Aprilia Sportcity Cube 250 - 300

SERVICE STATION MANUAL854214

SPORTCITY CUBE 250 - 300

SERVICE STATION MANUAL


THE VALUE OF SERVICE Thanks to continuous technical updates and specific training programs on aprilia products, only aprilia Official Network mechanics know this vehicle fully and have the special tools necessary to carry out maintenance and repair operations correctly. The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding, its regular maintenance and the use of Original Aprilia Spare Parts only are essential factors! For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or search directly on the inset map in our Official Website: www.aprilia.com Only aprilia Original Spare Parts ensure products already studied and tested during the vehicle design stage. All aprilia Original Spare Parts undergo quality control procedures to guarantee full reliability and duration. The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this manual remain unchanged, aprilia reserves the right, at any time and without being required to update this publication beforehand, to make 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 versions should be confirmed with the official Aprilia sales network. Copyright 2008 - Aprilia. All rights reserved. Reproduction of this publication in whole or in part is prohibited. Aprilia - After sales service. aprilia trademark is property of Piaggio & C. S.p.A.

SERVICE STATION MANUALSPORTCITY CUBE 250 - 300- This manual provides the main information to carry out regular maintenance operations on your vehicle. - This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing vehicles. Without this knowledge, repairing or checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures are not described in detail, be extremely cautious so as not to damage components or injure individuals. In order to optimise customer satisfaction when using our vehicles, aprilia s.p.a. commits itself to continually improve its products and the relative documentation. The main technical modifications 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 and technical changes related to the vehicle.

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS TOOLING MAINTENANCE ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE INJECTION SUSPENSIONS BRAKING SYSTEM COOLING SYSTEM CHASSIS PRE-DELIVERY

CHAR TOOL MAIN ELE SYS ENG VE ENG INJEC SUSP BRAK SYS COOL SYS CHAS PRE DE

INDEX OF TOPICS

CHARACTERISTICS

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Characteristics


Rules Safety rulesGENERAL PRECAUTIONS AND INFORMATION When repairing, dismantling and reassembling the vehicle, follow the recommendations given below carefully.CAUTION

USE OF NAKED FLAMES IS FORBIDDEN DURING ALL TYPES OF OPERATION. BEFORE STARTING ANY MAINTENANCE OPERATION OR 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 OTHER SCOOTER PARTS WITH YOUR MOUTH: SCOOTER COMPONENT ARE NOT EDIBLE, ON THE CONTRARY SOME OF THEM ARE HARMFUL AND EVEN TOXIC. CARBON MONOXIDE If you need to keep the engine running in order to carry out any procedure, please ensure that you do so in an 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-extraction system.CAUTION

EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH. FUELCAUTION

FUEL USED TO DRIVE EXPLOSION ENGINES IS HIGHLY FLAMMABLE AND CAN BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE.CAUTION

DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.CAUTION

KEEP OUT OF THE REACH OF CHILDREN. HIGH-TEMPERATURE COMPONENTS CHAR - 6


Characteristics

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 wearing insulating gloves or wait until the engine and the exhaust system have cooled down. TRANSMISSION OIL AND USED FORK OILCAUTION

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK. THE TRANSMISSION OIL MAY CAUSE SKIN DAMAGE IF HANDLED FREQUENTLY AND FOR LONG PERIODS. WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL. HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER. IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.CAUTION

DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.CAUTION

KEEP OUT OF THE REACH OF CHILDREN. BRAKE FLUIDCAUTION

THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING THE BRAKE SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKE SYSTEM. THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.CAUTION

KEEP OUT OF THE REACH OF CHILDREN. HYDROGEN GAS AND BATTERY ELECTROLYTECAUTION

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID, IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING THE BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IF THE ELECTROLYTIC FLUID GETS INTO CONTACT WITH THE SKIN, WASH WITH ABUNDANT COOL WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF IT COMES INTO CONTACT WITH THE EYES, CHAR - 7

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RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIALIST AS SOON AS POSSIBLE. IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES. KEEP IT AWAY OF FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCE. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.CAUTION

KEEP OUT OF THE REACH OF CHILDREN.CAUTION

THE BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTIVATED.

