 System ATC Aprilia Traction Control 60 ADD system Aprilia Dynamic Damping 63 Immobilizer system operation 65 Opening the saddle 66 Glove tool kit compartment 67 USB Port 67 Identification 69 Adjusting the windscreen 70 Provision for the installation of accessories 70 USE 75 Checks 76 Refuelling 79 Rear shock absorbers adjustment 80...

Page 6: ...ement 129 Position light replacement 130 Front light group 130 Headlight adjustment 131 Front direction indicators 133 Rear optical unit 133 Rear turn indicators 134 Number plate light 134 Rear view mirrors 135 Front and rear disc brake 136 Periods of inactivity 138 Cleaning the vehicle 139 Transport 143 Transmission chain 144 Chain backlash check 145 Chain backlash adjustment 145 Checking wear of...

Page 7: ...CAPONORD Chap 01 General rules 7 ...

Page 8: ...then carefully removing the insects and more stubborn stains before washing the vehicle To prevent stains do not wash the motorcycle immediately after exposure to sunlight and do not wash it in the sun If the vehicle is used during the winter months be sure to frequently wash the motor cycle To remove anti icing salt sprayed on roads in the winter wash the motorcycle with cold water immediately af...

Page 9: ...e stains from tree resins gasoline oil brake fluid or bird excrement in general must be removed immediately otherwise permanent stains on the paint can appear After washing it is easy to identify marks and residual stains remove them from the body using a soft cloth and brand name non abrasive polish and protect with a pro tective wax for cars Periodic care a thorough cleaning and regular protecti...

Page 10: ...RIGHTEN THEM WITH POLISH PASTE PRO TECT THEM WITH WAXES OR SUITABLE ACID FREE PRODUCTS E G VASELINE RADIATOR IF USING THE MOTORCYCLE IN THE WINTER ON ROADS WITH DEICING SALT REGULARLY WASH THE RADIATOR TO PREVENT AESTHETIC DAMAGE AND THE ENGINE FROM OVERHEATING WASH USING PLENTY OF WATER FOR EXAMPLE USE GARDEN RUBBER WITH WATER AT LOW PRESSURE RUBBER PARTS Clean the rubber parts using water and mi...

Page 11: ...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 ex traction system CAUTION EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH CAUTION CARBON MONOXIDE IS ODOURLESS AND COLOURLESS THEREFORE IT CANNOT BE DETECTED BY SMELL SIGHT OR OTHER SENSES DO NOT B...

Page 12: ...D FLAMES SPARKS OR OTHER SOUR CES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE DO NOT DISPERSE FUEL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN IF THE VEHICLE FALLS OR IS ON A STEEP INCLINE FUEL CAN LEAK Hot components The engine and the exhaust system components get very hot and remain in this con dition for a certain time interval after the engine has been switched off Before handling thes...

Page 13: ...E ENGINE OIL ICON IS ON WHILE THE ENGINE IS WORKING PROPERLY THIS MEANS THAT THE OIL PRESSURE IN THE CIRCUIT IS NOT ENOUGH IN THIS CASE THE ENGINE MUST BE IMMEDI ATELY SHUT OFF IN ORDER TO AVOID ANY POSSIBLE DAMAGE CARRY OUT ENGINE OIL LEVEL CHECK IF THE OIL PRESSURE LEVEL RE MAINS LOW ALTHOUGH THE PROCEDURE DESCRIBED ABOVE HAS BEEN PROPERLY CARRIED OUT CONTACT AN OFFICIAL Aprilia DEALER TO HAVE T...

Page 14: ...le flame which can nev ertheless cause burns CAUTION TAKE CARE NOT TO POUR COOLANT ONTO HOT ENGINE OR EXHAUST SYS TEM COMPONENTS THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES WHEN CARRYING OUT MAINTENANCE OPERATIONS IT IS ADVISA BLE TO WEAR LATEX GLOVES EVEN THOUGH IT IS TOXIC COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS NEVER LEAVE THE COOLANT IN OPEN CONTAINERS...

Page 15: ... DO NOT DISPOSE OF OIL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Brake and clutch fluid Brake and clutch fluid BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAIN TED SURFACES WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFU...

Page 16: ...T WITH YOUR EYES WASH WITH ABUNDANT WATER FOR FIF TEEN MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY THE BAT TERY RELEASES EXPLOSIVE GASES KEEP IT AWAY FROM FLAMES SPARKS CIGARETTES OR ANY OTHER HEAT SOURCES ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE DO NOT POUR IT OR SPILL IT PARTICU LARLY ON PLASTIC COMPO...

Page 17: ...e specified in this Use and Maintenance Booklet do not remove any mechanical or electrical component CAUTION SOME CONNECTORS IN THE VEHICLE MAY BE ACCIDENTALLY SWAPPED AND MAY COMPROMISE NORMAL VEHICLE OPERATION IF INCORRECTLY IN STALLED 17 1 General rules ...

Page 18: ...18 1 General rules ...

Page 19: ...CAPONORD Chap 02 Vehicle 19 ...

Page 20: ...02_01 20 2 Vehicle ...

Page 21: ...Legend Caponord 1200 1 Front left fork 2 Left headlamp 3 Central headlamp 4 Front left turn indicator 5 Windshield 6 Auxiliary fuses box 7 Clutch fluid reservoir 8 Left rear view mirror 9 Left light switch 10 Fuel tank cap 11 Fuel tank 21 2 Vehicle ...

Page 22: ...26 Rear right turn indicator 27 Right passenger grab handle 28 USB port 29 Main fuses 30 Battery 31 Adjustable rear shock absorber 32 Right hand light switch 33 Right rear view mirror 34 Front brake system fluid reservoir 35 Cooling liquid reservoir 36 Front right turn indicator 37 Front right headlamp 38 Front right fork 39 Front speed sensor 40 Front right brake calliper 41 Rear brake lever 42 R...

Page 23: ...02_03 23 2 Vehicle ...

Page 24: ...t fork 2 Left headlamp 3 Central headlamp 4 Front left turn indicator 5 Windshield 6 Auxiliary fuses box 7 Clutch fluid reservoir 8 Left rear view mirror 9 Left light switch 10 Fuel tank cap 11 Fuel tank 12 Rider saddle 13 Passenger saddle 24 2 Vehicle ...

Page 25: ...ht saddle bag 29 Rear right turn indicator 30 Right passenger grab handle 31 USB port 32 Main fuses 33 Battery 34 Adjustable rear shock absorber 35 Right hand light switch 36 Right rear view mirror 37 Front brake system fluid reservoir 38 Cooling liquid reservoir 39 Front right turn indicator 40 Front right headlamp 41 Front right fork 42 Front speed sensor 43 Front right brake calliper 44 Rear br...

Page 26: ... control lever 2 Instrument panel 3 Ignition switch steering lock 4 Front brake lever 5 Throttle grip 6 MODE Control 7 Warning lights Control 8 Horn button 9 Light switch 10 Starter button and engine stop switch On Off 11 Heated handgrip button if applicable 26 2 Vehicle ...

Page 27: ...12 Cruise control button if applicable Instrument panel 02_06 02_07 02_06 27 2 Vehicle ...

Page 28: ...isable a key that has been lost When the vehicle is delivered and approximately ten seconds after the key is set to ON the CODE icon will always be blinking the instrument panel requests a personal five digit code to be entered This request is no longer displayed once the personal code is entered For code entering procedure see the CONTROL BUTTONS section It is important to remember the personal c...

Page 29: ...rning light orange Digital lcd display 02_09 02_10 02_11 02_12 02_13 02_14 02_15 02_16 02_17 02_18 02_19 02_20 02_21 02_22 02_23 02_24 02_25 02_26 02_27 The following indicators will light up for a couple of seconds on the instrument panel when the ignition key is set to ON all the warning lights the backlighting turns off after the key is set to ON After two seconds all instruments immediately sh...

Page 30: ...tation in the ECU 2 Engine rpm 3 Speed speedometer can be displayed in Kph or in Mph 4 Fuel level 5 Selected engine mapping 6 Gear selected 7 Immobilizer alarm 8 Engine oil pressure alarm 9 ABS icon viewable in setting phase 10 Any service deadline 11 Engine alarm EFI Electronic Fuel Injection 12 Heated handgrip operating intensity level if applicable 13 Trip computer or any alarms specifically to...

