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APRILIA SPORTCITY ONE 125, Service Station Manual

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APRILIA SPORTCITY ONE 125 Service Station Manual Download Page 112

Removal

- First remove the transmission cover and the com-

plete driving pulley

- Install the base of the appropriate tool on the oil

guard using the screws provided.

- Screw the threaded bar onto the base of the tool

and extract the oil guard.

Specific tooling

020622Y

 

Transmission-side oil guard punch

Refitting

- Prepare the new oil guard, lubricating the sealing

lip. Warning: do not lubricate the surface for keying

onto the engine crankcase.

CAUTION

DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO
THE ENGINE CRANKCASE.

Engine

SPORTCITY ONE 125

ENG - 112

Summary of Contents for SPORTCITY ONE 125

Page 1: ...SERVICE STATION MANUAL 854184 SPORTCITY ONE 125 ...

Page 2: ...e any changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions shown in this publication are available in all countries The availability of individual models should be confirmed with the official aprilia sales network Copyright 2008 aprilia All rights reserved Reproduction of this...

Page 3: ...s and changes in repair procedures are communicated to all aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult aprilia CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates a...

Page 4: ...NDEX OF TOPICS CHARACTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS CHASSIS CHAS PRE DELIVERY PRE DE ...

Page 5: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 6: ... FLAMES SPARKS OR ANY OTHER SOURCE THAT MAY CAUSE FUEL TO CATCH FIRE OR EXPLODE CAUTION DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT CAUTION KEEP OUT OF THE REACH OF CHILDREN HIGH TEMPERATURE COMPONENTS The engine and the components of the exhaust system can get very hot and remain hot for some time even after the engine has been switched off Before handling these components make sure that you are ...

Page 7: ...burns CAUTION MAKE SURE NOT TO POUR THE COOLANT ON HOT ENGINE OR EXHAUST SYSTEM COMPO NENTS IT MAY CATCH FIRE PRODUCING INVISIBLE FLAMES WHEN CARRYING OUT MAIN TENANCE OPERATIONS IT IS ADVISABLE TO WEAR LATEX GLOVES EVEN IF IT IS TOXIC THE COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS THEY MAY DRIN...

Page 8: ... INSPECTION ON THE VEHICLE SWITCH OFF THE ENGINE AND REMOVE THE KEY WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD IF POSSIBLE RAISE THE VEHICLE USING A SUITABLE TOOL ON FIRM AND LEVEL GROUND TO AVOID BURNS PAY SPECIAL CARE WITH HOT ENGINE AND EXHAUST SYSTEM PARTS DO NOT HOLD ANY MECHANICAL OR ANY OTHER SCOOTER PARTS WITH YOUR MOUTH SCOOTER COMPONENTS ARE NOT EDIBLE ON THE CONTRARY SOME OF ...

Page 9: ...te them well Check that each component is fitted correctly After a repair or routine maintenance procedure carry out pre ride checks and test the ve hicle on private grounds or in an area with low traffic density Clean all junction surfaces oil guard rims and washers before refitting them Smear a light layer of lithium based grease on the oil guard rims Reassemble the oil guards and the bearings w...

Page 10: ...BECOME LOOSE AND EVEN DE TACHED THUS BLOCKING A WHEEL OR OTHERWISE COMPROMISING THE VEHICLE S MA NOEUVRABILITY THIS CAN LEAD TO FALLS WITH THE RISK OF SERIOUS INJURY OR DEATH Vehicle identification Quote the chassis number when purchasing spare parts NOTE DO NOT OBLITERATE OR ALTER THE VEHICLE IDENTIFICATION NUMBERS DOING SO IS CONSIDERED AN OFFENCE IN ALL COUNTRIES FURTHERMORE ALTERING THE IDENTI...

Page 11: ...00 rpm Maximum torque 10 04 Nm at 7 000 rpm SUPPLY By carburettor and with automatic petrol vacuum operated cock Standard carburettor KEIHIN CVK 26 Fuel Premium unleaded premium 4 stars petrol DIN 51607 with minimum octane rating of 95 NORM and 85 NOMM Ignition type CDI inductive Ignition advance Variable from 0 to 30 Spark plug CHAMPION RG6YC Alternative spark plug NGK CR7EB Spark plug electrode ...

Page 12: ...6 Rear position light stop light bulb 12V 5 21W 7 License plate light bulb 12V 5W 8 Instrument panel light bulbs 12V 1 2W 9 Oil pressure warning light 12V 1 2W 10 Turn indicator warning light 12V 1 2W 11 High beam warning light 12V 1 2W Frame and suspensions CHASSIS AND SUSPENSIONS Specification Desc Quantity Chassis type High strength steel tube chassis with reinforcements Steering inclination an...

Page 13: ... bar Tightening Torques FRAME ASSEMBLY Name Torque in Nm License plate holder support fixing screw 10 ENGINE LINK ROD UNIT Name Torque in Nm Nut fixing the chassis side swinging arm and the engine side swinging arm 42 5 Engine side swinging arm retaining nut 42 5 Chassis side swinging arm retaining nut 52 5 Buffer plate to chassis retaining nut 40 STAND UNIT Name Torque in Nm Central stand to chas...

Page 14: ...ves union screws 8 10 Engine oil pre filter cap 25 28 Timing chain oil pump compartment cover screws 4 5 Central screw 12 14 Cover screws 0 7 0 9 Oil pump screws 5 6 Oil sump screws 8 10 EXHAUST SYSTEM UNIT Name Torque in Nm Silencer protection fixing screw 6 Muffler plate engine fixing screw 25 5 Nut fixing exhaust manifold to engine 15 Silencer clamp to exhaust manifold fixing screw 25 5 FRONT W...

Page 15: ... 6 Helmet compartment fixing screw 3 Passenger handgrip profiles fixing screw 3 Passenger handgrip fixing screw 20 5 Battery cover fixing screw 6 Front head fixing screw 6 Front head fixing screw 3 Rear head fixing screw 3 Front wheel well fixing screw 6 Front wheel well fixing screw 3 Front mudguard fixing screw 6 Mats kit fixing screw 6 Mats kit fixing screw 3 Footrest fixing screw 6 Shield uppe...

Page 16: ...65 0 046 0 060 Coupling 1st oversize P1 57 218 57 225 57 165 57 172 0 046 0 060 Coupling 2nd oversize M2 57 397 57 404 57 344 57 351 0 046 0 060 Coupling 2nd oversize N2 57 404 57 411 57 351 57 358 0 046 0 060 Coupling 2nd oversize O2 57 411 57 418 57 358 57 365 0 046 0 060 Coupling 2nd oversize P2 57 418 57 425 57 365 57 372 0 046 0 060 Coupling 3rd oversize M3 57 597 57 604 57 544 57 551 0 046 0...

Page 17: ...ions Initials Quantity Half shaft transmission side 16 6 0 0 05 A D 0 20 0 50 Half shaft flywheel side 16 6 0 0 05 B D 0 20 0 50 Connecting rod with PP 18 0 10 0 15 C 0 20 0 50 Crankpin width 51 400 E AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF BEARINGS 125 Name Description Dimensions Initials Quantity Crankshaft Class 1 28 998 29 004 Crankshaft Class 2 29 004 29 010 Crankcase Class 1 3...

Page 18: ...ase axial clearance A 0 15 0 40 Slot packing system SHIMMING SYSTEM Measure taken Gasket thickness 0 0 1 0 8 0 05 0 1 0 3 0 6 0 05 0 3 0 4 0 4 0 05 Characteristic Compression ratio 10 6 0 5 1 Characteristics SPORTCITY ONE 125 CHAR 18 ...