Maintenance rulesGENERAL PRECAUTIONS AND INFORMATION When repairing, dismantling and reassembling the vehicle, follow the recommendations given below carefully.CAUTION

UNLESS OTHERWISE INDICATED, REFIT THE UNIT FOLLOWING THE REMOVAL STEPS BUT IN REVERSE ORDER. THE POSSIBLE OVERLAPPING OF OPERATIONS REFERRED TO IN THE OTHER CHAPTERS MUST BE CARRIED OUT LOGICALLY, AVOIDING ANY UNNECESSARY REMOVAL OF COMPONENTS. DO NOT POLISH MATT PAINTWORK WITH ABRASIVE PASTES. NEVER USE FUEL AS SOLVENT FOR CLEANING THE SCOOTER. DO NOT USE ALCOHOL, PETROL OR SOLVENTS TO CLEAN RUBBER AND PLASTIC PARTS AND THE SADDLE. USE ONLY WATER AND NEUTRAL SOAP INSTEAD. DISCONNECT THE NEGATIVE CABLE (-) OF THE BATTERY IF YOU INTEND TO CARRY OUT ELECTRICAL WELDING WORK. BEFORE REMOVING COMPONENTS Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle. Use the special tools designed for this scooter, as required.

REMOVAL OF COMPONENTS Do not loosen and/or tighten screws and nuts using pliers or other tools than the specially designed wrench. Mark positions on all connection joints (pipes, cables etc.) before separating them, and identify them with distinctive symbols. Each component needs to be clearly marked in order to be identified during reassembly. Clean and wash the dismantled components carefully using a low-flammability detergent.

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Keep coupled parts together since they have "adjusted" to each other due to normal wear and tear. Some components must be used together or replaced altogether. Keep away from heat sources.

REASSEMBLING COMPONENTSCAUTION

NEVER REUSE A CIRCLIP; IF A CIRCLIP HAS BEEN REMOVED, IT MUST BE REPLACED WITH A NEW ONE. WHEN INSTALLING A CIRCLIP, ENSURE THAT ITS ENDS ARE NOT STRETCHED MORE THAN IS NECESSARY TO FIT IT ONTO THE SHAFT. AFTER INSTALLING THE CIRCLIP, CHECK THAT IT IS FULLY AND CLEANLY INSTALLED IN ITS SEAT. DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS.NOTE

BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE THEY NEED REPLACING. Use only ORIGINAL aprilia SPARE PARTS. Comply with lubricant and consumables usage guidelines. Lubricate parts (whenever possible) before refitting them. When tightening nuts and screws, start from the ones with the largest section or from the internal ones, moving diagonally. Tighten nuts and screws in successive steps before applying the tightening torque. Always replace self-locking nuts, washers, sealing rings, circlips, O-rings, split pins and screws with new ones if their tread is damaged. When fitting bearings, make sure to lubricate them well. Check that each component is fitted correctly. After a repair or routine maintenance procedure, carry out pre-ride checks and test the vehicle on private grounds or in an area with low traffic density. Clean all coupling surfaces, oil guard rims and washers before refitting them. Apply a light layer of lithium-based grease on the oil guard rims. Reassemble the oil guards and the bearings with the brand or lot number facing outward (visible side). ELECTRIC CONNECTORS Electric connectors must be disconnected as described below as non-compliance with the procedure so described causes irreparable damage to both the connector and the cable harness: Press the relevant safety hooks, if any.CAUTION

TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES. Grip the two connectors and disconnect them by pulling them in opposite directions.

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NOTE

In presence of dirt, rust, humidity etc., clean the connector's internal parts carefully, using a pressurised air jet. Make sure that the cables are correctly linked to the connector's internal terminal ends.

THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAY ROUND. Then fit the two connectors making sure that they couple correctly (if the relevant hooks are provided, you will hear them "click" into place). TIGHTENING TORQUECAUTION

DO NOT FORGET THAT TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON WHEELS, BRAKES, WHEEL SPINDLES AND OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. IF THESE RECOMMENDATIONS ARE NOT COMPLIED WITH, ONE OF THE COMPONENTS MAY BECOME LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISING THE VEHICLE'S MANOEUVRABILITY. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH. BRAKE FLUIDCAUTION

DO NOT USE FLUIDS OTHER THAN THOSE PRESCRIBED AND DO NOT MIX DIFFERENT LIQUIDS WHEN TOPPING UP IN ORDER NOT TO DAMAGE THE BRAKE SYSTEM. DO NOT USE BRAKE FLUID TAKEN FROM OLD CONTAINERS OR FROM CONTAINERS THAT HAVE BEEN OPEN FOR A PROLONGED TIME. SUDDEN CHANGES IN THE PLAY OR ELASTIC RESISTANCE IN THE BRAKE LEVERS ARE DUE TO FAULTS IN THE HYDRAULIC CIRCUIT. MAKE ESPECIALLY SURE THAT BRAKE DISCS AND THE FRICTION MATERIAL ARE NOT SMEARED OR GREASY, PARTICULARLY AFTER CARRYING OUT MAINTENANCE AND INSPECTION OPERATIONS. CHECK THAT BRAKE WIRES ARE NOT TWISTED OR WORN. ENSURE THAT WATER OR DUST DO NOT INGRESS INADVERTENTLY INTO THE CIRCUIT. IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE HYDRAULIC CIRCUIT. DISC BRAKECAUTION

ANY OIL OR OTHER LIQUIDS ON A DISC WILL SOIL THE BRAKE PADS. SOILED PADS MUST BE REMOVED AND REPLACED. A SOILED DISC OR A DISC WITH TRACES OF OIL MUST BE CLEANED WITH A TOP QUALITY DEGREASING AGENT. IF THE SCOOTER IS USED CLOSE TO WATER OR ON DUSTY OR UNSURFACED ROADS, OR IF IT IS USED FOR SPORTS APPLICATION, HALVE THE SERVICE INTERVALS. COOLANT The cooling of the engine is by forced liquid circulation. The coolant liquid is made up of 50% de-ionised water and antifreeze solution in a base of ethylene glycol and corrosion inhibitors. The product recommended in the 'Recommended products table' is already mixed and ready to use.

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Characteristics

For the best functioning of the engine the temperature of the coolant fluid should register in the central zone of the appropriate gauge. If the needle enters the red zone, stop the engine, allow it to cool, and check the level of the fluid; if it is normal, contact an Official aprilia Dealer.CAUTION

DO NOT USE YOUR VEHICLE IF THE COOLANT LEVEL IS BELOW THE MINIMUM 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

DO NOT REMOVE THE EXPANSION TANK PLUG WHEN THE ENGINE IS HOT, SINCE COOLANT IS UNDER PRESSURE AND VERY HOT. CONTACT WITH SKIN OR CLOTHES MAY CAUSE SEVERE BURNS AND/OR INJURIES. TYRESCAUTION

CHANGING, REPAIR, MAINTENANCE AND BALANCING ARE IMPORTANT OPERATIONS THAT ARE CARRIED OUT BY QUALIFIED PERSONNEL USING SUITABLE TOOLS. THE NEW TYRES MAY BE COVERED WITH A THIN LAYER OF PROTECTIVE COATING THAT IS SLIPPERY. DRIVE CAREFULLY FOR THE FIRST FEW KILOMETRES (MILES). NEVER USE RUBBER TREATMENT AGENTS OF ANY KIND ON THE TYRES. IN PARTICULAR ENSURE THAT THE TYRES DO NOT COME INTO CONTACT WITH LIQUID FUEL THAT WOULD CAUSE A RAPID DETERIORATION OF THE RUBBER. A TYRE THAT HAS BEEN IN CONTACT WITH OIL OR PETROL MUST BE REPLACED AND NOT SIMPLY CLEANED. DO NOT FIT TYRES WITH INNER TUBES ON RIMS FOR TUBELESS TYRES AND VICE VERSA.

Vehicle identificationChassis number The chassis number is stamped on the chassis central bar. Remove the indicated cap placed inside the front glove-box in order to read this number.