Page 31: ... Trip odometer Reserve travel Travelling time Average travelling speed Maximum saved speed Clock 14 ATC Aprilia Traction Control 15 ADD Aprilia Dynamic Damping 16 Water temperature 02_10 31 2 Vehicle ...

Page 32: ...ne 02_12 ENGINE RPM In the middle of the digital display the indication of the engine rpm 2 is visible with a maximum threshold of 12 000 rpm 12 rpm x 1000 02_13 MAXIMUM SPEED In the middle of the digital display the indication of the maximum speed 3 is visible in kmph or mph depending on your Country NOTE YOU CAN HAVE THE INDICATED VALUE MODIFIED BY CONTACTING AN Offi cial Aprilia Dealer 32 2 Veh...

Page 33: ...E ONE OF THE OTHER BARS 02_15 Two kilometres 1 24 mi after the low fuel warning light turns on the kilometres trav elled with low fuel are shown on the digital display NOTE TO ENSURE A CORRECT READING THE FUEL LOW INDICATION MAY BE DE LAYED BY UP TO 60 SECONDS When the reserve fuel warning light is active pressing a MODE control button will cause it to disappear and reappear 60 seconds later NOTE ...

Page 34: ...wer left of the digital display the indication of the selected gear 6 currently in use can be viewed When the motorcycle is running idle the symbol 0 will be displayed 02_18 ENGINE ALARM EFI Electronic Fuel Injection If there is a system failure the key symbol will be viewable in the middle of the display or the request to enter the user code 7 34 2 Vehicle ...

Page 35: ...LINKING IT MEANS THERE IS AN ALARM DUE TO AB NORMAL OIL PRESSURE IN THE ENGINE 02_20 ABS In the middle of the digital display there is an ABS icon 9 that will only be viewable when setting system parameters 02_21 SERVICE THRESHOLD When the thresholds of the maintenance intervals have been exceeded an adjustable spanner icon will appear 10 in the middle of the digital display This indicator may be ...

Page 36: ... display 02_23 EFI The wording EFI Electronic Fuel Injection 12 will appear in the middle of the digital display should there be problem with the fuel injection 02_24 TRAVEL COMPUTER The travel computer 13 appears in the middle of the digital display to provide specific information on the distance travelled speed and travelling time 36 2 Vehicle ...

Page 37: ...5 preload appears in the right side of the digital display to show the selection made by the rider by way of certain symbols helmets and suitcases 02_27 WATER TEMPERATURE The running temperature of the cooling system 16 can be viewed in the right side of the digital display indicated by a series of bars If the temperature rises to a level that is too high the general warning light will also turn o...

Page 38: ...tal display Take your vehicle as soon as possible to an Official Aprilia Dealer In these cases the control unit activates a safety procedure that limits the vehicle performance so that the rider is able to reach an Official Apri lia Dealer at low speed According to the type of failure performance can be limited in two ways a by reducing the maximum torque produced b by keeping the engine at idle s...

Page 39: ...GHT AWAY AND WITH ROAD AS SISTANCE SERVICE TAKE THE VEHICLE TO AN Official Aprilia Dealer 02_30 Engine overheating alarm The engine overheating alarm is activated when the temperature is higher than or equal to 115 C 239 F and is signalled by all the notch levels turning on and the red general warning light turns on Mapping selection 02_31 The engine control unit foresees 3 different mapping varia...

Page 40: ...LAR CAUTION WHEN RIDING IN POOR GRIP CONDITIONS Push the starter button to go through the different mappings Five seconds after the engine is started this button can be used as a mapping selection button CAUTION MAP SELECTION IS ONLY PERMITTED WITH THE ENGINE RUNNING AND THE THROTTLE RELEASED MAP SELECTION IS ALSO POSSIBLE WITH THE MO TORCYCLE IN MOTION PROVIDED THAT THE THROTTLE GRIP IS RELEASED ...

Page 41: ...ain functions and settings of the digital display among which ATC ADD ABS Calibration Instrument panel backlighting Service functions 02_33 By briefly pressing button B it is possible to view the ATC ADD ABS functions in cycle ATC Aprilia Traction Control To modify the value of the displayed function briefly press button A which will in crease the intensity of the system s intervention from level ...

Page 42: ...NG BETWEEN LEVEL 1 AND LEVEL 3 To deactivate the system hold button A pressed from level 1 until the value displayed is ATC warning light will remain on with a steady light To exit the ATC function hold button B pressed for a few seconds or move off from a standstill NOTE WHEN THE BATTERY IS FIRST CONNECTED THE ATC WARNING LIGHT RE MAINS ON WITH A STEADY LIGHT NOT ACTIVE SYSTEM NOTE WHEN THE VEHIC...

Page 43: ...he driver and lug gage Two helmets correspond to the preload setting with driver and passenger Two helmets and a suitcase correspond to the preload setting with driver passenger and luggage Two helmets and a suitcase blinking in sequence correspond to the preload setting in automatic mode NOTE WITH THE MOTORCYCLE S INSTRUMENT PANEL SWITCHED OFF AT THE NEXT IGNITION OF THE SYSTEM THE ADD KEEPS THE ...

Page 44: ...THE BIKE S PANEL IS OFF AND WHEN TURNING IT ON THE NEXT TIME THE ABS SYSTEM IS STILL ACTIVE REGARDLESS OF WHAT WAS SET PRE VIOUSLY 02_37 CALIBRATION To access the CALIBRATION function simultaneously hold buttons A and B pressed for a few seconds When the function is activated with vehicle at a standstill the following wording will appear on the screen page of the display CAL The high beam light wi...

Page 45: ...PROCE DURE DURING CALIBRATION ATC IS AUTOMATICALLY DEACTIVATED IF PREVI OUSLY ACTIVATED 02_38 BACKLIGHTING To modify the intensity of the digital display s backlighting hold button B pressed for a few seconds to access the adjustments screen page Whenever button A is briefly pressed backlighting intensity indicated by a number on the digital display increases up to a maximum of 5 levels The functi...

Page 46: ...ode During the motorcycle s first ignition the message CODE will appear on the digital display blinking slowly This message warns the rider that the key safety code must be entered To access the function hold button A pressed for a few seconds Enter code 222 briefly pressing button B 02_40 Enter the new 5 digit personal code briefly pressing button B After entering the code it remains displayed un...

Page 47: ...sed for a few seconds Enter code 384 briefly pressing button B Enter the old code 02_42 At this point it is possible to insert the new code 02_43 MODE SWITCH By using the MODE switch it is possible to view reset or modify the information in the trip journal depending on the indicated value 47 2 Vehicle ...

Page 48: ...P JOURNAL 2 icon 2 on the DIGITAL DISPLAY turns on In both journals each time the MODE control is pressed briefly to the right or left the following information is displayed in sequence ODOMETER 1 TRIP ODOMETER 2 TRAVELLING TIME 3 AVERAGE SPEED 4 MAXIMUM SPEED 5 CLOCK 6 With the following options PARTIAL ODOMETER TRAVELLING TIME MAXIMUM SPEED holding the central button down resets all the saved va...

Page 49: ...ur indicator is shown Each time the MODE selector is pressed to the right the minute value increases likewise each time the MODE selector is pressed to the left the minute value decreases Press the MODE selector central part to store the set value and to exit the clock ad justment function 02_46 Ignition switch 02_46 The ignition switch 1 is located at the front of the fuel reservoir The vehicle i...

Page 50: ...g Turn the handlebar completely to the left Turn the key to OFF Push in the key and turn it anticlockwise to the left steer the handlebar slowly until the key is set to LOCK Remove the key CAUTION TO AVOID LOSING CONTROL OF THE VEHICLE NEVER TURN THE KEY TO LOCK WHILE RIDING Horn button 02_47 NOTE ELECTRICAL COMPONENTS FUNCTION ONLY WHEN THE IGNITION KEY IS SET TO ON 50 2 Vehicle ...

Page 51: ...ARNING LIGHT WITH ARROWS FLASHES QUICKLY IT MEANS THAT ONE OR BOTH TURN SIGNALS LIGHT BULBS ARE BURNT OUT The turn indicators have a self cancelling function that implements the following logic With the vehicle at a standstill speed zero the turn indicators continue flashing indefinitely With the vehicle in motion the turn signals self cancel when one the two following conditions is met After a ti...