Page 19: ...SL ACEA A3 JASO MA AGIP GEAR SYNTH SAE 75W 90 Gearbox oil API GL4 GL5 AGIP FORK 7 5W Fork oil AGIP GREASE SM2 Lithium grease with molybdenum for bearings and other points needing lubri cation NLGI 2 AGIP BRAKE 4 Brake fluid FMVSS DOT4 AGIP FILTER OIL Oil for air filter sponge SPORTCITY ONE 125 Characteristics CHAR 19 ...

Page 20: ...INDEX OF TOPICS TOOLING TOOL ...

Page 21: ...ey lock wrench 001467Y009 Bell for OD 42 mm bearings 001467Y013 Calliper to extract 15 mm diameter bear ings 008564Y Flywheel extractor 020074Y Support base for checking crankshaft alignment 020150Y Air heater support SPORTCITY ONE 125 Tooling TOOL 21 ...

Page 22: ...ion 020151Y Air heater 020262Y Crankcase splitting strip 020263Y Sheath for fitting the driven pulley 020306Y Punch for fitting the valve sealing rings 020335Y Dial gauge magnetic support Tooling SPORTCITY ONE 125 TOOL 22 ...

Page 23: ... Description 020357Y 32 x 35 mm adaptor 020359Y 42 x 47 mm adaptor 020360Y Adaptor 52x54 mm 020363Y 20 mm guide for oil seal 020364Y 25 mm Guide 020368Y driving pulley lock wrench SPORTCITY ONE 125 Tooling TOOL 23 ...

Page 24: ...ch 020376Y Adapter handle 020382Y Tool for removing valve cotters fitted with part 012 020382Y011 adaptor for valve removing tool 020412Y 15 mm Oil seal guide 020424Y Punch for fitting driven pulley roller casing Tooling SPORTCITY ONE 125 TOOL 24 ...

Page 25: ...020425Y Shaft oil seal punch 020426Y Piston fitting fork 020427Y Piston fitting ring 020428Y Support to check piston position 020431Y Valve oil seal extractor 020439Y 17 mm guide for oil seal SPORTCITY ONE 125 Tooling TOOL 25 ...

Page 26: ...Stores code Description 020565Y Flywheel lock calliper spanner Tooling SPORTCITY ONE 125 TOOL 26 ...

Page 27: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 28: ...I I I I I Engine oil R R R R R R R R R R R Hub oil R I I I R I I I R I I Headlight aiming adjustment A A A A A Brake pads I I I I I I I I I I I Sliding blocks Variable speed rollers I R I R I R I R I R Tyre pressure and wear I I I I I I I I I I I Vehicle road test I I I I I I I I I I I Idle speed A A A A A A Odometer gear L L L L L Suspensions I I I I I Steering I I I I I I Transmissions L L L L L...

Page 29: ...om its seat making sure no dust or dirt gets into the cylinder Check that spark plug electrode and central porcelain insulator do not have carbon deposits or corrosion if necessary remove them Use a thickness gauge to check the electrode gap and if necessary adjust it Make sure the washer is in good conditions Fit the washer and then finger tighten the spark plug Tighten to the specified torque Ch...

Page 30: ...RI CANTS ACCELERATES THE WEAR AND TEAR OF MOV ING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE Replacement CAUTION WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD To ensure long lasting and optimal scooter per formance change oil following the frequency indi cated in the scheduled maintenance tables For change Ride a few kilometres until the regular working temperature is reached th...

Page 31: ...R CONTAMINATED OR NOT RECOMMENDED LUBRI CANTS ACCELERATES THE WEAR AND TEAR OF MOV ING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE Air filter CAUTION CLEAN AND CHECK THE AIR FILTER CONDITIONS MONTHLY OR FOLLOWING THE INDICA TIONS IN THE SCHEDULED MAINTENANCE TABLES THIS WILL DEPEND ON USE CONDI TIONS IF THE SCOOTER IS USED ON DUSTY OR WET ROADS CLEAN AND CHANGE THE FILTER MORE FREQUENTLY Removing the...

Page 32: ...und Rest the vehicle on its centre stand Unscrew and take out the measuring tap dipstick 1 Place a container to collect the oil un der the engine oil filter Unscrew and remove the engine oil cartridge filter 2 CAUTION USED OIL CONTAINS SUBSTANCES THAT ARE HARM FUL TO THE ENVIRONMENT DISPOSE OF USED OIL AC CORDING TO THE REGULATIONS IN FORCE Unscrew and remove the oil drainage plug 3 and drain off ...

Page 33: ...the engine and let it cool off so that the oil in the crankcase flows down and cools as well NOTE FAILURE TO FOLLOW THESE OPERATIONS MAY RE SULT IN AN INCORRECT READING OF THE ENGINE OIL LEVEL Unscrew and pull out the measuring cap dipstick 1 Clean the area in contact with oil with a clean cloth Screw the cap dipstick 1 fully into its tube Remove the tap dipstick 1 again and read the level the oil...

Page 34: ...small quantities of oil until the recommended level is reached Once this operation is finished screw and tighten the cap dipstick 1 CAUTION RIDING THE VEHICLE WITH INSUFFICIENT LUBRICATION OR CONTAMINATED OR NOT REC OMMENDED LUBRICANTS ACCELERATES THE WEAR AND TEAR OF MOVING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE Fuel filter Cleaning the fuel filter Empty the fuel tank Unscrew the clamp 1 Remove...

Page 35: ...released If this does not occur NOTE USED THE SPECIFIC LUBRICANT AVAILABLE IN THE MARKET TO LUBRICATE THE COMPO NENTS Check the position and lubrication of the following components throttle grip cable sheath throttle grip regulator 2 cable terminals throttle grip Check the throttle grip adjustment NOTE APPLY A GOOD QUANTITY OF SCOOTER CABLE GREASE TO LUBRICATE THE THROTTLE GRIP SYSTEM COMPONENTS T...

Page 36: ...GRIP CLOSES SMOOTHLY AND TOTALLY WHEN RE LEASED Braking system CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO THE REGULAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED Level check NOTE CARRY OUT THESE OPERATIONS ONLY WITH THE VEHICLE ON A FLAT AND STABLE SUR FACE SUCH AS A GARAGE CONCRETE FLOOR Re...

Page 37: ... FLUID RESER VOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE CAUTION TO AVOID SPILLING BRAKE FLUID WHILE TOPPING UP KEEP THE FLUID LEVEL IN THE RES ERVOIR PARALLEL TO THE RESERVOIR EDGE AND DO NOT SHAKE THE VEHICLE Remove the gasket 5 NOTE TO REACH THE MAXIMUM LEVEL TOP UP UNTIL COV ERING THE SIGHT GLASS COMPLETELY BUT LEAVE A 5 6 MM 0 20 0 23 IN MARGIN FROM THE RESERVOIR E...

Page 38: ...ZLE THE VEHICLE RIDING TOWARDS YOUR DIRECTION THIS MAY ALSO REDUCE THE POSSIBILITY OF SEEING AN OBSTA CLE AHEAD OF YOU ON THE ROAD WHEN RIDING AT NIGHT IT IS ALWAYS ADVISABLE TO REDUCE SPEED WHEN RIDING AT NIGHT SO AS TO HAVE ENOUGH TIME TO AVOID POTENTIAL OBSTACLES AND TO ADAPT YOUR SELF TO LOW VISIBILITY CONDITIONS RESULTING FROM DARKNESS NOTE THE PROCEDURE DESCRIBED HEREIN COMPLIES WITH THE ITA...