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Engine number The engine number is stamped near the rear shock absorber lower support.CAUTION ALTERING IDENTIFICATION NUMBERS CAN BE SERIOUSLY PUNISHED BY LAW, PARTICULARLY MODIFYING THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE THE WARRANTY.

Dimensions and massSIZESSpecification Max. length Max. length (to brake levers (to mirrors)) Max. height (to the rear-view mirrors) Saddle height Wheelbase Minimum ground clearance Kerb weight Desc./Quantity 1965 mm 720 mm (890 mm) 1.143 mm 790 mm 1360 mm 130 mm 148 kg

EngineENGINE TECHNICAL DATASpecification Engine model Engine type Valve quantity Cylinder quantity Overall engine capacity Bore/stroke Compression ratio MAX power MAX. torque Start-up Engine revs at idle speed Clutch Lubrication system Cooling Valve clearance SUPPLY Throttle body diffuser Fuel IGNITION Ignition advance Spark plug Desc./Quantity M288M (250) M28LM (300) Single-cylinder, 4-stroke, 4 valves, wet sump forced lubrication system, overhead camshaft. 4 1 244.29 cm (250) 278.3 cm (300) 72 mm / 60 mm (250) 75 mm / 63 mm (300) 11.0 0.5 : 1 16.5 kW at 8,000 rpm (250) 16.5 kW at 7,500 rpm (300) 21 Nm at 6,250 rpm (250) 22 Nm at 6,500 rpm (300) Electric 1600 100 rpm Automatic centrifugal dry clutch Wet sump forced lubrication system. forced-circulation air cooling driven by a centrifugal pump Inlet: 0.10 Outlet: 0.15 By electronic injection with electric fuel pump 32 mm Use premium unleaded petrol only, with minimum octane rating of 95 (NORM) and 85 (NOMM). Capacitive discharge ignition, variable advance Variable managed by control unit. 5idle speed - 15 > 6,000/8,000 rpm CHAMPION RG4 - PHP (250) NGK CR8EKB (300)

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Characteristics

Specification Spark plug electrode gap

Desc./Quantity 0.7 - 0.8 mm

TransmissionTRANSMISSIONSpecification Gear Main transmission Secondary transmission Engine/wheel total ratio Desc./Quantity continuous and automatic variator V-belt Gear reduction unit - minimum: 1:2.3 - maximum: 1:0.815

CapacitiesCAPACITYSpecification Fuel (reserve included) Fuel reserve Engine oil - engine oil change and engine oil filter replacement Transmission oil Fork oil Depth of fork oil level from the rim / without spring / fork included Coolant Seats Vehicle max. load (rider + passenger + luggage) Desc./Quantity 9l 1.5 l 1100 cm 250 cm 135 1 cm per stem 99 1.5 mm 1.5 l (50% water + 50% ethylene glycol antifreeze fluid) 2 210 kg

Electrical systemBULBS/WARNING LIGHTS1 2 3 4 5 6 7 8 9 10 11 12 Specification High-/low-beam bulb Tail light bulb Front turn indicator bulbs Rear turn indicator bulbs Rear tail light /stop light bulb License plate light bulb Instrument panel lighting bulb Turn indicator warning light High-beam warning light Low fuel warning light Engine oil pressure warning light / EFI warning light High coolant temperature gauge warning light Desc./Quantity 12 V - 55 W - H7 12V - 5W 12 V - 10 W (Amber) 12 V - 10 W (White) 12 V - 5/21 W (Red) 12V - 5W LED LED LED LED LED LED

ELECTRICAL SYSTEMSpecification Battery (Permanent magnet) Generator Desc./Quantity 12V - 10 Ah 12V - 320 W

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Frame and suspensions

CHASSIS AND SUSPENSIONSSpecification Size "A" Size "B" Trail Chassis type Steering inclination angle Front suspension Front suspension travel Rear suspension Rear suspension travel Desc./Quantity 423.5 mm 479 mm 86.2 mm High-strength steel tubular chassis, single spar at the front, superimposed double cradle at the rear. 26.5 Hydraulic action telescopic fork 100 mm hydraulic action double-acting shock absorber, adjustable preloading 80 mm