Page 52: ... the in termediate reset position causes both the time and distance counters to reset and recommence from zero 02_49 High low beam selector 02_49 The high beams are switched on with the light switches located at the centre Press the light switch to the right to turn on the high beam light 02_50 Passing button 02_50 Uses the high beam flash in case of danger or emergency Releasing the switch deacti...

Page 53: ...ch are activated cyclically from level 1 minimum to level 3 maximum each time the control is pressed After level 3 pressing the control again deactivates the function If the key is switched to the OFF position upon restarting the function will be deacti vated NOTE THE HANDGRIPS ARE HEATED ONLY WHEN THE ENGINE IS RUNNING AND ABOVE 2000 RPM REGARDLESS OF THE SELECTED INTENSITY LEVEL 53 2 Vehicle ...

Page 54: ... THIS BUTTON CAN BE USED AS MAPPING SELECTION BUTTON 02_54 Engine stop switch 02_54 It acts as an engine cut off or emergency stop switch Press this switch to stop the engine Button Cruise Control 02_55 02_56 IF APPLICABLE Cruise control is an electronic system which keeps the vehicle at the speed selected by the rider 54 2 Vehicle ...

Page 55: ...t panel The system can be used in a specific speed range only for third through sixth gear even while decelerating with the throttle grip closed as defined in the table below SYSTEM ACTIVATION SPEED SPEED 3rd 4th 5th 6th MIN Speed 50 km h 31 07 mph 60 km h 37 28 mph 65 km h 40 39 mph 70 km h 43 50 mph MAX Speed 100 km h 62 14 MPH 120 km h 74 56 MPH 160 km h 99 42 MPH 180 km h 111 85 MPH 02_55 55 2...

Page 56: ... increase speed up to a maximum 30 km h 18 64 mi more than the selected speed without deactivating the system e g overtake If the speed is increased by more than 30 km h 18 64 mi the system will be deacti vated status changes from SET to ON When throttle is released the motorcycle will return to the selected cruising speed By exceeding the maximum threshold set for each gear in the previous table ...

Page 57: ... ABS The ABS system is a device that prevents wheel locking in case of an emergency braking thus increasing vehicle stability when braking compared with a conventional braking system The ABS system enhances control over the vehicle taking into consideration never to exceed the physical limits of vehicle grip on the road The rider is fully responsible for riding at a suitable speed based on weather...

Page 58: ...he vehicle after the initial instrument panel check the ABS warning light flashes until a speed of 5 kph 3 1 mph is exceeded and then it switches off or continues to flash even after exceeding the speed of 5 kph 3 1 mph If the ABS warning light continues flashing or is permanently on a failure has been detected and the ABS has been automatically deactivated In this case carry out the following ope...

Page 59: ...BOTH THE FRONT AND REAR WHEELS BY OB TAINING INFORMATION FROM THE ROTATION LOCKING TONE WHEELS ALWAYS CHECK THAT THE TONE WHEEL IS CLEAN AND REGULARLY CHECK THAT THE DISTANCE FROM THE SENSOR IS CONSTANT ON ALL 360 GRADES SHOULD THE WHEELS BE REMOVED AND REFITTED IT IS VERY IMPORTANT TO CHECK THAT THE DISTANCE BETWEEN TONE WHEEL AND SENSOR IS THE ONE SPECIFIED FOR CHECKING AND ADJUSTMENT CON TACT A...

Page 60: ...istance between tone wheel and rear sensor 0 3 2 00 mm 0 012 0 079 in System ATC Aprilia Traction Control ATC is a system that monitors and if necessary limits rear wheelspin under acceler ation to increase vehicle stability While ATC improves vehicle control it does not allow the physical handling limits of the vehicle to be exceeded The rider is fully responsible for riding at a suitable speed b...

Page 61: ... or if there is a malfunction Indicator light flashing slowly with system active after key on before exceeding 5 Km h 3 1 mph or in the event of certain malfunctions causing the ATC level to be locked ATC settings no longer modifiable Indicator light flashing quickly when the system intervenes effectively on the traction control ATC SYSTEM DEACTIVATED MANUALLY When starting the vehicle after the i...

Page 62: ... the ATC system deactivated indication persists NOTE SHOULD THIS OCCUR CONTACT AN aprilia Official Dealer THE ATC SYSTEM ACTS ON REAR WHEEL BY OBTAINING INFORMATION FROM THE ROTATION LOCKING TONE WHEELS FITTED ON BOTH WHEELS ALWAYS CHECK THAT THE TONE WHEELS ARE CLEAN AND REGULARLY CHECK THAT THE GAP BETWEEN THE TONE WHEEL AND THE SENSOR IS CONSTANT AROUND THE ENTIRE CIRCUMFERENCE OF THE TONE WHEE...

Page 63: ... FEW km h mi IN THE DIGITAL DISPLAY SUCH BEHAVIOUR IS TO BE CONSIDERED NORMAL AND DOES NOT CREATE MALFUNCTIONS IN THE SYSTEM Characteristic Distance between tone wheel and front sensor 0 3 2 00 mm 0 012 0 079 in Distance between tone wheel and rear sensor 0 3 2 00 mm 0 012 0 079 in ADD system Aprilia Dynamic Damping ADD Aprilia Dynamic Damping is an integrated system that controls the semi active ...

Page 64: ...he height steady as much as possible The system works in two phases 1 With the vehicle at a standstill the engine running gear in idle crutch closed the system performs a first overall preload adjustment if certain signal constance condi tions are met 2 With the vehicle moving the system continuously monitors various signals coming from the vehicle and if certain signal constance conditions are me...

Page 65: ...ACTIVATED WHEN THE ENGINE IS ACTUALLY STARTED 02_57 Immobilizer system operation 02_57 For enhanced theft protection the vehicle is equipped with an electronic immobilizer system that is activated automatically when the ignition key is removed Keep the second key in a safe place since it is not possible to make a copy if it gets lost This would imply replacing numerous parts of the vehicle besides...

Page 66: ... the vehicle on its stand Insert the key 1 in the lock located on the left fairing Turn the key 1 clockwise and remove the passenger saddle 2 There is a useful document compartment in the vehicle tail fairing Remove the pas senger saddle 2 to reach it 02_59 To lock the saddle 2 Move the passenger saddle 2 to fasten the front retainers correctly Push the back of the passenger saddle 2 where the rea...

Page 67: ...tment 02_61 USB Port 02_61 02_62 02_63 There is USB port in the glove box toolkit To use it remove the cover and the protective plug TO AVOID THAT WATER AND OR HUMIDITY CAN DAMAGE THE USB PORT USE THE PROTECTIVE COVER EVEN WHEN A DEVICE IS CONNECTED THE INCLUDED USB PORT IS COMPATIBLE WITH DEVICES OF THE FOLLOW ING BRANDS Apple iPhone Apple iPod Apple iPod Nano Apple iPod Touch 67 2 Vehicle ...

Page 68: ...CE IS CONNECTED ENSURE THE CORRECT POSITIONING OF THE CABLE TO AVOID THAT IT WILL BE SMASHED 02_63 To remove the cover press the locking tongue The USB port is activated once the key is turned to position ON WARNING PROLONGED USE OF THE PLUG SOCKET MAY RESULT IN PARTIAL DIS CHARGE OF THE BATTERY 68 2 Vehicle ...

Page 69: ...mber is handy when purchasing spare parts CAUTION THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISH ABLE CRIME HOWEVER THE LIMITED WARRANTY FOR NEW VEHICLES WILL BE VOID IF THE VEHICLE IDENTIFICATION NUMBER VIN HAS BEEN MODI FIED OR NOT PROMPTLY DETERMINED 02_64 CHASSIS NUMBER The chassis number is stamped on the right side of the headstock Chassis No 69 2 Vehicle ...

Page 70: ...o adjust the windscreen manually as follows upholding the windscreen and working on both its sides loosen the two knobs adjust the windscreen to the desired position upholding the windscreen and working on both its sides tighten the two knobs Provision for the installation of accessories 02_67 02_68 02_69 02_70 02_71 02_72 SIDE PANNIERS if applicable 70 2 Vehicle ...

Page 71: ...H BAG AN EXCESSIVE LOAD COULD DAMAGE IT COVER OPENING Rest the vehicle on its stand Introduce the key 1 in the pannier cover handle 2 Turn the key 1 anticlockwise 02_67 Lift the handle 2 and free it from the cover 3 Open the cover 3 71 2 Vehicle ...

Page 72: ...VAL Lift the safety stopper 02_70 Introduce the key 1 in the pannier cover handle 2 Turn the key 1 anti clockwise Pull the pannier and free it from the stopper Lift it and unthread it from the fixing hooks 72 2 Vehicle ...

Page 73: ...02_71 73 2 Vehicle ...

Page 74: ...74 2 Vehicle ...

Page 75: ...CAPONORD Chap 03 Use 75 ...

Page 76: ... TECTED OR SUSPECTED CHECKING TAKES VERY LITTLE TIME BUT CON SIDERABLY INCREASES SAFETY CAUTION ACCORDING TO THE TIME ELAPSED FROM THE MOMENT THE KEY IS SET TO KEY ON UNTIL THE ENGINE STARTS THE STOP LIGHT CAN BE ACTIVATED FOR ABOUT HALF A SECOND OR NOT 03_01 This vehicle has been programmed to indicate in real time any operation failure stored in the electronic control unit memory Every time the ...

Page 77: ... lubricate if necessary Engine oil Check and or top up as required Wheels tyres Check that tyres are in good conditions Check inflation pressure tyre wear and potential damage Remove any possible strange body that might be stuck in the tread design Brake levers Check they function smoothly Lubricate the joints and adjust the travel if necessary Clutch Check for proper operation Check clutch lever ...

Page 78: ...cate couplings and joints if necessary Check the safety switch for correct operation Clamping elements Check that the clamping elements are not loose Adjust or tighten them as required Drive chain Check it for backlash Fuel tank Check the coolant level and refill if necessary Check the circuit for leaks or obstructions Check that the tank cap closes correctly Coolant Fluid level inside the expansi...

Page 79: ...are perfectly clean and in good conditions 03_02 Refuelling 03_02 To refuel Lift the cover 1 Introduce the key 2 in the fuel tank cap lock 3 Turn the key clockwise pull and open the fuel tank lid Characteristic Fuel tank reserve included 24 l 5 28 UK gal 6 34 US gal Fuel reserve 4 l 0 88 UK gal 1 06 US gal Refuel CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCES TO THE FUEL 79 3 Use ...

Page 80: ...JURIES AND FIRE HAZARD DURING REFUELLING AVOID THE USE OF ELECTRIC DEVICES AND OR MO BILE PHONES BECAUSE FUEL VAPOURS MAY CAUSE DAMAGE TO OBJECTS AND OR PERSONAL INJURIES after refuelling The fuel cap may only be refitted with the key 2 inserted Once the key 2 is inserted press the cap to close it again Remove the key 2 Close the cover 1 MAKE SURE THE CAP IS TIGHTLY CLOSED Rear shock absorbers adj...

Page 81: ...NTENANCE OPERATIONS AT HALF THE INTERVALS SPECI FIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDI TIONS OFF ROAD OR FOR TRACK USE CAUTION DO NOT STRAIN THE ROTATION OF ADJUSTMENT SETTINGS 1 2 BEYOND THE END OF THE STROKE IN BOTH SENSES IN ORDER TO AVOID ANY DAM AGE Standard rear shock absorber setting is adjusted to suit most high and low speed riding conditions to transport the rider...

Page 82: ...s configured for use with semi active shock absorbers CAUTION THE REAR SHOCK ABSORBER IS ELECTRONICALLY MANAGED BY THE VCU AND CAN BE SET WITH THE CONTROLS ON THE INSTRUMENT PANEL TO AL WAYS HAVE IDEAL RIDING CONDITIONS Rear shock absorbers setting 03_05 03_06 Caponord 1200 REAR SHOCK ABSORBER ADJUSTMENT Spring preloading Hydraulic rebound damping Rider Open 0 turns turn counter clockwise Open 17 ...

Page 83: ...0 turns turn counter clockwise Open 5 clicks turn counter clockwise 03_05 NOTE BEFORE PROCEEDING WITH THE ADJUSTMENT OF THE SHOCK ABSORBER CLOSE THE ADJUSTERS COMPLETELY CLOCKWISE Caponord 1200 Travel Pack 03_06 This version is configured for use with semi active shock absorbers CAUTION THE REAR SHOCK ABSORBER IS ELECTRONICALLY MANAGED BY THE VCU AND CAN BE SET WITH THE CONTROLS ON THE INSTRUMENT ...

Page 84: ...king in sequence correspond to the motorcycle set ting in automatic mode NOTE WITH THE MOTORCYCLE S INSTRUMENT PANEL SWITCHED OFF AT THE NEXT IGNITION OF THE SYSTEM THE ADD KEEPS THE SETTINGS CHOSEN PREVIOUSLY Front fork adjustment 03_07 03_08 Caponord 1200 Operating the front brake lever press the handlebar repeatedly to send the fork fully down The shock absorber should compress and extend smoot...

Page 85: ...open by 5 turns for both stanchions Hydraulic braking in extension fully screwed open by 10 turns left stanchion Hydraulic braking in compression fully screwed open by 10 turns left stanchion CAUTION TO PREVENT DAMAGE DO NOT FORCE THE ADJUSTER 1 2 BEYOND THE RESPECTIVE END OF TRAVEL IN EITHER DIRECTION USE THE SAME SPRING PRELOAD SETTINGS FOR BOTH STEMS RIDING THE VEHICLE WITH DIFFER ENT SETTINGS ...

Page 86: ...The standard setting of the stanchion is obtained by starting off from a fully closed nut clockwise and opening it anti clockwise by 5 turns CAUTION THE ONLY ADJUSTMENT POSSIBLE CAN BE PERFORMED ON THE RIGHT STANCHION WHILE THE LEFT ONE CANNOT BE ADJUSTED SINCE IT IS ELECTRONICALLY MANAGED 03_09 Justering af greb til forbremse 03_09 Adjust the distance between the lever end and the hand grip by tu...

Page 87: ...w To adjust push the control lever forward and turn the set screw until the arrow points at the desired number Running in Running in is essential to ensure the durability of the vehicle During the first 1000 Km 621 37 mi observe the following rules to ensure the reliability and performance of the vehicle throughout its lifetime Avoid full throttle starts and hard acceleration Avoid hard or prolong...

Page 88: ...ged braking That is to permit the adequate adjustment of the pad fric tion material to the brake discs AFTER THE SPECIFIED MILEAGE TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE AFTER RUN IN TABLE IN THE SCHEDULED MAINTENANCE SECTION TO AVOID INJURING YOURSELF OTH ERS AND OR DAMAGING THE VEHICLE Starting up the engine 03_11 03_12 03_13 03_14 03_15 This vehicle is e...

Page 89: ...GINE WILL STOP WITH THE SIDE STAND RETRACTED THE ENGINE MAY BE STARTED WITH THE GEARBOX IN NEUTRAL OR WITH GEAR ENGAGED AND THE CLUTCH LEVER PRESSED 03_11 Get onto the bike in riding position Make sure that the stand has been fully retracted Make sure the light switch 1 is set to the low beam light position Set the engine stop switch 2 to RUN Turn the key 3 and set the ignition switch to ON At thi...

Page 90: ...ndicator light 7 lit There is a starter on the vehicle controlled by the control unit that starts working automatically whenever necessary cold start TO AVOID EXCESSIVE BATTERY CONSUMPTION DO NOT HOLD DOWN THE STARTER BUTTON 2 MORE THAN TEN SECONDS IF THE ENGINE FAILS TO START AFTER THIS TIME WAIT TEN SECONDS AND PRESS THE STARTER BUTTON 2 AGAIN PRESS THE STARTER BUTTON 2 BUT DO NOT ACCELERATE AND...

Page 91: ...ES THIS WILL ALLOW THE ENGINE TO WARM UP AND REDUCE POLLUTING EMISSIONS AND FUEL CONSUMPTION WHEN THE EFI ICON APPEARS AND THE GENERAL WARNING LIGHT IS PER MANENTLY ON WHILE THE ENGINE IS NORMALLY RUNNING IT MEANS THE ECU HAS DETECTED SOME FAULT CONTACT AN Official Aprilia Dealer ASAP WHEN THE EFI ICON APPEARS AND THE GENERAL WARNING LIGHT IS BLINK ING WHILE THE ENGINE IS NORMALLY RUNNING IT MEANS...

Page 92: ...e when torque demand is requested by means of the throttle is the same as when riding on level ground thus shifting the characteristic power reduction to the highest speeds As a result throttles are fully open but the throttle grip is not fully twisted therefore in case the throttle grip is further and fully twisted the vehicle performance will not be further enhanced 03_16 Moving off riding 03_16...

Page 93: ...ENCE HELPS YOU JUDGE THE DISTANCE SEPARAT ING YOU AND THE VEHICLE BEHIND 03_18 With throttle grip 2 closed Pos A and engine at idle operate the clutch lever 3 Push the gearbox lever 4 downward to select the first gear Release the clutch lever activated during start up CAUTION WHEN TURNING OFF THE VEHICLE DO NOT RELEASE THE CLUTCH TOO QUICKLY OR SUDDENLY AS THIS COULD CAUSE THE ENGINE TO STOP OR TH...

Page 94: ...econd gear RIDE IN THE CORRECT GEAR AND SPEED FOR THE CONDITIONS DO NOT CHANGE GEAR AT A TOO LOW RPM LEVEL Release the throttle grip 2 Pos A operate the clutch lever 3 lift the gearshift lever 4 release the clutch lever 3 and accelerate Repeat the last two operations and engage a higher gear IF THE ENGINE OIL PRESSURE ICON IS DISPLAYED AND THE GENERAL WARNING LIGHT IS ON DURING REGULAR ENGINE OPER...

Page 95: ...E COULD OVERREV THE ENGINE THAT IS THE MAXIMUM RPM VALUE PERMITTED FOR THE ENGINE COULD BE EXCEEDED 03_20 Moving off riding 03_19 03_20 03_21 03_22 03_23 03_24 03_25 CAUTION IF WHILE RIDING THE LOW FUEL WARNING LIGHT 1 ON THE INSTRUMENT PANEL TURNS ON IT MEANS THERE IS STILL SOME FUEL LEFT REFUEL AS SOON AS POSSIBLE CAUTION WHEN TRAVELLING WITHOUT PASSENGERS MAKE SURE THE PASSENGER FOOTRESTS ARE F...

Page 96: ...ENCE HELPS YOU JUDGE THE DISTANCE SEPARAT ING YOU AND THE VEHICLE BEHIND 03_22 With throttle grip 2 closed Pos A and engine at idle operate the clutch lever 3 Push the gearbox lever 4 downward to select the first gear Release the clutch lever activated during start up CAUTION WHEN TURNING OFF THE VEHICLE DO NOT RELEASE THE CLUTCH TOO QUICKLY OR SUDDENLY AS THIS COULD CAUSE THE ENGINE TO STOP OR TH...

Page 97: ...nd gear RIDE IN THE CORRECT GEAR AND SPEED FOR THE CONDITIONS DO NOT CHANGE GEAR AT A TOO LOW RPM LEVEL 03_24 Release the throttle grip 2 Pos A operate the clutch lever 3 lift the gearshift lever 4 release the clutch lever 3 and accelerate Repeat the last two operations and engage a higher gear IF THE ENGINE OIL PRESSURE ICON IS DISPLAYED AND THE GENERAL WARNING LIGHT IS ON DURING REGULAR ENGINE O...

Page 98: ...THAN ONE GEAR AT A TIME COULD OVERREV THE ENGINE THAT IS THE MAXIMUM RPM VALUE PERMITTED FOR THE ENGINE COULD BE EXCEEDED Release the throttle grip 2 Pos A If necessary pull the brake levers gently and reduce speed Operate the clutch lever 3 and lower the gearshift lever 4 to engage a lower gear Release the brake levers when it is operated Release the clutch lever 3 and accelerate moderately IF AN...

Page 99: ...WILL CONTINUE TO OPERATE WITH LIMITED PERFORMANCE IMMEDIATELY CONTACT AN Official Aprilia Dealer IN ORDER TO AVOID CLUTCH OVERHEATING SHUT THE ENGINE OFF AS SOON AS POSSIBLE ONCE THE VEHICLE HAS STOPPED AND AT THE SAME TIME THE GEAR IS ENGAGED AND THE CLUTCH LEVER OPERATED OPERATING ONLY EITHER THE FRONT OR THE REAR BRAKE SIGNIFICANTLY REDUCES BRAKING POWER AND A WHEEL MAY GET BLOCKED RESULTING IN...

Page 100: ...s to slow down Once the speed is reduced before stopping the vehicle Operate the clutch lever 2 so that engine does not shut off When the vehicle is at a standstill Set the gearshift lever in neutral green N indicator light lit Release the clutch lever While at a temporary halt keep at least one of the vehicle brakes held CAUTION WHENEVER POSSIBLE AVOID ROUGH BRAKING SUDDEN DECELERATION AND BRAKIN...

Page 101: ...E UNATTENDED WITH THE ENGINE ON OR THE KEY IN THE IGNITION SWITCH CAUTION IF THE VEHICLE FALLS OR IS ON A STEEP INCLINE FUEL CAN LEAK FUEL USED TO DRIVE INTERNAL COMBUSTION ENGINES IS HIGHLY FLAM MABLE AND CAN BECOME EXPLOSIVE UNDER CERTAIN CONDITIONS DO NOT REST THE RIDER OR PASSENGER WEIGHT ON THE SIDE STAND Catalytic silencer The vehicle has a silencer with a platinum palladium rhodium three wa...

Page 102: ...element belonging to a new vehicle or any other action by anyone leading to render it non operating if not for maintenance repair or replacement reasons in order to control noise emission before the sale or delivery of the vehicle to the ultimate buyer or while it is used using the vehicle after that device or element has been removed or rendered non operating Check the muffler exhaust silencer an...

Page 103: ...left grip and put the right hand on the upper rear part of the vehicle Push the side stand with your right foot to fully extend the stand Lean the vehicle until the stand touches the ground Turn the handlebar fully leftwards CAUTION MAKE SURE THE VEHICLE IS STABLE 03_27 CAUTION CAREFULLY CLEAN THE STAND JOINT BY REMOVING THE DIRT THEN LUBRICATE THE JOINT EVERY 5000 km 31036 mi For the lubricating ...

Page 104: ...ft grip and grab the passenger handle with the right hand on the upper rear part of the vehicle Push the centre stand downward with your right foot and simultaneously lift the motorcycle with your right hand and pull it back CAUTION MAKE SURE THE VEHICLE IS STABLE Suggestion to prevent theft CAUTION WHEN USING A DISC LOCKING DEVICE PAY UTMOST ATTENTION TO RE MOVE IT BEFORE RIDING FAILURE TO OBSERV...

Page 105: ...tional anti theft device Make sure all vehicle documents are in order and the road tax paid Write down your personal details and telephone number on this page to help identifying the owner in case of vehicle retrieval after a theft LAST NAME NAME ADDRESS TELEPHONE NO WARNING IN MANY CASES STOLEN VEHICLES CAN BE IDENTIFIED BY DATA IN THE USE MAINTENANCE BOOKLET 03_30 105 3 Use ...

Page 106: ...he event of the rider or the passenger falling off the vehicle and or the vehicle falling or overturning When getting on and off the vehicle make sure nothing is restricting your movements do not hold any objects in your hands helmet gloves or goggles not put on Always get on and off the vehicle on the left side and with the side stand lowered 106 3 Use ...

Page 107: ... BALANCE THE VEHICLE WHILE THE PASSENGER IS GETTING ON OR OFF THE VEHICLE When getting on and off the vehicle the passenger must move carefully so as not to cause a loss of stability for vehicle and rider CAUTION THE RIDER MUST INSTRUCT THE PASSENGER ON HOW TO GET ON AND OFF THE VEHICLE SAFELY THE VEHICLE IS EQUIPPED WITH PASSENGER FOOTRESTS TO FACILITATE GETTING ON OR OFF THE VEHICLE THE PASSENGE...

Page 108: ...WILL PREVENT A FALL ON THE LEFT SIDE AND BE READY TO PUT YOUR LEFT FOOT ON THE GROUND Place both feet on the ground straighten and balance the vehicle keeping it upright in riding position CAUTION THE RIDER MUST NOT EXTRACT OR ATTEMPT TO EXTRACT THE PASSENGER FOOTRESTS WHILE SEATED BECAUSE THIS MIGHT COMPROMISE VEHICLE STABILITY AND BALANCE Have the passenger fold out the two passenger footrests G...

Page 109: ...LEFT SIDE AND BE READY TO PUT YOUR LEFT FOOT ON THE GROUND Place both feet on the ground and keep the vehicle balanced in the upright position Give instructions as necessary to help the passenger dismount the vehicle RISK OF FALLING AND OVERTURNING MAKE SURE THE PASSENGER HAS GOT OFF THE VEHICLE DO NOT REST YOUR WEIGHT ON THE SIDE STAND Tilt the motorcycle until the stand touch the ground Grasp th...

Page 110: ...CAUTION MAKE SURE THE VEHICLE IS STABLE 110 3 Use ...

Page 111: ...CAPONORD Chap 04 Maintenance 111 ...

Page 112: ...COLD OIL LEVEL COULD TEM PORARILY DROP BELOW THE MIN MARK THIS SHOULD NOT BE CONSIDERED A PROBLEM PROVIDED THAT THE ALARM WARNING LIGHT AND THE ENGINE OIL PRESSURE ICON DO NOT TURN ON SIMULTANEOUSLY ON THE DISPLAY CAUTION DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL PREFERABLY CHECK THE OIL AFTER A JOURNEY OF AFT...

Page 113: ...k the oil level from the sight glass on the clutch case MAX maximum level MIN minimum level The difference between the MAX and MIN marks is approx 460 cm 28 07 cu in The oil level is correct when it is close to the MAX mark CAUTION THE VEHICLE MUST BE UNLOADED 04_04 Engine oil top up 04_04 CAUTION DO NOT GO BEYOND THE MAX AND BELOW THE MIN LEVEL MARK TO AVOID SEVERE ENGINE DAMAGE 113 4 Maintenance...

Page 114: ...D OF THE MANUAL Top up the oil in the reservoir until you reach the correct level Engine oil change CAUTION TO CHANGE THE ENGINE OIL PLEASE CONTACT AN Official aprilia Dealer IF YOU ARE ADEQUATELY TRAINED AND EXPERIENCED REFER TO THE IN STRUCTIONS IN THE WORKSHOP BOOKLET AVAILABLE ALSO AT ANY DEAL ER Engine oil filter replacement CAUTION TO REMOVE AND CLEAN THE ENGINE OIL FILTER PLEASE CONTACT AN ...

Page 115: ...EBAR RESULTING IN AN UNPLEASANTLY HARSH RIDE AND POOR ROAD HOLDING ESPECIALLY WHEN CORNERING AN UNDERINFLATED TYRE ON THE OTHER HAND WILL EXTEND THE CON TACT PATCH TO INCLUDE A LARGER PORTION OF THE TYRE SIDEWALLS WHEN THIS IS THE CASE THE TYRE MIGHT SLIP ON OR BECOME DETACHED FROM THE WHEEL RIM LEADING TO LOSS OF CONTROL OVER THE VEHICLE TYRES MAY EVEN DETACH FROM THE WHEEL RIMS UNDER VERY HARD B...

Page 116: ...E COATED WITH A SLIPPERY COATING RIDE WITH CAUTION DURING THE FIRST KILOMETRES DO NOT APPLY UNSUITA BLE LIQUIDS ON TYRES WHEN TYRES ARE OLD THE MATERIAL MAY HARD EN AND NOT PROVIDE ADEQUATE ROAD HOLDING EVEN IF TYRES ARE STILL WITHIN THE WEAR LIMIT SHOULD THIS OCCUR REPLACE THE TYRES Minimum tread depth front and rear 2 mm 0 079 in USA 3 mm 0 118 in or more if so required by appli cable legislatio...

Page 117: ...MUM LEVEL MARKED MIN CAUTION COOLANT IS TOXIC IF INGESTED CONTACT WITH YOUR EYES OR SKIN MAY CAUSE IRRITATION IF THE FLUID GETS IN CONTACT WITH THE EYES OR SKIN RINSE REPEATEDLY WITH PLENTY OF WATER AND SEEK MEDICAL ADVICE IF SWALLOWED INDUCE VOMITING RINSE MOUTH AND THROAT WITH PLENTY OF WATER AND SEEK MEDICAL ADVICE IMMEDIATELY CAUTION TAKE CARE NOT TO POUR COOLANT ONTO HOT ENGINE OR EXHAUST SYS...

Page 118: ...URNS AND OR INJURIES NOTE TAKE YOUR VEHICLE TO AN Official APRILIA Dealer TO HAVE THE COOLANT CHANGED WARNING WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING UP THE COOLANT LEVEL 04_05 CHECK AND TOPPING UP Shut off the engine and wait until it cools off Keep the vehicle upright and with the two wheels on the ground Turn the handlebar to the left keeping the vehicle upright Make sure th...

Page 119: ...or the front brake rest the vehicle on its stand and turn the handlebar so that the fluid in the reservoir is parallel to the reservoir edge Check that the fluid in the reservoir is above the MIN reference mark For the rear brake keep the vehicle upright and check that the fluid in the reservoir is parallel to the reservoir edge Make sure that the fluid level in the reservoir is above the MIN refe...

Page 120: ...CTIONS IN THE WORKSHOP BOOKLET WHICH IS AVAILABLE FROM ANY DEALER 04_09 Checking clutch fluid 04_09 Rest the vehicle on its stand Turn the handlebar so that the fluid in the reservoir is parallel to the reservoir edge Make sure that the fluid level in the reservoir is above the MIN reference mark Top up if the fluid does not reach at least the MIN reference mark 120 4 Maintenance ...

Page 121: ...D EXPERIENCED REFER TO THE IN STRUCTIONS IN THIS WORKSHOP BOOKLET AVAILABLE ALSO AT ANY DEALER 04_10 Battery removal 04_10 04_11 04_12 Make sure that the ignition switch is set to OFF Remove the saddle Remove the tool kit Remove the fixing screw 1 of the rider saddle 04_11 Undo the screws 2 and remove the cover 3 121 4 Maintenance ...

Page 122: ...ES ARE NOT INVERTED CAUTION UPON REFITTING CONNECT THE LEAD TO THE POSITIVE TERMINAL FIRST AND AFTERWARDS THE LEAD TO THE NEGATIVE TERMINAL CHECK THAT THE BATTERY LEADS AND TERMINALS ARE IN GOOD CONDITION NOT CORRODED OR COVERED BY DEPOSITS COVERED BY NEUTRAL GREASE OR PETROLEUM JELLY Checking the electrolyte level WARNING THIS VEHICLE IS FITTED WITH A MAINTENANCE FREE BATTERY AND DOES NOT NEED AN...

Page 123: ... CAUTION WHEN RECHARGING OR USING THE BATTERY BE CAREFUL TO HAVE THE ROOM ADEQUATELY AIRED DO NOT BREATH GASES RELEASED WHEN THE BATTERY IS RECHARGING Switch on the battery charger Characteristic Recharge modes Recharge Ordinary Electric Current 1 0 A Time 8 10 hours Recharge Fast Electric Current 6 A Time 1 hour 123 4 Maintenance ...

Page 124: ...ery to avoid sulphation Remove the battery In winter or when the vehicle is out of use for prolonged periods check charge level frequently about once a month to prevent deterioration Recharge it fully with an ordinary charge If the battery is still on the vehicle disconnect the cables from the terminals NOTE THE FIRST TIME THE ENGINE IS STARTED AFTER RECONNECTING THE BAT TERY LEADS WAIT 20 SECONDS...

Page 125: ... Dealer 04_13 To check Set the ignition switch to OFF to avoid an accidental short circuit Open the cover of the secondary fuse box on the front left Take out one fuse at a time and check if the filament is broken Before replacing the fuse find and solve whenever possible the problem that caused it to blow If the fuse is damaged replace it with one of the same current rating To check the main fuse...

Page 126: ...DARY FUSES front left side above the water radiator Caponord 1200 1 A Recovery logic relay safety Stop Horn Daylight running light License plate light 10 A 2 Instrument panel power supply anti theft power supply if installed EVC power supply arrangement bludeash key 7 5 A 3 ECU positive live 15 A 4 Permanent ECU positive 7 5 A 5 Coils injectors petrol pump 15 A 6 Low beam high beam light power rel...

Page 127: ...pply anti theft power supply if installed VCU power supply arrangement bludeash key 7 5 A 3 ECU positive live 15 A 4 Permanent ECU positive 7 5 A 5 Coils injectors petrol pump 15 A 6 Low beam high beam light power relay lights 15 A 7 Fans 15 A NOTE THREE FUSES 8 ARE SPARE FUSES 04_16 MAIN FUSES under the saddle remove the battery protection A Battery recharge primary injection relay key arrangemen...

Page 128: ...ES FOR THE BULB TO COOL OFF WEAR CLEAN GLOVES OR USE A CLEAN DRY CLOTH TO REPLACE THE BULB DO NOT LEAVE PRINTS ON THE BULB AS THIS MAY CAUSE IT TO OVERHEAT OR EVEN BLOW OUT IF YOU TOUCH THE BULB WITHOUT WEARING GLOVES CLEAN OFF PRINTS WITH ALCOHOL TO AVOID DAMAGING THE BULB DO NOT FORCE ELECTRICAL CABLES BULB LAYOUT In the headlamp there are two tail light bulbs side two low beam light bulbs side ...

Page 129: ... LED 04_17 Low High beam lamp replacement 04_17 04_18 REPLACEMENT OF LOW BEAM BULB Rest the vehicle on its stand Disconnect the connector 1 04_18 Turn the bulb holder 2 anticlockwise and remove it Replace the bulb 129 4 Maintenance ...

Page 130: ...ector 1 04_20 Turn the bulb holder 2 anticlockwise and remove it Replace the bulb Front light group NOTE IN CASE OF MOTORCYCLE WASH OR IN CASE OF BOUNCING VARIATIONS THE FRONT PROJECTOR MIGHT MIST UP THE BEHAVIOUR IS TOTALLY NOR MAL AND THE CONDENSED WATER WILL QUICKLY DISAPPEAR BY USING THE LOW BEAM AND HIGH BEAM FUNCTION 130 4 Maintenance ...

Page 131: ...he vehicle on a level surface 10 m 32 8 ft away from a vertical wall Turn on the dipped beam light sit on the vehicle and check that the light beam projected onto the wall is a little below the level of the headlight about 9 10 of the total height To carry out vertical adjustment of the light beam Rest the vehicle on its stand Remove the horn fixing screw 1 04_23 Remove the horn 2 after having dis...

Page 132: ...light beam down 04_26 In order to carry out horizontal adjustment of the light beam Rest the vehicle on its stand Working from the rear side of the windshield use a crosshead screwdriver to operate on the specific central screws 6 SCREW it clockwise to move the light beam to the left UNDO it anticlockwise to move the light beam to the right NOTE CHECK THAT THE LIGHT BEAM HORIZONTAL DIRECTION IS CO...

Page 133: ...its fitting Insert a bulb of the same type adequately WARNING IF THE HEADLIGHT 4 PROTRUDES FROM ITS FITTING INSERT IT AGAIN PROPERLY Rear optical unit CAUTION TO REMOVE CHECK AND REPLACE THE BULB PLEASE CONTACT AN Official Aprilia Dealer IF YOU ARE ADEQUATELY TRAINED AND EXPERIENCED RE FER TO THE INSTRUCTIONS IN THIS WORKSHOP BOOKLET AVAILABLE ALSO AT ANY DEALER 133 4 Maintenance ...

Page 134: ...ss 2 Press bulb 3 slightly and turn it anticlockwise Pull the bulb 3 out of its fitting Insert a bulb of the same type adequately WARNING IF THE HEADLIGHT 4 PROTRUDES FROM ITS FITTING INSERT IT AGAIN PROPERLY 04_29 Number plate light 04_29 04_30 Remove the bulb holder fixing screw 1 134 4 Maintenance ...

Page 135: ...4_32 Park the vehicle on its centre stand on safe and level ground Move the protection casing 1 HOLD THE REAR VIEW MIRROR 4 TO AVOID DROPPING IT BY ACCIDENT 04_31 Keep the screw 2 blocked and completely unscrew the nut 3 HANDLE PLASTIC AND PAINTED COMPONENTS WITH CARE DO NOT SCRATCH OR SPOIL THEM 135 4 Maintenance ...

Page 136: ...T THE REAR VIEW MIRRORS CORRECTLY AND TIGHTEN THE NUTS IN ORDER TO ENSURE STABILITY 04_32 After refitting Adjust the rear view mirror angle correctly Front and rear disc brake 04_33 04_34 THOROUGHLY DRY THE BRAKE DISCS WHEN YOU HAVE FINISHED CLEAN ING TO AVOID THE PADS STICKING TO THE DISCS 136 4 Maintenance ...

Page 137: ...ds as follows at the front for the front brake callipers on the right side of the vehicle look from above downwards for the rear brake cal liper CAUTION EXCESSIVE WEAR OF THE FRICTION MATERIAL MAKES THE PAD METAL SUPPORT GET INTO CONTACT WITH THE DISC WHICH RESULTS IN A MET ALLIC NOISE AND SPARKS IN THE CALLIPER THEREFORE BRAKING EFFI CIENCY AND DISC SAFETY AND INTEGRITY ARE AT RISK 137 4 Maintena...

Page 138: ...garaging the motorcycle as one can forget to do so afterwards Proceed as follows Remove the battery Wash and dry the vehicle Polish the painted surfaces Inflate the tyres Set the vehicle in a room with no heating or humidity with minimum temper ature variations and not exposed to sun rays Wrap and tie a plastic bag around the exhaust pipe opening to keep moisture out NOTE PLACE A SUITABLE SUPPORT ...

Page 139: ...tly if exposed to adverse conditions such as Air pollution cities and industrial areas Salinity and humidity in the atmosphere seashore areas hot and wet weath er Special environmental seasonal conditions use of salt anti icing chemical products on the roads in winter Always clean off any smog and pollution residue tar stains insects bird droppings etc from the bodywork Avoid parking the vehicle u...

Page 140: ...Y AFFECTED DUE TO THE PRESENCE OF WATER ON THE FRICTION SURFACES OF THE BRAKING CIRCUIT ALLOW LONGER BRAKING DISTAN CES TO PREVENT ACCIDENTS BRAKE REPEATEDLY TO RESTORE NORMAL OPERATION CARRY OUT THE PRE RIDE CHECKS To remove dirt and mud accumulated on painted surfaces wet the soiled areas thor oughly with a low pressure water jet then remove dirt and mud with a soft car body sponge soaked abunda...

Page 141: ...HED IN DIRECT SUNLIGHT ESPECIALLY DURING SUMMER OR WITH THE BODYWORK STILL HOT AS THE CAR SHAMPOO CAN DAMAGE THE PAINT WORK IF IT DRIES BEFORE BEING RINSED OFF CAUTION DO NOT USE WATER OR LIQUIDS AT TEMPERATURES OVER 40 C 104 F WHEN CLEANING THE VEHICLE PLASTIC PARTS DO NOT AIM HIGH PRES SURE AIR WATER JETS OR STEAM JETS DIRECTLY ON THESE COMPO NENTS DO NOT USE ALCOHOL OR SOLVENTS TO CLEAN ANY RUB...

Page 142: ...ECOME SLIP PERY 04_36 04_37 WHEN USING A HIGH PRESSURE CLEANING SYSTEM AFTER ENSURING THAT THE DETERGENT USED IS COMPATIBLE WITH THE MOTORCYCLE FIN ISH MAINTAIN A DISTANCE OF AT LEAST HALF A METRE BETWEEN THE NOZZLE AND THE SURFACE BEING CLEANED 142 4 Maintenance ...

Page 143: ...Transport 04_39 NOTE BEFORE TRANSPORTING THE VEHICLE IT IS NECESSARY TO EMPTY THE FUEL TANK AND THE CARBURETTOR ADEQUATELY CHECKING THAT THEY ARE DRY DURING TRANSPORT THE VEHICLE SHOULD BE UPRIGHT AND SECURELY ANCHORED AND SHOULD HAVE THE FIRST GEAR ENGAGED SO AS TO AVOID POSSIBLE FUEL OIL OR COOLANT LEAKS 143 4 Maintenance ...

Page 144: ...VICE INSTEAD TO HAVE THE INFLAMMABLE FLUIDS DRAINED Transmission chain DO NOT ALTER THE FINAL DRIVE RATIO 17 42 OR THE NUMBER OF CHAIN LINKS 112 Characteristic Final drive gear ratio 17 42 Type Endless without master link and with sealed links No of links 112 144 4 Maintenance ...

Page 145: ... over 30 mm 1 18 in or below 25 mm 0 98 in adjustment is necessary CAUTION IF CLEARANCE IS GREATER AT SOME POSITIONS THIS MEANS THAT SOME CHAIN LINKS ARE FLATTENED OR JAMMED TO AVOID RISK OF SEIZURE LUBRICATE THE CHAIN ON A REGULAR BASIS Chain backlash adjustment CAUTION TO ADJUST THE CHAIN BACKLASH PLEASE CONTACT AN Official Aprilia Dealer IF YOU ARE ADEQUATELY TRAINED AND EXPERIENCED REFER TO TH...

Page 146: ...e more frequent if there are signs of quick rust Lubricate the chain whenever necessary After washing and drying the chain lubricate it with spray grease for sealed chains CAUTION LUBRICATE THE CHAIN ON A REGULAR BASIS IF YOU ARE RIDING IN THE RAIN ON WET ROADS AFTER THE VEHICLE HAS BEEN WASHED OR IF YOU FIND DRY OR RUSTY PARTS FLATTENED OR JAMMED CHAIN LINKS SHOULD BE LUBRICATED AND GOOD OPERATIN...

Page 147: ...ING THE CHAIN CHAIN LUBRICANTS AVAILABLE ON THE MARKET CAN CONTAIN SUBSTAN CES THAT DAMAGE THE CHAIN S RUBBER O RINGS NEVER USE THE VEHICLE JUST AFTER LUBRICATING THE CHAIN AS THE LUBRICANT WOULD BE SPRAYED OUTWARD AND SPREAD OUT IN THE SUR ROUNDING AREA 147 4 Maintenance ...

Page 148: ...148 4 Maintenance ...

Page 149: ...CAPONORD Chap 05 Technical data 149 ...

Page 150: ... 56 69 in Saddle height 870 mm 34 25 in Wheelbase 1 555 mm 61 22 in Kerb weight Caponord 1200 251 kg 553 36 lb Kerb weight Caponord 1200 Travel Pack 265 kg 584 22 lb Dry weight without fuel Caponord 1200 233 kg 513 68 lb Dry weight without fuel Caponord 1200 Travel Pack 247 kg 544 54 lb ENGINE Model M558M 150 5 Technical data ...

Page 151: ...roke 106 x 67 8 mm 4 17 x 2 67 in Compression ratio 12 0 0 5 1 Electric Electric starter Engine idle speed 1450 100 rpm Clutch Multiple disk oil bathed clutch with control on the left side of the handlebar Lubrication Wet crankcase Pressure system regulated by a trochoidal pump with oil radiator Air filter Sponge Cooling Fluid 151 5 Technical data ...

Page 152: ...K gal 6 34 US gal Fuel reserve 4 l 0 88 UK gal 1 06 US gal Engine oil 3 1 l without oil filter change 0 68 UK gal 0 82 US gal 3 35 l with oil filter change 0 74 UK gal 0 88 US gal Coolant 2 5 l 0 55 UK gal 0 66 US gal Seats 2 Maximum weight limit 473 kg 1 042 78 lb GEAR RATIOS Gear ratio Gear primary drive 40 69 152 5 Technical data ...

Page 153: ... 28 secondary 5th gear ratio 23 26 secondary 6th gear ratio 24 25 secondary Final drive gear ratio 17 42 DRIVE CHAIN Type Endless without master link and with sealed links No of links 112 Model 525 ZRPK FUEL SYSTEM Type Electronic injection Multipoint Throttle valve diameter Ø 52 mm 2 05 in 153 5 Technical data ...

Page 154: ... mm 5 04 in SUSPENSION Front Caponord 1200 Telescopic fork UPSIDE DOWN upside down stanchions fork with full adjustable stanchions with 43mm diameter adjustment of hydraulic brake extended on left stanchion and compression on right stanchion and of spring preload on both Front Caponord 1200 Travel Pack Telescopic fork UPSIDE DOWN upside down stanchions fork with stanchions with 43mm diameter hydra...

Page 155: ...ring extension and spring preload with knob Rear Caponord 1200 Travel Pack Oscillating swingarm connected with cantilever type link to a Sachs single shock absorber with adjustment of hydraulic braking during extension and compression semi active Aprilia Dynamic Damping technology with piggy back tank and automated management or manually on instrument panel of spring preload via electro hydraulic ...

Page 156: ...piston calliper WHEEL RIMS Type Light alloy rims with extractable bolt Front 3 50 x 17 Rear 6 00 x 17 TYRES Tyre type standard DUNLOP QUALIFIER II Only for 78 kW PIRELLI ANGEL GT versions Front tyre 120 70 ZR17 58W Front tyre pressure rider only 2 4 bar 240 kPa 34 81 PSI rider passenger 2 5 bar 250 kPa 36 26 PSI 156 5 Technical data ...

Page 157: ... 8 bar 280 kPa 40 61 PSI SPARK PLUGS Standard spark plugs NGK CR8EKB Spark plug electrode gap 0 6 0 7 mm 0 024 0 028 in Resistance 5 kOhm ELECTRICAL SYSTEM Battery VTX14 BS 12 V 12 Ampere hour Main fuses 30A Auxiliary fuses 7 5 A 10 A 15 A Alternator permanent magnet type 13 V 690 W at 6 000 rpm 157 5 Technical data ...

Page 158: ... White light Rear daylight running light stop light LED Licence plate light 12V 5W Multifunction display lighting LED WARNING LIGHTS Turn indicators LED High beam light LED Fuel reserve LED Cruise control warning light LED Gear in neutral LED General warning LED ABS LED ATC LED 158 5 Technical data ...

Page 159: ...5 6 mm 0 12 0 16 0 20 0 24 in L shaped hex Allen keys 1 One 10 13 mm 0 39 0 51 in double open ended spanner 2 Pliers to extract fuses 3 Double ended Phillips hexagonal screwdriver 4 Toolkit pouch 5 Maximum weight allowed 1 5 kg 3 3 lb 159 5 Technical data ...

Page 160: ...160 5 Technical data ...

Page 161: ...CAPONORD Chap 06 Programmed maintenance 161 ...

Page 162: ...determined mileage is reached Carrying out scheduled services on time is essential for the validity of your warranty For further information regarding Warranty procedures and Scheduled Maintenance please refer to the Warranty Booklet NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECI FIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDI TIONS OFF ROAD OR FOR TRACK USE I INS...

Page 163: ...ive chain 7 I I I I I Transmission cables and controls I I I Steering bearings and steering clearance I I I Wheel bearings I I Control unit diagnosis I I I Brake discs I I I Air filter I R I R Engine oil filter R R R Fork I I General vehicle operation I I I Valve clearance A A Cooling system I I Braking systems I I I Light circuit I I I Safety switches I I 163 6 Programmed maintenance ...

Page 164: ... I Fork oil seals I I I I Flexible coupling 6 I I Clutch lever pin 7 L L L L L Tyres pressure wear 5 I I I I I Wheels I I I Bolts and nuts tightening I I I Stand joint L L L L L Suspension and setting I I I Fault warning light on instrument panel 4 Fuel lines 3 I I Clutch wear I I Brake pad wear I I I I I 164 6 Programmed maintenance ...

Page 165: ...shock absorber Caponord 1200 Travel Pack AGIP MP GREASE Black smooth textured lithium calcium soap based grease containing EP extreme pressure additives with optimal water repellent properties ISO L X BCHB 2 DIN 51 825 KP2K 20 AGIP CHAIN LUBE SPRAY Spray lubricating grease AGIP BRAKE 4 Brake Clutch fluid SAE J 1703 FMVSS 116 DOT 3 4 ISO 4925 CUNA NC 956 DOT 4 synthetic fluid AGIP PERMANENT SPECIAL...

Page 166: ...166 6 Programmed maintenance ...

Page 167: ...gine stop 54 F Fork 84 Fuel 12 Fuses 125 G Gearbox oil 15 H Headlight 131 Horn 50 I Identification 69 Immobilizer 65 Instrument panel 27 M Maintenance 111 161 162 Maintenance Table 162 Mirrors 135 O Oil filter 114 R rear view mirrors 135 Ride by wire 92 S Saddle 66 Scheduled maintenance 162 Shock absorbers 80 82 Spark plug 116 Stand 16 103 Start up 54 Stop switch 54 T Technical data 149 Transmissi...

Page 168: ...quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only and are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publication beforehand to make any change...

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