Page 39: ...entre stand on safe and level ground Hold the knob 4 operating inside the wheel well SCREW it clockwise to raise the light beam UNSCREW it anticlockwise to lower the light beam NOTE IN COMPLIANCE WITH LOCAL LEGISLATION SPECIFIC PROCEDURES MUST BE FOLLOWED WHEN ALIGNING THE LIGHTS SPORTCITY ONE 125 Maintenance MAIN 39 ...

Page 40: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 41: ...ng bulbs 8 High beam warning light 9 Turn indicator warning light 10 Fuel level instrument 11 Instrument panel 12 NTC temperature sensor 13 Blinker 14 Low beam High beam Passing switch 15 Key switch 16 Turn indicators switch 17 Starter button 18 Front stop switch 19 Rear stop switch SPORTCITY ONE 125 Electrical system ELE SYS 41 ...

Page 42: ... unit 33 Automatic starter 34 PTC heater 35 Regulator 36 Oil pressure sensor 37 Pick up 38 Generator 39 Front right turn indicator 40 High beam light 41 Front position light 42 Low beam light 43 Front left turn indicator 44 Front headlamp 45 Ground point on chassis CABLE COLOURS Ar Orange Az Sky blue B Blue Bi White G Yellow Gr Grey M Brown N Black R Red V Green Vi Purple Ro Pink Electrical system...

Page 43: ...Components arrangement SPORTCITY ONE 125 Electrical system ELE SYS 43 ...

Page 44: ...e front handlebar cover 2 Battery To reach it remove the appropriate cover placed under the saddle 3 Main fuse Remove the battery cover to reach it 4 Starter motor Remove the helmet compartment to reach it Electrical system SPORTCITY ONE 125 ELE SYS 44 ...

Page 45: ...regulator Remove the rear central cover to reach it Characteristic Battery recharging voltage 13 14 5 V at 4000 rpm 7 Auxiliary fuses To reach them open the front glove compartment 8 Control unit To reach it remove the legshield SPORTCITY ONE 125 Electrical system ELE SYS 45 ...

Page 46: ...ttle valve position sensor To reach it remove the inspection compartment placed in the helmet compartment 11 Turn indicators To reach them remove the legshield 12 Horn Remove the shield back plate to reach it Electrical system SPORTCITY ONE 125 ELE SYS 46 ...

Page 47: ...re sensor The connector is placed under the ve hicle right fairing Characteristic Pick up resistance value 130 Ω Generator phases resistance values 1 1 Ω Generated current 13A at 6000 rpm 15 Automatic starter To reach the connector remove the right side fairing 16 Start up remote control switch Remove the right side fairing to reach it SPORTCITY ONE 125 Electrical system ELE SYS 47 ...

Page 48: ...ance value with full tank 7 4 Ω 18 Diagnostics socket Remove the battery cover to reach it Ground points Ground point on chassis Remove the rear central cover to reach it Ground point on engine Remove the helmet compartment to reach it Checks and inspections Electrical system SPORTCITY ONE 125 ELE SYS 48 ...

Page 49: ...resistance present be tween terminals No 10 Blue Yellow cable and No 12 Blue cable If the value measured is incorrect re peat the check directly on the compo nent Disconnect the Pick Up connector and measure the resistance between the pin corresponding to the Blue Yellow cable of the wiring and the ground con nection on the engine If the value measured is correct check wiring continuity Characteri...

Page 50: ...check wiring continuity Characteristic Coil primary resistance value 0 5 Ω Coil secondary check Disconnect the spark plug cap from the coil cable and measure the resistance between the cable end and the coil negative terminal Characteristic Coil secondary resistance value 3000 300 Ω Battery recharge circuit With engine running at high revs measure the voltage present at the battery poles Character...

Page 51: ...n the stator If a correct value is measured check wiring continuity Recharge system voltage check Connect the ammeter induction clamp to the voltage regulator positive termi nal Red Orange Measure the battery voltage and turn ing on the vehicle lights with engine off wait for the voltage to set at about 12 V Start the engine and measure the cur rent generated by the system with lights on and a hig...

Page 52: ...ORMED WITH THE RELATIVE CONNECTORS DIS CONNECTED Check continuity of the Green cable which connects the horn button to 15A fuse C Check that the horn switch works properly Check continuity of the Grey cable which connects the switch to the horn Turn signals system check CAUTION THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS CONNECTED Check that bulb operates properly Chec...

Page 53: ...hts list BULBS AND WARNING LIGHTS Specification Desc Quantity 1 Low beam bulb 12 V 35 W Halogen H8 2 High beam bulb 12 V 35 W Halogen H8 3 Tail light bulb 12V 3W 4 Front turn indicator bulbs 12 V 21 W Halogen H21W 5 Rear turn indicator bulbs 12V 16W 6 Rear position light stop light bulb 12V 5 21W 7 License plate light bulb 12V 5W 8 Instrument panel light bulbs 12V 1 2W 9 Oil pressure warning light...

Page 54: ...IRCUIT WHICH MAY TOTALLY DESTROY YOUR SCOOTER AS WELL AS INJURE YOU The vehicle has one fuse located in the battery compartment and two fuses located in the front glove compartment FUSE CHART Specification Desc Quantity 1 Fuse A Capacity 20 A Protected circuits Recharge circuit oil pressure sen sor oil pressure warning light 2 Fuse B Capacity 7 5 A Protected circuits Start up circuit starter motor...

Page 55: ...with a standard tester If voltage is over 12 60V the battery can be installed without any refresh If voltage is below 12 60 V a renewal recharge is required as explained in 2 3 Constant voltage battery charge mode 4 Constant voltage charge equal to 14 40 14 70V Initial charge current equal to 0 3 0 5 of the battery rated capacity Charge time 10 to 12 h recommended Minimum 6 h Maximum 24 h 5 Consta...

Page 56: ... hours recharge with the specific battery charger at a density of about 1 10 of the battery nominal capacity and until the acid density is about 1 27 corresponding to 31º Bé and these values are stabi lised Once the charge is complete level the acid by adding distilled water Close and clean carefully Once the above operations have been performed install the battery on the ve hicle ensuring that it...

Page 57: ...ch the negative terminal before removing the battery from the vehicle Normal bench charging must be performed using the special battery charger setting the battery charge selector to the type of battery that requires recharging that is at a current equal to 1 10 of the battery rated capacity Connections to the power supply source must be implemented by connecting corre sponding poles to and to The...

Page 58: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 59: ...anifold to engine 15 Undo and remove the screws 2 Remove the muffler NOTE UPON REFITTING REPLACE THE GASKET BETWEEN THE EXHAUST MANIFOLD AND THE MUFFLER WITH A NEW ONE Locking torques N m Muffler plate engine fixing screw 25 5 Removal of the engine from the vehicle Rest the vehicle on its centre stand Remove the side fairings Take out the spark plug tube Disconnect the starter motor power connecto...

Page 60: ...e the wiring Remove the low pressure pipe 6 from the cylinder head Disconnect the carburettor pipe 7 from the carburettor Remove the throttle grip transmission from the carburettor by acting on the appropriate set screws and release the transmission from the engine Engine from vehicle SPORTCITY ONE 125 ENG VE 60 ...

Page 61: ...ustment nut 5 CAUTION SUPPORT THE SCOOTER FIRMLY Undo the shock absorber lower screw 10 with washer Locking torques N m Lower part of the shock absorber retaining nut 42 5 Undo the two screws 11 Locking torques N m Buffer plate to chassis retaining nut 40 Remove the Seeger ring 12 Remove the plate SPORTCITY ONE 125 Engine from vehicle ENG VE 61 ...

Page 62: ...perating on the chassis lift the vehi cle rear part Completely slide off the engine rod ful crum pin Slide off the engine towards the back Locking torques N m Engine side swinging arm retaining nut 42 5 Engine from vehicle SPORTCITY ONE 125 ENG VE 62 ...

Page 63: ...INDEX OF TOPICS ENGINE ENG ...

Page 64: ...om the engine oil filling hole Remove the 10 screws and the earth cable fas tened under one of them Remove the transmission cover If this operation is performed directly on the vehicle it is necessary to remove the cooling air coupling and the three air filter housing retainers Specific tooling 020423Y Driven pulley lock wrench Air duct Unscrew the Torx screws fixing the air manifold bulkhead and ...

Page 65: ...he driven pulley shaft bearing Remove the clip from the inside of the cover Use the specific tools to remove the bearing from the crankcase CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAM AGING THE COVER PAINT Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor SPORTCITY ONE 125 Engine ENG 65 ...

Page 66: ...020357Y 32 x 35 mm adaptor 020412Y 15 mm guide Removing the driven pulley Remove the spacer the clutch bell and the whole driven pulley unit NOTE THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED Inspecting the clutch drum Check that the clutch bell is not worn or damaged Measure the clutch bell inside diameter Characteristic Max value clutch bell Max value Ø 134 5 mm Clutch bell standa...

Page 67: ...nkshaft alignment Using a feeler pin gauge and the magnetic base measure the bell eccentricity Repeat the measurement in 3 positions Central internal external If faults are found replace the bell Specific tooling 020074Y Support base for checking crankshaft alignment 020335Y Magnetic support for dial gauge Characteristic clutch bell inspection Limit eccentricity Admissible limit eccentricity 0 15 ...

Page 68: ...en pulley unit seals NOTE UPON RUNNING IN THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD Characteristic Check minimum thickness 1 mm Engine SPORTCITY ONE 125 ENG 68 ...

Page 69: ...taining collar Remove the collar with the aid of 2 screwdrivers Remove the 3 guide pins and the movable half pulley Removing the driven half pulley bearing Remove the retaining ring using two flat blade screwdrivers Using a hammer and pin knock the ball bearing out as shown in the figure Remove the roller bearing using the specific ex tractor NOTE REST THE HALF PULLEY ON A WOOD SURFACE TO AVOID DA...

Page 70: ...r permitted Ø 40 96 mm Standard diameter Ø 40 965 mm Inspecting the driven sliding half pulley Remove the 2 inner sealing rings and the two O rings Measure the inside diameter of the mobile half pulley bushing Characteristic Minimum admissible diameter Ø 41 08 mm Standard diameter Ø 41 035 mm Engine SPORTCITY ONE 125 ENG 70 ...

Page 71: ...m adaptor 020376Y Adaptor handle 020439Y 17 mm guide Refitting the driven pulley Check that the faying surfaces between the 2 half pulleys and the belt do not show any signs of wear scoring and grease Insert the new oil seals and O rings on the mov able half pulley Assemble the half pulley on the ringlet with the appropriate protection sheath Make sure the pins and collar are not worn re assemble ...

Page 72: ...lley Characteristic Standard length 106 mm Refitting the clutch Versione 125 Refit the clutch assembly following the removal operations but in reverse order use the calliper spanner and lock the nut to the prescribed torque CAUTION USE A BOX SPANNER WITH SMALL CHAMFER SO AS NOT TO DAMAGE THE CLUTCH NUT UPON FITTING THE CLUTCH ASSEMBLY LOCK NUT MAKE SURE THE AS SEMBLY IS WELL SECURED IN IT SEAT UNT...

Page 73: ...m bottom of the toothing does not show signs of incisions or cracks see figure the rim bottom of the tooth must not have incisions or cracks if it does change the belt Check that the driving belt is not damaged Check the width of the belt BELT SIZE Specification Desc Quantity Minimum width 21 5 mm Standard width 22 5 0 2 mm SPORTCITY ONE 125 Engine ENG 73 ...

Page 74: ...ers Remove the return rollers plate with the relative guide pads Inspecting the rollers case Check that the internal bushing is not abnormally worn and measure inner diameter NOTE DO NOT LUBRICATE OR CLEAN THE BUSHING BUSHING ROLLER CONTAINER Specification Desc Quantity Maximum allowable diameter Ø 26 121 mm Standard diameter Ø 26 0 0 021 mm BUSH SLIDE PULLEY Specification Desc Quantity Minimum di...

Page 75: ...ct with the belt on either of the pulley halves Pre assemble the movable half pulley with the roller contrast plate by placing the rollers as shown in the figure that is during insertion the closed side should be on the left side of the pulley thrust Mount the complete bushing unit on the driving shaft SPORTCITY ONE 125 Engine ENG 75 ...

Page 76: ...368Y driving pulley lock wrench Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Locking torques N m Locking torque 75 83 Refitting the transmission cover Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover Replace the cover tightening the 10 screws at the specifi...

Page 77: ...nt spring Remove the 7 flanged screws as shown in the figure Remove the rubber cover and the brake pad lever sliding unscrewing the relevant retaining screw to reach the rear of the cover Take off the hub cover and relevant gaskets Removing the wheel axle Remove the intermediate gear and the complete hub cover SPORTCITY ONE 125 Engine ENG 77 ...

Page 78: ... ad equately supporting the hub cover as shown in the figure Specific tooling 020376Y Adaptor handle 020364Y 25 mm guide With the appropriate tools remove the oil seal as shown in the figure Specific tooling 020376Y Adaptor handle 020359Y 42x47 mm adaptor Removing the driven pulley shaft bearing If it is necessary to remove the driven pulley shaft from the relevant bearing and oil seal remove driv...

Page 79: ...ents Inspecting the hub cover Check that the fitting surface is not dented or distorted Check the capacity of the bearings and the brake camshaft If faults are found replace the hub cover Refitting the driven pulley shaft bearing Heat up the parts using the specific heat gun Specific tooling 020150Y Air heater support 020151Y Air heater Reassemble the driven pulley axle bearing positioning it with...

Page 80: ...020364Y 25 mm guide 020360Y Adaptor 52 x 55 mm 020376Y Adaptor handle Assemble the Seeger ring Assemble the oil seal flush with the in ternal surface as shown in the figure to the hub using the adequate tools and with the seal lip towards the inside of the hub Specific tooling 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm Refitting the hub cover bearings For the fitting of the hub box bearings...

Page 81: ...ew gasket together with the centring dow els Fit the gearbox cover making sure the breather pipe is in the correct position Screw the 7 screws to the specified torque po sitioning the support plate of the pipe in the posi tion shown in the figure Remove the control pin of the shoe taking care so as the long tooth coincides with the groove on the control lever Locking torques N m Locking torque 24 ...

Page 82: ...usings Remove the gasket seal of the housing on the head NOTE IF THE FLYWHEEL HOUSING IS NOT REMOVED IT IS AL SO NECESSARY TO REMOVE THE TWO KNOB SCREWS On the vehicles equipped with the engines mentioned if they are losing a full circle at full gas we suggest to intervene on the vacuum socket inserting on the inlet manifold widening the hole from 0 4 mm to 1 5 mm Remember that such operation must...

Page 83: ... two Pick Up screws and the one for the wiring harness bracket as well as the two stator fixing screws shown in the figure Remove the stator and its wiring Refitting the stator Refit the stator and flywheel carrying out the re moval procedure in reverse tightening the retain ers to the specified torque Place the cable harness as shown in the figure NOTE THE PICK UP WIRE SHOULD BE POSITIONED BETWEE...

Page 84: ... the flywheel components Check the integrity of the internal plastic parts of the flywheel and the Pick Up control plate Refitting the flywheel magneto Fit the flywheel being careful to insert the key properly Lock the flywheel nut to the prescribed torque Check that the Pick Up air gap is between 0 34 0 76 mm The air gap cannot be modified when assembling the Pick Up Different values result from ...

Page 85: ...moving the timing system drive Remove the parts listed below first transmission cover belt driving pulley oil pump pulley cover and pinion separator washer Remove the tappet cover Remove the central screw fastener and the au tomatic valve lifter retaining cover as shown in the figure Remove the return spring of the automatic valve lifter assembly and the automatic valve lifter as sembly and its en...

Page 86: ...ioner pad The chain tensioning pad must be removed from the transmission side As regards the lower chain guide pad it may only be removed after the head has been removed NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED See also Electric fan Removing the cam shaft Remove the two screws and the cam shaft re tainer shown in the diagram Re...

Page 87: ...nd in criss cross fashion Remove the head the two centring dowels and the gasket NOTE IN CASE OF NEED THE HEAD MAY BE REMOVED WITH THE CAMSHAFT PINS ROCKING LEVERS AND FIXING BRACKET THE HEAD CAN ALSO BE REMOVED WITH OUT REMOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER Removing the valves Using the specific tool fitted with the element shown in the figure remove the cotters the plates and ...

Page 88: ...gs the wrist pin and the piston Remove the 3 piston rings from the piston NOTE BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DUR ING REMOVAL Inspecting the small end Measure the internal diameter of the small end using an internal micrometer NOTE IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANK...

Page 89: ...006 Measure the outside diameter of the piston per pendicular to the gudgeon pin axis Measure 36 5 mm from the piston crown s shown in the figure NOTE THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON Using a bore meter measure the inner cylinder diameter at three different points according to the direct...

Page 90: ...ersize They are also classified into 4 categories A A B B C C D D Inspecting the piston Carefully clean the seal housings Measure the coupling clearance between the seal rings and the grooves using suitable sensors as shown in the diagram If the clearance is greater than that indicated in the table replace the piston STANDARD COUPLING CLEARANCE Name Description Dimensions Initials Quantity Top pis...

Page 91: ...ing the punch Fit the wrist pin stop using the plug as shown in the figure NOTE THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY CAUTION USING A HAMMER TO POSITION THE RINGS CAN DAM AGE THE LOCKING HOUSING Choosing the gasket Provisionally fit the piston into the cylinder with out any base gasket Assemble a dial gauge on the specific tool Set the dial gauge to zero at a contrast plane ...

Page 92: ...e opposite side from the ring gap and the word TOP towards the crown of the piston The tapered side of the middle piston ring should always be facing away from the crown of the pis ton Fit the middle piston ring with the identification letter facing the crown of the piston In any case the step must be facing opposite the piston top Fit the top piston ring with the word top or the reference mark fa...

Page 93: ...Y Piston fitting band Inspecting the cylinder head Using a trued bar check that the cylinder head surface is not worn or distorted Check that the camshaft and rocking lever pin bearings show no signs of wear Check that the cylinder head cover surface the intake manifold and the exhaust manifold are not worn Characteristic Maximum admitted unevenness Head check 0 05 mm STANDARD DIAMETER Specificati...

Page 94: ...e way mechanism is not worn Check the condition of the tensioner spring If examples of wear are found replace the whole assembly Inspecting the valve sealings Measure the width of the sealing surface on the valve seats VALVE SEAL SURFACE Specification Desc Quantity Inlet valve seal surface 2 4 2 8 mm Outlet valve seal surface 2 2 2 6 mm Inspecting the valve housings Remove any carbon formation fro...

Page 95: ...acteristic Wear limits Max 1 6 mm Inspecting the valves Measure the diameter of the valve stems in the three positions indicated in the diagram Calculate the clearance between valve and valve guide Characteristic Minimum diameter admitted Inlet 4 96 mm Minimum diameter admitted Outlet 4 95 mm Standard clearance Inlet 0 013 0 040 mm Standard clearance Outlet 0 025 0 052 mm Maximum clearance admitte...

Page 96: ...a fine grained lapping compound During grinding keep the cylinder head in a horizontal position This will prevent the lapping compound residues from penetrating between the valve stem guide coupling CAUTION TO AVOID SCORING THE CONTACT SURFACE DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COM POUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAP...

Page 97: ... a time Specific tooling 020306Y Punch for assembling valve seal rings Fit the valves the springs and the spring retaining caps Using the appropriate tool with adapter 11 compress the springs and insert the cotters in their seats Specific tooling 020382Y Tool for removing valve cotters fitted with part 012 020382Y011 adapter for valve removal tool Inspecting the cam shaft Inspect the cam shaft for...

Page 98: ...ance admitted 0 42 mm Check there are no signs of wear on the auto matic valve lifter cam or the end of stroke roller or the rubber buffer on the automatic valve lifter retaining cover Check that the valve lifting spring has not yielded Replace any defective or worn components Check there are no signs of scoring or wear on the rocking lever bolt Check there are no signs of wear on the pad from con...

Page 99: ...and tighten them to the specified torque NOTE BEFORE INSTALLING THE HEAD MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COM PRESSED AIR JET Locking torques N m Locking torque 11 13 Fit the timing chain sprocket wheel on the crank shaft with the chamfer facing the insertion side Loop the timing chain around the sprocket on the crankshaft Fit the tensioner pad by the cylinder head Fit the s...

Page 100: ...ence 2V in corre spondence with the reference mark on the head Fit the pulley onto the camshaft Assemble the counterweight with the corre sponding fixing screw and tighten to the specified torque Locking torques N m Locking torque 7 8 5 Fit the end stop ring on the automatic valve lifter cam and fit the automatic valve lifter cam to the cam shaft Fit the automatic valve lifter return spring During...

Page 101: ...r tightening it to the prescribed torque Locking torques N m Locking torque 5 6 Adjust the valve clearance Fit the spark plug Characteristic Spark plug Champion RG6YC Electric characteristic Electrode gap 0 8 mm Locking torques N m Locking torque 12 14 Assemble the casing sealing gasket on the head On the fitting direction use the supplements on the timing side as reference Assemble the screw fixi...

Page 102: ...e the driving pulley the belt and the transmission cover as described in the transmis sion chapter Locking torques N m Locking torque 11 13 Crankcase crankshaft Precautionary remove the following units transmission cover driving pulley driven pulley and belt rear hub cover gears bearings and oil seals as described in the transmission chapter Remove the oil sump the by pass the chain compartment co...

Page 103: ...ves Remove the 11 coupling screws to the crankcase Separate the crankcase while keeping the crank shaft in one of the two halves of the crankcase Remove the crankshaft CAUTION IF YOU FAIL TO DO THIS THE CRANKSHAFT MIGHT AC CIDENTALLY FALL Remove the coupling gasket of the crankcase halves Remove the two screws and the internal cover shown in the diagram CAUTION WHILE OPENING THE CRANKCASES AND REM...

Page 104: ...in the diagram CAUTION BE CAREFUL NOT TO LET THE MEASUREMENT BE AF FECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS Characteristic Standard clearance 0 036 0 054 mm If the axial clearance between crankshaft and crankcase is exceeding and the crankshaft does not have any defect the problem must be due to either excessive wear or wrong machining on the crankcase CAUTION THE CRANKSHAFT CAN BE REUSED WHE...

Page 105: ...he oil seal capacity the toothed gear and the threaded tangs are in good working order In case of failures replace the crankshaft The connecting rod head bushings cannot be re placed For the same reason the connecting rod may not be replaced and when cleaning the crankshaft be very careful that no impurities get in through the shaft s lubrication holes In order to prevent damaging the connecting r...

Page 106: ...oil pressure NOTE THE JET IS FED THROUGH THE MAIN BUSHINGS PROP ER OPERATION OF THIS COMPONENT IMPROVES THE PISTON TOP COOLING CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO DETECT PISTON TEMPERATURE IN CREASE FAILURE OR LEAK CAN CONSIDERABLY DE CREASE THE MAIN BUSHING AND CONNECTING ROD LUBRICATION PRESSURE On the flywheel side crankcase half take partic ular care cleaning the oil ducts for the main ...

Page 107: ...ng the crankshaft plain bearings To obtain a good bushing lubrication it is neces sary to have both an optimal lubricating pressure 4 bar and a good oil flow rate the bushings must be correctly positioned so as not to obstruct the oil supply channels The main bushings are comprised of two half bearings one containing holes and channels for lubrication and the other solid The solid half bearing is ...

Page 108: ...a coupling selection The bushing housings in the crankcase are classified into 2 categories Cat 1 and Cat 2 just like those for the crankshaft 3 The main bushings are subdivided into 3 thickness categories see the table below NOTE DO NOT TAKE THE MEASUREMENT ON THE TWO HALF SHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION MAIN BEARINGS Specification ...

Page 109: ...TO DAMAGE THE SHAFT THREA DED TANGS Locking torques N m Locking torque 11 13 Lubricate the flywheel oil seal Use the appropriate tool to assemble the oil seal Fit a new O ring on the pre filter and lubricate it Insert the pre filter on the engine with its corre sponding cover to the specific torque NOTE REMOVE ANY EXCESS FROM THE CRANKCASE COU PLING GASKET ON THE CYLINDER PLANE TO ENSURE BETTER SE...

Page 110: ...Conceptual diagrams Engine SPORTCITY ONE 125 ENG 110 ...

Page 111: ... 2 4 2 atm Remove the appropriate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the prescribed torque and fit the fan cover If the oil pressure is outside the specified limits in the following order check the oil filter the oil by pass valve the oil pump and the crankshaft seals NOTE THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND...

Page 112: ...e threaded bar onto the base of the tool and extract the oil guard Specific tooling 020622Y Transmission side oil guard punch Refitting Prepare the new oil guard lubricating the sealing lip Warning do not lubricate the surface for keying onto the engine crankcase CAUTION DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO THE ENGINE CRANKCASE Engine SPORTCITY ONE 125 ENG 112 ...

Page 113: ...AUTION ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS WHEN THE POSITION IS REACHED DO NOT RETRACT THE OIL GUARD FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL GUARD SHEATH Orientate the oil guard by inserting the bracket which is part of the specific tool Tighten the threaded bar onto the crankshaft as far as it will go SPORTCITY ONE 125 E...

Page 114: ...CHAIN Oil pump Removal Remove the chain cover acting on the 3 retaining screws as shown in the figure and the relevant copper washer Extract the cover using the appropriate appen dages NOTE WITH THE AIM OF AVOIDING DAMAGING THE APPEN DAGES PRACTICE A RUN PARALLEL TO CRANKSHAFT Remove the cover of the pump control pulley us ing the two retainers as shown in the figure Block the rotation of the oil ...

Page 115: ...THE INITIAL DIRECTION OF ROTATION IS MAINTAINED Inspection Remove the two screws and the oil pump cover Remove the clip retaining the innermost rotor Remove and wash the rotors thoroughly with pet rol and compressed air Reassemble the rotors in the pump body keep ing the two reference marks visible Replace the clip Using a thickness gauge check the distance be tween the rotors in the position show...

Page 116: ...haft or body Check there are no signs of scoring or wear on the oil pump cover If you detect non conforming measurements or scoring replace the faulty parts or the assembly Fit the pulley to the pump the central screw to the specified torque and the belleville washer Fit the oil pump cover by tightening the two screws to the prescribed torque NOTE FIT THE BELLEVILLE WASHER SO THAT ITS OUTER CURVED...

Page 117: ...figure and the 2 rear brake transmission fixing brackets Remove the spring the by pass piston and the gasket shown in the second image Inspecting the by pass valve Check the unloaded spring length Check that the small piston is not scored Ensure that it slides freely on the crankcase and that it guarantees a good seal If not eliminate any impurities or replace defec tive parts Characteristic By pa...

Page 118: ... drive belt the sprocket wheel and the transmission cover as de scribed in the Transmissions chapter When testing the lubrication system refer to the Crankcase and Crankshaft chapter re garding lubrication of the crankshaft and con necting rod Locking torques N m Locking torque 11 13 Fuel supply With the multimeter check if the potentiometer is working correctly by placing the probes on both conta...

Page 119: ...ction the clamps anchoring the carburettor to the filter housing and to the inlet manifold the air delivery pipe to the diaphragm the heater the intake fitting and the TPS cable Remove the heater Remove the protection the bracket and the start er acting on the screw shown in the figure Remove the 2 screws and the starter support with the gasket SPORTCITY ONE 125 Engine ENG 119 ...

Page 120: ...G DURING THE REMOVAL OF THE CARBURETTOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY Remove the vacuum valve together with the di aphragm Unscrew the bayonet joint 1 8 of a turn and re move take out the spring and vacuum valve nee dle Engine SPORTCITY ONE 125 ENG 120 ...

Page 121: ...he intake pump from the tank NOTE CAUTION THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES SPRING AND BALL NOTE AVOID REMOVING THE PISTON OF THE PUMP AND ITS CONTROL Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side Remove the float and the plunger Remove the maximum nozzle SPORTCITY ONE 125 Engine ENG 121 ...

Page 122: ... Remove the maximum nozzle Remove diffuser Engine SPORTCITY ONE 125 ENG 122 ...

Page 123: ...he minimum flow set screw and the spring CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS FUEL SUPPLY PIPE PLUNGER HOUSING STARTER NOZZLE PIT COVER FOR PROGRESSIONS AND INLET NOZZLE MINIMUM AND MAXIMUM AIR GAUGE THROTTLE VALVE CONTROL SHAFT DO NOT REMOVE THROTTLE SHAFT CONNEC TION SCREWS THE FIXING SCREWS ARE CAULKED AF TER ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT...

Page 124: ...let section controlled by flow screw progression holes near the throttle valve For the starter circuit blow the connection pipe properly with the jet This is necessary because the nozzle support hides other inaccessible internal calibrations Blow the intake nozzle properly NOTE THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE NOZZLE INCORRECT ORIENTATION RESU...

Page 125: ... minimum nozzle properly and reassemble it Properly wash and blow the components of the sprayer maximum circuit the diffuser and the noz zle Introduce the sprayer in the carburettor body with the shortest cylindrical part directed to the diffuser Assemble the diffuser making sure the sprayer is being adequately inserted and lock it Assemble the maximum nozzle Check that the tapered pin does not sh...

Page 126: ...ing Nozzle NOTE THE IN VALVE NOZZLE CORRESPONDING TO THE AC CELERATION PUMP IS MILLED Check the screw tightness introducing a small amount of fuel in the tank Assemble a new gasket on the tank Assemble the tank on the carburettor body fas tening the 4 screws Check that the control roller is free to rotate in its own seat NOTE MAKE SURE THE TANK GASKET IS CORRECTLY INTRO DUCED NOTE AVOID DEFORMING ...

Page 127: ...described above Inspecting the valve and needle Check that the tapered pin of the vacuum valve does not show wear Check that the depression valve does not show threads on the external surfaces Check that the vacuum intake hole is not clogged Check that the diaphragm is not damaged or has hardened otherwise replacement the whole valve Insert the tapered pin into the vacuum valve housing Reassemble ...

Page 128: ... Reassemble the spring with the pin lock Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover Tighten the screws Engine SPORTCITY ONE 125 ENG 128 ...

Page 129: ... Wash and blow dry the filter sponge of the ambient pressure intake Reassemble the filter with its clamp SPORTCITY ONE 125 Engine ENG 129 ...

Page 130: ... deformed The starter must be more or less functional depending on the ambient temperature Measure the protrusion of the piston as shown in the figure and check its corresponding value Make sure that the starter is adjusted for the ambient temperature The starter should disconnect progressively by means of electric heating Check the starter resistance when adjusted to the ambient temperature With ...

Page 131: ...ith the machined side contacting the starter tighten the fixing screws Position the starter as shown in the figure Assemble the protection casing NOTE TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION NOT TO GENERATE SHORT CIRCUITS USE A CABLE SECTION WITH A TERMINAL SUITABLE TO BE CONNECTED TO THE STARTER Characteristic Starter pin travel 10 mm at 24 Starter resistance 20 Ohm at 24 Check the automati...

Page 132: ...Engine SPORTCITY ONE 125 ENG 132 ...

Page 133: ...ing it run at 50 Km h for at least 5 minutes Connect the multimeter thermometer 020331y to the sump using a cap with oil expressly pre pared for probes Start the engine and before adjusting idle speed make sure that the oil temperature is between 70 80 C Using the rpm indicator or any other instrument 020332y adjust the idle screw to obtain 1600 rpm 1700 rpm NOTE THE WASTED SPARK IGNITION SYSTEM O...

Page 134: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 135: ...vehicle so that the wheel can move freely and the vehicle does not fall CAUTION MAKE SURE THE SCOOTER IS STABLE AND FIRM IF IT FALLS IT MAY INJURY YOU OR OTHER PEOPLE DAMAGE THE VEHICLE ITSELF OR ANY ADJACENT OBJECTS Loosen the two locking screws of the wheel axle 1 Loosen the wheel axle fixing screw 2 Slide off the axle and remove the wheel CAUTION NEVER TOUCH THE FRONT BRAKE LEVER ONCE THE FRONT...

Page 136: ...ings do not show flaws or jamming Otherwise replace them Check that the internal spacer does not show abnormal wear Otherwise re place it With a hot air gun heat the seat of the bearing on the brake calliper side With an appropriate tool refit the bear ing on the brake disc side Insert the spacer bushing on the brake disc side With a hot air gun heat the seat of the bearing on the side the odomete...

Page 137: ...Check wheel on the wheel balancer and turn it several times paying attention to its position when it stops If the wheel is steadily balanced it will not always stop at the same point If it always stops at the same point the wheel is not balanced and must be balanced Place weights on the lightest part of the wheel so that it does not stop any more at a particular point after being turned several ti...

Page 138: ...ce the wheel between the fork rods by inserting correctly the odometer transmission in the housing on the fork rod Insert the fork shaft and screw the nut 1 to the prescribed torque Locking torques N m Wheel pin to fork fixing nut 46 5 Tighten the two locking 2 screws of the wheel axle Locking torques N m Wheel pin hub fixing screw 10 Handlebar Removal NOTE Suspensions SPORTCITY ONE 125 SUSP 138 ...

Page 139: ...nd rear handlebar covers Disconnect the brakes transmission and the supply cables of the stop but tons Unscrew the nut 1 and collect the washer To refit carry out the removal operations but in reverse order and tighten the screw 1 to the prescribed torque Locking torques N m Handlebar to headstock fixing nut 52 5 Front fork SPORTCITY ONE 125 Suspensions SUSP 139 ...

Page 140: ...and or cracked If there are signs of excessive wear or damage replace the affected component Replace oil seal 4 and the dust guard 5 and fit it once you have lubricated its seat Replace the O ring on cap 1 Replace sealing washer 2 FITTING Refit the stem and the pumping member and tighten screw 3 with its washer 2 Pour the recommended quantity of specific oil into the stem unit Insert the spring an...

Page 141: ... not fall CAUTION MAKE SURE THE SCOOTER IS STABLE AND FIRM Remove the handlebar Remove the front brake calliper Release the fork from the odometer ca ble and from the front brake calliper pipe Loosen the tightening ring nut 1 and collect the shim washer 2 Locking torques N m Upper ring nut 37 5 SPORTCITY ONE 125 Suspensions SUSP 141 ...

Page 142: ... hammer Carefully wash the bearings components Check wear status of the upper rings 2 and 6 and of the lower rings 5 and 8 of the bearings To refit carry out the removal operations but in reverse order Appropriately lubricate the bearings with recommended products Steering bearing Checking bearing clearance To check the steering it is necessary to Park the vehicle on its centre stand Place the sup...

Page 143: ...d the shield back plate Loosen the tightening nut 1 using an adequate open wrench CAUTION DO NOT TIGHTEN THE ADJUSTMENT NUT 2 TOO MUCH BECAUSE IT MAY DAMAGE THE STEERING BEARINGS Tighten the adjustment nut 2 until the the bearing clearance is completely eliminated Check clearance as described above Make sure the front fork can move all long its stroke from left to right or vice versa rotating free...

Page 144: ...d the cap 2 Pull the rear brake and keep it pulled with a clamp Unscrew the wheel fixing nut and col lect the washer Take out the wheel from its housing To refit carry out the removal operations but in reverse order be careful to use a new split pin Locking torques N m Rear wheel to hub fixing nut 115 Swing arm Suspensions SPORTCITY ONE 125 SUSP 144 ...

Page 145: ...Screw 3 Spring 4 Rod engine attachment 5 Bushing 6 Buffer 7 Bracket 8 Seeger ring 9 Hexagonal screw 10 Needle bearing 11 Spacer 12 Nut 13 Spacer 14 Rod chassis attachment 15 Screw SPORTCITY ONE 125 Suspensions SUSP 145 ...

Page 146: ... the stroke direc tion If there is any clearance check all the retainers that connect the support Shock absorbers Removal CAUTION HOLD THE REAR PART OF THE FRAME CAUTION PLACE A SUPPORT OF SUITABLE THICKNESS UNDER THE REAR WHEEL TO PREVENT THE ENGINE FROM FALLING Rest the vehicle on its centre stand Remove the tail section and unscrew nut 1 fixing the shock absorber to the chassis Suspensions SPOR...

Page 147: ...taining nut 22 5 Lower part of the shock absorber retaining nut 42 5 Centre stand Rest the vehicle on its centre stand Place a support under the vehicle so that it does not fall after the centre stand is removed CAUTION MAKE SURE THE SCOOTER IS STABLE AND FIRM IF IT FALLS IT MAY INJURY YOU OR OTHER PEOPLE DAMAGE THE VEHICLE ITSELF OR ANY ADJACENT OBJECTS Remove the two springs 1 SPORTCITY ONE 125 ...

Page 148: ...lide off the pin To refit carry out the removal operations but in reverse order and tighten the nut to the prescribed torque Locking torques N m Central stand to chassis fixing screw 42 5 Suspensions SPORTCITY ONE 125 SUSP 148 ...

Page 149: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 150: ... WHEN PADS ARE WORN THE BRAKE FLUID LEVEL DECREASES PROGRESSIVELY TO COM PENSATE PAD WEAR If the fluid does not reach the MIN reference mark Check brake pads for wear If there is no need to replace any pads discs check the braking system to determine the cause of the problem by checking the brake pipe condition Mainly check if there are broken or cracked areas the connections are properly tight en...

Page 151: ...Y TO BOTH CALLIP ERS Undo the two screws indicated and re move the brake calliper NOTE SHOULD IT BE NECESSARY TO REPLACE THE CALLIP ER FIRST LOOSEN THE JOINT CONNECTING THE PIPE TO THE BRAKE CALLIPER Refitting To fit follow the removal steps but in reverse order and tighten the locking screws to the prescribed torque using the recommended product Recommended products Loctite 243 Medium strength th...

Page 152: ...liper Undo the two screws indicated Remove the brake pads CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE CONTROL LEVER OTHERWISE THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAKAGE Check friction material for appropriate thickness If thinner than the minimum value replace it Characteristic Friction material minimum thickness 1 5 Braking system SPORTCITY ONE 125...

Page 153: ...eeding the braking system NOTE IF THERE IS AIR IN THE HYDRAULIC SYSTEM THE WATER WILL ABSORB MOST OF THE POWER OF THE BRAKE MAIN CYLINDER AND THEREFORE IT WILL REDUCE THE CALLIPER PERFORMANCE WHEN BRAKING THE PRESENCE OF AIR IS SIGNALLED BY THE SPONGI NESS OF THE BRAKE CONTROL AND POOR BRAKING EFFICIENCY CAUTION CONSIDERING THE DANGER POSED FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY TO BLEED T...

Page 154: ...SING THE BRAKE LEVER 5 CLOSE THE BLEED PLUG 2 TO PREVENT WATER FROM ENTERING THE BRAKE SYSTEM When the brake fluid that comes out is homogeneous without bubbles it means air has successfully been eliminated from the system Close the bleed plug 2 accurately and tighten it correctly NOTE REPEAT THE LAST TWO OPERATIONS UNTIL THE BUBBLES ARE TOTALLY ELIMINATED Refit the protection cap 1 on the bleed p...

Page 155: ...p to handlebar fixing screw 8 05 Brake pipe to brake pump fixing screw 18 Rear drum brake Remove the rear wheel Hold the lower shoe and slide it with the upper one For fitting First assembly two shoes and the springs then place them on the pin and on the cam To replace the transmission Remove the front handlebar cover Loosen the brake set screw Release the transmission from its clamps to the engin...

Page 156: ...o adjust the drum brake Unscrew the lock nut Adjust the activation point of the rear drum brake by acting on the set screw 1 With the brake lever released the wheel should rotate freely Braking system SPORTCITY ONE 125 BRAK SYS 156 ...

Page 157: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 158: ...nut 10 Rear rack Remove the three screws 1 shown in figure and collect the washers Locking torques N m Passenger handgrip fixing screw 20 5 Driving mirrors Undo the screw 1 and remove the rear view mirror Collect the cover and spacer Locking torques N m Mirror fixing screw 25 Chassis SPORTCITY ONE 125 CHAS 158 ...

Page 159: ...ver Undo the four screws 1 and release it from the connector and from the od ometer cable Instrument panel Remove the front handlebar cover Undo the four screws 1 Front handlebar cover Remove the rear view mirrors Undo the two screws 1 SPORTCITY ONE 125 Chassis CHAS 159 ...

Page 160: ...gshield Undo the indicated screw To replace the bulb Slide off the rubber bulb holder Hold the bulb press it and turn it anti clockwise Legshield Remove the shield back plate Working from the front wheel well in ternal side undo the three screws 1 from both sides of the vehicle Chassis SPORTCITY ONE 125 CHAS 160 ...

Page 161: ...ate Before fitting the shield back plate re move the footrest fixing screws in order to insert the two plastic parts NOTE UPON FITTING REMEMBER TO CONNECT THE FRONT TOP BOX OPENING TRANSMISSION Front wheel housing Remove the legshield Remove the front mudguard Remove the front wheel Undo the five screws 1 SPORTCITY ONE 125 Chassis CHAS 161 ...

Page 162: ...he rear light unit from the side fairings Undo the screw 2 and remove the taillight fairing Inside the rear light unit there are One position light stop light bulb 3 Two turn indicator bulbs 4 To replace the tail stop bulb Hold the bulb holder turn it anticlockwise and slide it off Chassis SPORTCITY ONE 125 CHAS 162 ...

Page 163: ... the rubber bulb holder turn it anticlockwise and slide it off Hold the bulb and slide it off Footrest Undo the screw 2 and remove the protection Undo the four screws 3 Remove the front knee guard panel Remove the rear central cover Remove the two screws 1 SPORTCITY ONE 125 Chassis CHAS 163 ...

Page 164: ...th sides of the vehicle Undo the two screws 3 Release the helmet compartment from the cable harnesses From both sides of the vehicle undo the screw 4 placed under the footrest Remove the two fairings together with the rear light unit Release it from the rear light unit cable harnesses Chassis SPORTCITY ONE 125 CHAS 164 ...

Page 165: ...cense plate holder Undo the two screws 1 Undo the two screws indicated Air filter Remove the rear central cover Undo the two screws 1 Disconnect the vapour recovery pipe SPORTCITY ONE 125 Chassis CHAS 165 ...

Page 166: ...mudguard Undo the two screws 1 Undo the screw 2 Helmet bay Remove the saddle Remove the luggage rack Remove the rear central cover Remove the side fairings Undo the two screws 1 placed inside the helmet compartment Remove the battery cover and the bat tery Chassis SPORTCITY ONE 125 CHAS 166 ...

Page 167: ...d under the footrest Remove the two fairings together with the rear light unit Release it from the rear light unit cable harnesses Fuel tank Remove the saddle Remove the luggage rack Remove the rear central cover Remove the side fairings Remove the helmet compartment Operating from both sides of the vehi cle undo the two screws 1 Locking torques N m SPORTCITY ONE 125 Chassis CHAS 167 ...

Page 168: ...nk to chassis rear fixing screw 10 Loosen the two screws 3 placed in side the rear wheel well Disconnect the connector of the fuel probe 4 and release the tank from the pipes Front mudguard Operating from both sides of the vehi cle undo the three screws 1 Chassis SPORTCITY ONE 125 CHAS 168 ...

Page 169: ...ews 1 and remove the cover by sliding it upwards so as to detach the locking tabs Battery Remove the three screws 1 and re move the battery cover Disconnect the negative and positive cables 2 Slide off the breather pipe 3 SPORTCITY ONE 125 Chassis CHAS 169 ...

Page 170: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 171: ...parts fixing screws Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and relevant warning lights Headlight adjustment according to regulations in force Front and rear brake light buttons and relevant bulb Turn indicators and relevant warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel ...

Page 172: ...E OF CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKIN...

Page 173: ... operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Lock checking Tyre pressure checking Installation of mirrors and possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT...

Page 174: ... ESSENTIAL TO PROTECT THE LICENSE PLATE SIDE EXTENSION AGAINST MUFFLER WARM GASES A License plate Italy B License plate side extension Germany C Heat guard adhesive to be added to the side extension Pre delivery SPORTCITY ONE 125 PRE DE 174 ...

Page 175: ...lutch 66 68 69 72 E Engine oil 32 F Fork 139 Fuel 34 118 167 Fuses 54 H Headlight 38 160 Horn 52 Hub oil 29 I Identification 10 Instrument panel 159 M Maintenance 28 Mirrors 158 R Recommended products S Saddle Shock absorbers 146 Spark plug 29 Stand T Tank 167 Transmission 11 64 76 Tyres 13 ...

Page 176: ...W Warning lights ...

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