BrakesBRAKESSpecification Front brake Rear brake Desc./Quantity 260-mm disc brake with hydraulic transmission 220-mm disc brake with hydraulic transmission

Wheels and tyresWHEELS AND TYRESSpecification Wheel rims Front wheel rim Rear wheel rim Tyres Front tyre Rear tyre Rear tyre standard inflation pressure Front tyre standard inflation pressure Front tyre standard inflation pressure with passenger Rear tyre standard inflation pressure with passenger Desc./Quantity Made of light alloy 2.75 x 15" 3.00 x 15" Without inner tube (Tubeless) 120/70 - 15'' 56P 130/80 - 15'' 63P 200 kPa (2.0 bar) 200 kPa (2.0 bar) 200 kPa (2.0 bar) 230 kPa (2.3 bar)

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Tightening TorquesHANDLEBARName Handlebar to fork retainer Safety screw Steering set nut Steering series fixing lock nut Instrument panel support to handlebar retainer Mirror supports to handlebar retainer Mirrors retainer Torque in Nm 4820% 2020% 1520% 11020% 620% 5220% 2520%

CHASSISName License plate holder curved support to chassis retainer Passenger grab handle to chassis retainer Horn to chassis retainer Regulator to chassis retainer Switch to chassis retainer Fuel tank to chassis retainer Helmet compartment to chassis retainer Air deflector to chassis retainer Coil to chassis retainer Torque in Nm 2520% 2520% 1020% 1020% 1020% 1020% 520% 520% 520%

ELECTRICAL SYSTEMName Starter motor cable retainer Battery to relay retainer Starter motor on relay retainer Battery cable harness ground lead retainer Torque in Nm 520% 420% 420% 1020%

SADDLEName Hinge on saddle retainer Torque in Nm 720%

LOCKSName Glove-box lock on cover retainer Saddle lock on right and left half-tail sections retainer Saddle lock on helmet compartment retainer Torque in Nm 420% 320% 520%

INSTRUMENT PANELName Instrument panel to rear panel retainer Instrument panel to instrument panel support retainer Rear panel to handlebar retainer Front panel to lower clamp retainer Front panel to rear panel retainer Lower clamp to rear panel retainer Left and right tool holder retainer Torque in Nm 0.820% 4.520% 120% 120% 320% 120% 520%

REAR BODYWORKName Retroreflector to license plate holder retainer License plate to license plate holder retainer Rear taillight to right and left half-tail sections retainer Front retainer for right and left half-tail sections on helmet compartment Rear retainer for right and left half-tail sections on helmet compartment Rear light cover on license plate holder retainer Torque in Nm 1.520% 120% 120% 420% 120% 120%

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Characteristics


Name Rear light cover on helmet compartment retainer Rear light cover on tail sections retainer License plate holder on right and left half-tail sections retainer License plate holder on rear mudguard chassis retainer Luggage carrier cover on luggage carrier retainer Retainer between passenger grab handle cover and passenger grab handle Right and left half-tail sections on helmet compartment retainer Fuel probe lid on helmet compartment retainer Retainer for lower lock of right and left half-tail sections on right and left half-tail sections

Torque in Nm 6 120% 320% 520% 120% 120% 120% 120% 320%

CENTRAL BODYWORKName Central inspection cover on helmet compartment retainer Central inspection cover on right and left fairings retainer Left side inspection cover retainer Right side inspection cover retainer Battery cover retainer Footrest retainer Right and left lower shield retainer Glove-box lid on internal legshield retainer Internal legshield to external legshield retainer Glove-box net on internal legshield retainer Glove-box lid reinforcing retainer Bag hook retainer Air intake on internal legshield retainer Torque in Nm 120% 320 320% 320% 320% 320% 320% 120% 120% 120% 120% 120% 120%

FRONT AND REAR BRAKEName Calliper on fork retainer Calliper on muffler plate retainer Pipe cable guide on link rod retainer Pipe cable guide on air deflector retainer Right and left pump on handlebar retainer Rear calliper support to muffler plate retainer Rear calliper support on muffler plate retainer Front pipe cable guide on fork retainer Torque in Nm 2520% 2520% 1020% 520% 1020% 2520% 2520% 1020%

FRONT BODYWORKName Right and left air intake on shield retainer Right and left turn indicators on external legshield retainer Front headlamp on external legshield retainer External legshield on cover retainer External legshield on shield retainer Front mudguard clamp on fork retainer External legshield on under-footrest retainer Front mudguard on clamps retainer Case on internal legshield retainer Torque in Nm 120% 120% 120% 120% 120% 120% 320% 520% 220%

FILTER CASINGName Sleeve on carburettor retainer Sleeve on filter housing retainer Filter housing on engine retainer Torque in Nm 220% 220% 820%

COOLING UNITName Thermal switch retainer Head pipe on radiator retainer Pump pipe on radiator retainer Radiator on bulkhead retainer Torque in Nm 2020% 220% 220% 720%

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Characteristics

Name Electric fan on radiator retainer Expansion tank on air deflector retainer

Torque in Nm 120% 420%

FRONT WHEELName Pin retainer Safety screw retainer Torque in Nm 5020% 1020%

LINK RODName Connecting rod to chassis retainer Connecting rod to engine retainer Chassis connecting rod on engine connecting rod retainer Silent-block on chassis retainer Torque in Nm 6020% 4020% 6020% 5020%

EXHAUSTName Manifold to engine retainer Muffler to manifold retainer Muffler on plate retainer Protection on muffler retainer Torque in Nm 1520% 1620% 2520% 720%

REAR WHEELName Rear wheel retainer Speed sensor screw retainer Speed sensor on muffler plate retainer Torque in Nm 11020% 1020% 1020%

STANDName Stand to engine retainer Torque in Nm 2720%

ENGINEName Muffler plate on engine Fuel breather pipe cable guide on crankcase Anti-vibration roller Driven pulley shaft nut Clutch assembly nut on driven pulley Driving pulley nut Flywheel nut Oil filter fitting on crankcase Minimum oil pressure sensor engine oil drainage plug/mesh filter oil pump driving crown gear screw Timing chain tensioner support screw Engine crankcase coupling screws Rear hub cover screws Oil pump cover screws Transmission cover screws Oil sump screws Screws fixing oil pump to crankcase Stator unit screws () Starter motor screws Screws for engine crankcase internal bulkhead (transmissionside half shaft) Torque in Nm 2520% 1020% 12 16 54 60 55 60 75 83 54 60 27 33 12 14 24 30 10 14 11 13 11 13 24 27 0.7 0.9 11 13 10 14 56 34 11 13 46

REAR SUSPENSIONName Right and left shock absorber to chassis retainer Shock absorber on engine bracket retainer Torque in Nm 2520% 4020%

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Characteristics


Name Shock absorber on muffler plate retainer Shock absorber bracket on engine retainer

Torque in Nm 4020% 2520%

FUEL SUPPLY SYSTEMName Probe to tank retainer Fuel coupling clamp retainer Tank to helmet compartment retainer Petrol pump on helmet compartment retainer Torque in Nm 1.520% 120% 220% 220%

Overhaul data Assembly clearances Cylinder - piston assy.250 cm Version

CYLINDER - PISTONSpecification Piston diameter Cylinder diameter Desc./Quantity 71.967+0.014 -0.014 mm 72+0.038 +0.01 mm

CYLINDER - PISTON COUPLING CATEGORYName Cylinder - Piston Cylinder - Piston Cylinder - Piston Cylinder - Piston NOTE Initials M=1 N=2 O=3 P=4 Cylinder 72.01 72.017 72.017 72.024 72.024 72.031 72.031 72.038 Piston 71.953 71. 960 71.960 71.967 71.967 71.974 71.974 71.981 Play on fitting 0.050 0. 064 0.050 0.064 0.050 0.064 0.050 0.064

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Characteristics

THE PISTON MUST BE FITTED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE FITTED WITH THE REFERENCE TOP OR THE STAMPED MARK FACING UPWARDS. - Check the pin outside diameter - Calculate the rod small end - gudgeon pin coupling clearance.

CharacteristicPin diameter: Standard clearance 0.015 0.029 mm Pin diameter: Standard diameter 14.996 15.000 mm Piston check - Measure the diameter of the bearings on the piston.

CharacteristicStandard diameter 15+0.006 +0.001 mm

- Calculate the pin - piston coupling clearance.NOTE

THE PIN HOUSINGS HAVE TWO LUBRICATION CHANNELS FOR THIS REASON MEASURE THE DIAMETER ACCORDING TO THE PISTON AXIS

CharacteristicStandard clearance: 0.001 0.010 mm - Carefully clean the sealing rings housings. - Measure the sealing rings - grooves coupling clearance using suitable sensors, as shown in the diagram - If clearances measured exceed the limits specified in the table below, the piston should be replaced by a new one.NOTE MEASURE CLEARANCE BY INSERTING THE BLADE OF THE THICKNESS GAUGE FROM THE 2nd SEALING RING SIDE.

Fitting clearance1st compression ring - standard coupling clearance 0.015 0.06 mm 1st compression ring maximum clearance allowed after use 0.07 mm 2nd compression ring - standard coupling CHAR - 19

Characteristics


clearance 0.015 0.06 mm 2nd compression ring maximum clearance allowed after use 0.07 mm oil scraper - standard coupling clearance 0.015 0.06 mm oil scraper - maximum clearance allowed after use 0.07 mm - Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified according to their diameter. The coupling is carried out in pairs (M-M, N-N, O-O, P-P).

CharacteristicMaximum run-out allowed: 0.05 mm Sealing rings check - Alternately fit the 3 sealing rings in the cylinder in the area where it keeps its original diameter. Using the piston, fit the rings perpendicularly to the cylinder axis. - Measure the opening of the sealing rings using a thickness gauge (see picture). - Replace the piston rings if values higher than those prescribed are measured.NOTE BEFORE REPLACING ONLY THE PISTON RINGS, MAKE SURE THAT COUPLING CLEARANCE BETWEEN THE PISTON RINGS AND ITS GROOVES, AND THAT BETWEEN THE PISTON AND THE CYLINDER ARE AS SPECIFIED. IN ANY CASE, NEW PISTON SEALING RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD ONES.

Characteristic1st compression ring Standard opening: 0.15 0.30 mm 2nd compression ring Standard opening: 0.20 0.40 mm oil scraper Standard opening: 0.20 0.40 mm 300 cm Version

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Characteristics

CYLINDER - PISTONSpecification Piston diameter Cylinder diameter Desc./Quantity 74.967+0.014 -0.014 mm 75+0.038 +0.01 mm

COUPLING CATEGORIESName cylinder-piston cylinder-piston cylinder-piston cylinder-piston NOTE Initials M N O P Cylinder 75.01 75.017 75.017 75.024 75.024 75.031 75.031 75.038 Piston 74.953 74.960 74.960 74.967 74.967 74.974 74.974 74.981 Play on fitting 0.050 0.064 0.050 0.064 0.050 0.064 0.050 0.064

THE PISTON MUST BE FITTED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE FITTED WITH THE REFERENCE TOP OR THE STAMPED MARK FACING UPWARDS. - Check the pin outside diameter

CharacteristicPin outside diameter 16+0 -0.004 mm

CHAR - 21

Characteristics


- Measure the diameter of the bearings on the piston.

CharacteristicStandard diameter 16+0.006 +0.001 mm

- Calculate the pin - piston coupling clearance.NOTE

THE PIN HOUSINGS HAVE TWO LUBRICATION CHANNELS FOR THIS REASON MEASURE THE DIAMETER ACCORDING TO THE PISTON AXIS

CharacteristicStandard clearance: 0.001 0.010 mm - Carefully clean the sealing rings housings. - Measure the sealing rings - grooves coupling clearance using suitable sensors, as shown in the diagram - If clearances measured exceed the limits specified in the table below, the piston should be replaced by a new one.NOTE MEASURE CLEARANCE BY INSERTING THE BLADE OF THE THICKNESS GAUGE FROM THE 2nd SEALING RING SIDE.

Fitting clearance1st compression ring - standard coupling clearance 0.015 0.06 mm 1st compression ring maximum clearance allowed after use 0.07 mm 2nd compression ring - standard coupling clearance 0.015 0.06 mm 2nd compression ring maximum clearance allowed after use 0.07 mm oil scraper - standard coupling clearance 0.015 0.06 mm oil scraper - maximum clearance allowed after use 0.07 mm

CHAR - 22


Characteristics

- Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified according to their diameter. The coupling is carried out in pairs (M-M, N-N, O-O, P-P).

CharacteristicMaximum run-out allowed: 0.05 mm

Crankcase - crankshaft - connecting rod250 cm - 300 cm Versions CRANKSHAFT

CRANKSHAFT / CONNECTING ROD AXIAL CLEARANCEName Half shaft, transmission side Half shaft, flywheel side Connecting rod Spacer tool Description Dimensions 16.6 +0-0.05 16.6 +0-0.05 18 -0.10 -0.15 51.4 +0.05 Initials A B C E Quantity D = 0.20 0.50 D = 0.20 0.50 D = 0.20 0.50 D = 0.20 0.50

Crankshaft bearing diameter. Measure bearing at both axis x and y.

CHAR - 23

Characteristics


CRANKSHAFTSpecification Camshaft bearings: Standard diameter: Cat. 1 Camshaft bearings: Standard diameter: Cat. 2 Desc./Quantity 28.998 29.004 mm 29.004 29.010 mm

CHAR - 24


Characteristics

MAXIMUM OFF-LINE ALLOWEDSpecification A= B= C= D= Desc./Quantity 0.15 mm 0.010 mm 0.010 mm 0.10 mm

CHAR - 25

Characteristics


CharacteristicCrankshaft-crankcase axial clearance (H) 0.15 0.40 mm - Measure the inside diameter of the rod small end using a bore meter.NOTE IF THE ROD SMALL END DIAMETER EXCEEDS THE STANDARD DIAMETER, SHOWS SIGNS OF WEAR OR OVERHEATING, REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.

CharacteristicStandard diameter 15 +0.025 +0.015 mm (250 cm version)16 +0.025 +0.015 mm (300 cm version)

- In order to obtain proper bushing lubrication, it is necessary to have both an outstanding lubricating pressure and a good oil flow rate. Therefore, the bushings must be correctly positioned so as not to obstruct the oil supply channels. - The main bushings are comprised of 2 half-bearings, one with holes and channels for lubrication while the other is solid. - The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason, it is arranged opposed to the cylinder. - So as not to obstruct the oil supply channels, the coupling surface of the two half-bearings must be perpendicular to the cylinder axis as shown in the figure. - The oil supplying channel section is also influenced by the depth to which the bushings are driven compared with the crankshaft axial clearance of the limiting surface. - Measure the bushings diameter at the 3 positions indicated in the figure. - Repeat the measurements for the other half of the bushing. See figure. - There are three crankcase versions: with BLUE, YELLOW or GREEN main bushings. - There is only one type of main bushing housing hole in the crankcase. The standard bushing diameter after driving is variable on the basis of a coupling selection. - The bushing seats in the crankcase are classified into 2 categories - Cat 1 and Cat 2 - just like those for the crankshaft - The main bushings are subdivided into 3 categories according to thickness; see table below:

BUSHINGSTYPE B C E IDENTIFICATION BLUE YELLOW GREEN CRANKSHAFT HALF-BEARINGS 1.973 1.976 1.976 1.979 1.979 1.982

CHAR - 26


Characteristics

COUPLINGBUSHING CATEGORY B C C E CRANKCASE HALVES CATEGORY 2 1 2 1 BUSHING INSIDE DIAMETER AFTER FITTING 29.024 29.054 29.024 29.054 29.018 29.048 29.018 29.048

Match the shaft with two category 1 crank webs with the category 1 crankcase (or cat. 2 with cat. 2) