APRILIA SPORTCITY 125 Manual Download

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NOTES

ASK FOR GENUINE SPARE PARTS ONLY

use and maintenance

SportCity 125 - 200

Summary of Contents for SPORTCITY 125

Page 1: ...8104819 SPORTCITY 125 200 ...

Page 2: ...t in serious injury or even death CAUTION Indicates a potential hazard which may result in minor personal injury or damage to the vehicle CAUTION The word CAU TION in this manual identifies important information or instructions TECHNICAL INFORMATION The operations preceded by this symbol must be repeated on the opposite side of the vehicle Unless expressly indicated otherwise re assembly is a reve...

Page 3: ...y emission and noise control regula tions in place requiring that motor vehicles undergo periodical inspections Users in these countries must contact an aprilia Authorised Dealer to have the non homologated components replaced with others homologated for use in the country in question have their vehicles inspected at the re quired intervals CAUTION Soon after purchas ing the vehicle write down the...

Page 4: ...THE STAND 32 SUGGESTIONS TO PREVENT THEFT 33 MAINTENANCE 33 SCHEDULED MAINTENANCE CHART 34 IDENTIFICATION DATA 36 CHECKING AND TOPPING UP ENGINE OIL LEVEL 37 AIR FILTER 38 CHECKING THE BRAKE PADS FOR WEAR 39 INSPECTING THE FRONT AND REAR SUSPENSIONS 40 ADJUSTING THE REAR SUSPENSION 40 REMOVING THE BATTERY FUSE COMPARTMENT COVER 41 REMOVING THE ENGINE INSPECTION COVER 41 REMOVING THE FRONT COVER 42...

Page 5: ...safe drive SAFE DRIVE ...

Page 6: ...rowsiness Most road accidents are caused by inexpe rienced riders NEVER lend your vehicle to a beginner and make sure any person borrowing your vehicle fills the legal requirements for driv ing Strictly observe all posted signs and na tional and local road regulations Avoid any sudden or risky manoeuvres that may endanger your and other people s safety for example wheelies speeding etc and adjust ...

Page 7: ... devices that you cannot check by yourself Remember to report any malfunction to the technicians and or mechanics to facilitate their work Never use the vehicle when the amount of damage it has suffered makes it unsafe to ride Never change the position inclination or colour of number plate turn indicators lights and horns Any modification made to the vehicle will invalidate the warranty Making any...

Page 8: ... you or become entangled with moving parts or with the handlebars Do not ride with sharp or pointed objects in your pockets as they might cause injury in the event of a fall this includes keys pens glass vials etc note that the same ap plies to your passenger ACCESSORIES The owner of the vehicle is responsible for the choice installation and use of any ac cessory Any accessories installed must not...

Page 9: ...nly distributed across both sides of the vehicle to keep it stable Make sure that the luggage is firmly secured to the vehicle es pecially before long trips Avoid fixing bulky heavy and or dangerous objects to the handlebars mudguards and forks this could slow down the vehicle s response in turns and would inevitably af fect handling Do not secure bulky bags to the vehicle sides as they could hit ...

Page 10: ...GEMENT OF THE MAIN ELEMENTS KEY 1 Expansion tank 2 Coolant expansion tank plug 3 Rear brake fluid reservoir 4 Left rear view mirror 5 Bag hook 6 Air filter 7 Centre stand 8 Engine oil filler plug 9 Left passenger footpeg 10 Battery 11 Fuse carrier 12 Frame number 13 Front cover ...

Page 11: ...e 2 Seat 3 Fuel tank 4 Fuel tank filler plug 5 Right rear view mirror 6 Front brake fluid reservoir 7 Warning horn 8 Glove compartment 9 Ignition switch steering lock 10 Battery compartment cover 11 Spark plug 12 Right passenger footpeg 13 Antitheft hook for the aprilia Body Guard shielded cable J ...

Page 12: ...bar 2 Rear brake lever 3 Front brake lever 4 Throttle grip 5 Electrical controls on the right side of the handlebar 6 Ignition switch steering lock 7 Instruments and indicators INSTRUMENTS AND INDICATORS KEY 1 Green turn indicator warning light 2 Blue high beam warning light 3 Orange low fuel light 4 Service warning 5 Oil pressure indicator 6 Digital clock 7 Multifunction digital computer 8 Coolan...

Page 13: ...en the light comes on refuel as soon as possible see page 19 FUEL Fuel level indicator It indicates the approximate fuel level in the tank Digital clock Displays current hour and minutes Coolant temperature indicator It indicates the approximate temperature of the coolant in the engine When the first section comes on the temperature allows you to ride the vehicle The normal running temperature ran...

Page 14: ...n the high beam comes on while if it is in position the low beam comes on CONTROLS ON RIGHT HANDLE BAR CAUTION The electric compo nents only operate when the ignition switch is in the position 5 MODE BUTTON Move the MODE button to the left to switch the instrument panel 6 ENGINE STOP SWITCH 7 STARTER BUTTON Press the button to have the starter motor crank the engine For the starting procedure see ...

Page 15: ...ose control of the vehi cle OPERATION To lock the steering Turn the handlebar fully to the left Turn the key 2 to position CAUTION Turn the key and steer the handlebar at the same time Press the key 2 and turn it anticlock wise to the left then steer the handle bar slowly until the key 2 reaches posi tion Extract the key Position Function Key removal Steering lock The steer ing is locked It is not...

Page 16: ... is displayed on multi function display 1 hold down the Mode button 2 for more than ten seconds to change the unit of measurement from kilo metres Km to miles Mi While pressing the button the current unit of measure ment is flashing Should the button be pressed for less than ten seconds the con version will not take place Setting the clock CAUTION For safety reasons it is possible to set this func...

Page 17: ...vent the vehicle from being stolen it is advisable to secure it with the aprilia Body Guard shielded cable 3 availa ble at any aprilia Authorised Dealer CAUTION Do not use the hook to lift the vehicle or for any purpose other than securing the vehicle once it has been parked UNLOCKING LOCKING THE SEAT OPERATION To unlock the seat proceed as follows Position the vehicle on the centre stand Insert t...

Page 18: ...GLOVE COMPARTMENT It is placed under the handlebar on the in ner part of the shield To reach it Insert the key 1 in the lock Turn the key clockwise pull it and open the door 2 CAUTION Before locking the door make sure that you have not left the key in the glove compartment To lock the door 2 raise and press it It is not necessary to use the key Maximum allowed weight 1 5 kg TOOL KIT The tool kit 3...

Page 19: ...ng a hose DO NOT RELEASE FUEL INTO THE EN VIRONMENT KEEP AWAY FROM CHILDREN Use only premium grade leaded petrol 4 Stars 4 or unleaded petrol with 95 RON and 85 MON octane rating minimum FUEL TANK CAPACITY reserve included 8 5 l TANK RESERVE 1 4 l To reach the filler plug proceed as follows Raise the seat see page 17 UNLOCK ING LOCKING THE SEAT Unscrew the filler plug 1 LUBRICANTS WARNING Prolonge...

Page 20: ...applies to both braking systems WARNING Sudden changes in brake lever play or a spongy feel of the lever may indicate problems with the hydraulic system If in doubt about the braking efficiency of your bike or if you are not able to per form routine checks contact an aprilia Authorised dealer WARNING Pay special attention to the brake disc and friction material making sure that they are neither di...

Page 21: ...ollows CAUTION Position the vehicle on firm and flat ground Position the vehicle on the centre stand Rotate the handlebar so that the fluid contained in the brake reservoir is paral lel to the MIN mark stamped on the glass gauge 1 Make sure that the fluid contained in the reservoir exceeds the MIN mark stamped on the glass gauge 1 MIN minimum level If the fluid is below the MIN mark CAUTION Brake ...

Page 22: ...tex gloves during servicing Have the coolant changed at an aprilia Authorised Dealer Coolant mixture is a 50 solution of water and antifreeze This is the ideal solution for most operating temperatures and provides good corrosion protection This solution is also suited to the warm season as the mixture is less prone to evaporative loss and will reduce the need for top ups In addition less water eva...

Page 23: ...o turns without remov ing it Wait a few seconds in order to release any residual pressure Unscrew and remove the plug 1 WARNING Coolant is toxic when ingested Contact with eyes or skin may cause irritation Do not put your fingers or any other ob ject into the filler opening in order to en sure that there is coolant CAUTION Never top up beyond the MAX level mark or coolant will leak out when the en...

Page 24: ...ff the rims under harsh braking Finally the vehicle could skid during cornering Inspect tyre surface condition and check for wear as worn tyres lead to poor road holding and handling Some of the tyres approved for this ve hicle are equipped with wear indicators There are several kinds of wear indica tors For more information on how to check the tyres for wear contact your Dealer Visually inspect t...

Page 25: ... LENCER WARNING Tampering with the noise control sys tem is prohibited Owners are warned that the law may for bid The removal or disconnection of any de vice or element of design incorporated into any new vehicle to limit the noise emis sions before its sale or delivery to the final purchaser or while it is in use except if car ried out for maintenance repair or replace ment purposes and The use o...

Page 26: ... smooth operation throttle should snap fully open and closed at all positions of the steering Adjust and or lubricate as required 43 Wheels tyres Check tyre surface inflation pressure Check for wear or damage 24 Steering Steering should rotate smoothly and evenly There should be no play or looseness Centre stand Make sure that it works smoothly and that the spring tension brings it back to its nor...

Page 27: ... at least one wheel by pulling a brake lever 5 If this operation is not carried out the start relay receives no current and therefore the engine does not start CAUTION After a long period of inactivity carry out the operations described at page 29 STARTING AFTER A LONG PERIOD OF INACTIVITY CAUTION To avoid the exces sive wear of the battery do not keep the starter push button pressed for more than...

Page 28: ...ITH FLOODED ENGINE If the starting is not carried out properly or if there is too much fuel in the intake ducts and in the carburettor the engine may get flooded To clean a flooded engine Press the start push button 4 for a few seconds letting the engine crank with completely open throttle 6 Pos C STARTING THE ENGINE FROM COLD If ambient temperature is low close to or below 0 C you may have troubl...

Page 29: ... If you are riding solo make sure the passenger footpegs are folded up be fore moving off While riding keep your hands on the handlebar and your feet on the foot pegs NEVER RIDE IN ANY POSITION OTHER THAN THE RECOMMENDED RIDING POSITION If you are riding with a passenger give your passenger proper instructions to avoid problems when manoeuvring Before leaving make sure that the stand stands is are...

Page 30: ...se the brakes to keep the vehicle at standstill Do not use engine braking or the clutch may overheat WARNING When approaching a turn slow down or brake and take the turn at moderate constant speed or accelerate slightly braking in a turn will greatly increase your chances of skidding Continued application of the brakes on long downhill grades may cause the brakes to overheat thereby reducing braki...

Page 31: ...illy roads are ideal for an effective running in of engine suspension and brakes CAUTION Only after the first 500 km 312 mi of running in is it possi ble to obtain the best speed and acceler ation performance from the vehicle Follow these recommendations Do not open the throttle completely if the speed is low both during and after the running in u 0 100 km 0 62 mi Until you have covered the first ...

Page 32: ...e engine stop switch 1 to position CAUTION With the engine stopped and the ignition switch in position the battery may run flat Rotate the key 2 and set the ignition switch 3 to position Position the vehicle on the stand see on the side PLACING THE VEHICLE ON THE STAND CAUTION It is not necessary to close the fuel tap when the engine is off since it is equipped with an automatic clos ing system CA...

Page 33: ...e engine and remove the key from the ignition switch allow for the engine and exhaust system to cool down where possible lift the mo torcycle using adequate equipment placed on firm and level ground Ensure the area is well ventilated before proceeding Be careful of any parts of the engine or exhaust system which may still be hot to the touch in order to avoid scalds or burns Do not put any vehicle...

Page 34: ...ng f c Air filter d Throttle operation c c Brake locking operation c c Converter grease e Stop light switch c Coolant c every 1000 km c every 16 months e Engine oil e every 1000 km c every 6000 km e Headlight beam direction operation c Tyre inflation pressure every month c Battery terminals tightening c Front suspension c c Brake pad wear c every 2000 kmc c check and clean adjust lubricate or chan...

Page 35: ...lutch jaws c Valve clearance c Brake fluid c c cevery 2 years e Front suspension fluid c c e Transmission fluid e every 6000 km c every 24000 km e Engine oil filter screen and magnetic screw c c Converter rollers and converter plastic guides c e Wheels tyres c Nut bolt screw tightening c c Cylinder head nut tightening c Draining brake fluid c Fuel hose c every 2 years e c check and clean adjust lu...

Page 36: ...ts CAUTION Altering a vehicle identification numbers is illegal and pun ished by the law with fines and imprison ment In addition altering the frame number invalidates the warranty FRAME NUMBER The frame number is stamped on the frame central tube To read it it is neces sary to remove the indicated cap Frame no ENGINE NUMBER The engine number is stamped near the lower support of the rear shock abs...

Page 37: ...e oil with a clean cloth Tighten the plug dipstick 1 completely screwing it into the filling hole 2 Withdraw the plug dipstick 1 again and read the oil level on the dipstick itself MAX maximum level MIN minimum level The difference between MAX and MIN amounts to approximately 200 cu cm The level is correct if the oil reaches ap prox the MAX mark on the dipstick CAUTION Never exceed the MAX mark or...

Page 38: ...the air box Slide out the filter 3 from the air box cover 2 CLEANING WARNING Do not use petrol or inflammable sol vents to wash the filtering element in order to avoid fires or explosions Wash the filtering element 3 with clean non inflammable solvents or solvents with high volatility point then let it dry thoroughly Apply a filter oil on the whole surface of the filtering element Check if there a...

Page 39: ... between brake disc and brake pads Use a flashlight and a mirror proceed as follows FRONT BRAKE CALLIPER From below on the front part for the left pad A from above on the front part for the right pad B REAR BRAKE CALLIPER From above on the rear part for both pads C WARNING If brake pads were allowed to wear down until uncovering the metal sub strate metal to metal contact with the brake disc would...

Page 40: ...justment of the spring preload The standard adjustment set by the manufacturer is suitable for a rider weighing about 70 kg If your weight and needs are different adjust the ring nut 1 with the appropriate spanner provided in the tool kit thus setting the ideal travelling conditions Turn the adjusting ring nut 1 shock ab sorber spring preload adjustment see table CAUTION Adjust both rear shock abs...

Page 41: ... side opposite to the screws Remove the battery compartment cover CAUTION Upon reassembly fit the tabs correctly in the appropriate seats REMOVING THE ENGINE INSPEC TION COVER Carefully read page 33 MAINTE NANCE Raise the seat see page 17 UNLOCK ING LOCKING THE SEAT Release and remove the screws 3 Release and remove the screws 4 CAUTION Proceed with care Do not damage the tabs and or their seats H...

Page 42: ...as fol lows Ride for a few miles until reaching the operating temperature then stop the en gine Raise the seat Start the engine The engine idle speed must be approxi mately 1600 100 rpm In this case the en gine does not make the rear wheel rotate If necessary Working from the suitable hole under the seat adjust the screw 2 positioned on the carburettor By SCREWING IT clockwise you in crease the en...

Page 43: ...ten the lock nut 2 and check free play again Refit the protection 1 WARNING When finished turn the handlebar to make sure its movement does not affect the engine idle rpm and check that the throttle grip when opened and then re leased returns smoothly to the closed position SPARK PLUG Carefully read page 33 MAINTE NANCE Check the spark plug after the first 1000 km 625 mi and change it every 6000 k...

Page 44: ...ug by one half turn to compress the washer Spark plug tightening torque 18 Nm 1 8 kgm CAUTION The spark plug must be tightened firmly otherwise the engine may overheat and severe damage may occur Use recommended spark plugs only see page 55 TECHNICAL DATA A spark plug of the wrong rating may shorten engine life and cause loss of performance Position the spark plug cap properly to prevent it coming...

Page 45: ... THE BAT TERY If the vehicle remains unused for more than fifteen days it is necessary to recharge the battery in order to prevent sulphation see page 46 CHARGING THE BATTERY Remove the battery see page 46 RE MOVING THE BATTERY and store it in a cool dry place To avoid degradation in the wintertime or while the vehicle is stored away check bat tery charge at regular intervals monthly Recharge the ...

Page 46: ...the battery compartment cover see page 41 REMOVING THE BAT TERY FUSE COMPARTMENT COVER Remove the battery see page 46 RE MOVING THE BATTERY Be sure to have a suitable battery charg er ready at hand Set the battery charger for a slow charge Connect the battery to the battery charg er WARNING Charge or use the battery in a well ven tilated place Do not inhale the gases produced by the battery under ...

Page 47: ...A fuses first and then the 20A fuse Check as follows Remove the battery compartment cover see page 41 REMOVING THE BAT TERY FUSE COMPARTMENT COVER Extract all fuses one by one and check for blown fuses A blown fuse is identi fied by the filament 1 in the centre be ing broken Before replacing a fuse identify the cause of the failure if possible Replace the blown fuse with a new one with equal curre...

Page 48: ...te prompt service VERTICAL ADJUSTMENT OF THE HEADLIGHT BEAM For a quick beam inspection place the ve hicle on level ground ten metres away from a vertical wall Switch on the low beam sit astride the ve hicle and make sure that the light spot on the wall is just below the horizontal line of the headlight about nine tenths of overall height To adjust the headlight beam Use a screwdriver to turn the ...

Page 49: ...ulb check the fuses see page 47 CHANGING THE FUSES CHANGING THE FRONT TURN IN DICATOR BULBS Carefully read on the side LAMPS To change the bulbs CAUTION The following infor mation applies to all turn indicators Unscrew and remove the screw 1 CAUTION Proceed with care Do not damage the tabs and or their seats Remove the shield 2 Press the bulb 3 slightly and rotate it anticlockwise CAUTION If the b...

Page 50: ... diator cowling fit the tabs under the radia tor LOW HIGH BEAM BULB HALOGEN BULB CAUTION Never pull on the wiring to disconnect a bulb connector Take the bulb electrical connector and disconnect it Disengage the bulb clip 5 Extract the bulb Upon reassembly Fit the bulb in the reflector make sure that reference tab 6 is in the correct po sition Engage the bulb clip 5 Connect the electrical connecto...

Page 51: ...CAUTION Insert the bulb into the bulb holder so that the two pins slide into the slots in the holder Fit a new bulb of equal rating REAR TURN INDICATOR BULB Remove the coloured shield 7 pay at tention not to damage it Press the bulb slightly and rotate it anti clockwise Extract the bulb from its seat CAUTION When reassem bling correctly position the tail light seat 3 CAUTION Tighten the screws 6 g...

Page 52: ...the centre stand Stop the engine and wait until it has cooled down Prepare a container large enough to hold the fuel in the tank and place it on the floor on the left side of the vehicle Remove the fuel filler plug Drain fuel using a manual pump or simi lar system WARNING After draining the tank tighten the filler plug To drain the carburettor completely pro ceed as follows Remove the battery comp...

Page 53: ...dy sponge soaked with abundant water and shampoo 2 4 parts of shampoo Then rinse with plenty of water and dry with chamois leather Clean the outer parts of the engine using a degreaser small brushes and cloth CAUTION To clean the lights use a sponge soaked with water and a mild detergent rubbing the surfaces delicately and rinsing frequently with plenty of water Wash the vehicle thoroughly before ...

Page 54: ...aces Remove the cloth Refit the spark plug Remove the battery see page 46 RE MOVING THE BATTERY and page 45 LONG INACTIVITY OF THE BAT TERY Wash and dry the vehicle see page 53 CLEANING Polish painted surfaces with wax Inflate the tyres see page 55 TECHNI CAL DATA By means of a suitable support position the vehicle so that both tyres are raised from the ground Store the vehicle in an unheated dry ...

Page 55: ...displacement 198 cu cm Bore stroke W 57 mm 48 6 mm Bore stroke 72 mm 48 6 mm Compression ratio W 12 Ø 0 5 1 Compression ratio 11 5 Ø 0 5 1 Starting electric Engine idling rpm 1600 100 rpm Clutch automatic dry centrifugal clutch Gearbox automatic Cooling liquid cooling forced circulation with centrifugal pump Valve clearance Intake 0 10 Exhaust 0 15 CAPACITIES Fuel reserve included 8 6 l Fuel reser...

Page 56: ...or unleaded petrol with 95 RON and 85 MON octane rating minimum FRAME Type one beam at the front split in two overlapping cradles at the rear in steel tubes with high yield point Steering head angle 26 5 SUSPENSIONS Front hydraulically operated telescopic fork Stroke 100 mm Rear hydraulic double effect shock absorber with preload adjustment Stroke 80 mm BRAKES Front disc brake Æ 260 mm with hydrau...

Page 57: ...4 4000 rpm Spark advance Variable managed by ECU 5 minimum 15 6000 8000 rpm SPARK PLUG Standard NGK CR7EB As an alternative NGK CR8EB NGK CR9EB CHAMPION RG6YC CHAMPION RG4HC Spark plug gap 0 7 0 8 mm ELECTRIC Battery 12 V 12 Ah SYSTEM Fuses 20 15 7 5 A Generator with permanent magnet 12 V 180 W LAMPS Low high beam 12 V 55 W H7 Parking light 12 V 3 W Turn indicator light 12 V 10 W Rear parking ligh...

Page 58: ... 67 of volume Bearings and other lubrication points recommended BIMOL GREASE 481 GREASE SM2 As an alternative to recommended grease use top brand rolling bearing grease that will resist a temperature range of 30 C 140 C with drop ping point 150 C 230 C high corrosion protection good resistance to water and oxidisation Battery lead protection Neutral grease or Vaseline WARNING Use new brake fluid o...

Page 59: ...59 NOTES ASK FOR GENUINE SPARE PARTS ONLY use and maintenance SportCity 125 200 ...

Page 60: ... 8 7 38 25 24 20 1 21 2 42 40 41 43 37 36 1 1 1 19 26 3 28 4 22 23 17 1 1 30 27 1 1 1 31 1 1 1 15 1 1 1 45 44 16 29 1 5 39 1 11 9 10 1 13 13 6 14 12 ON B G B G B Gr V Ar R Ar LOCK OFF V Ar M V G R R N R Ar R Ar 15 A R R B G R R B G Az M N N Bi Bi N 20 A Bi Vi B B 4 3 1 2 Gr V B 3 2 1 3 2 8 4 5 6 1 7 Bi Vi B G Bi N B N V N 15 A 7 5 A R N B V V G B Ar V V R V Ar V N V R Az V G G B R G R M V R R N Ro...

Page 61: ... 18 19 Starter relay 20 Starter motor 21 Main fuses 22 Main fuses 23 Power outlet 24 Battery 25 H T coil 26 Spark plug 27 Automatic cold start 28 C D I control unit 29 Oil sensor connector only 30 Oil pressure sensor 31 Pick up 32 Generator 33 Voltage regulator 34 Thermal switch 35 Fan 36 Case light 37 Case light switch 38 Front right turn indicator 39 Headlight parking light 40 High beam bulb 41 ...

Page 62: ...62 NOTES ASK FOR GENUINE SPARE PARTS ONLY use and maintenance SportCity 125 200 ...

Page 63: ...63 NOTES ASK FOR GENUINE SPARE PARTS ONLY use and maintenance SportCity 125 200 ...

Page 64: ...actors To find contact information of the Authorised Dealer and or Service Centre nearest you please consult the Yellow Pages or the map pro vided at our web site www aprilia com When you demand aprilia Original Parts you are purchasing products that have been developed and tested as early as the vehicle de sign stage aprilia Original Parts systematically undergo strict quality control procedures ...

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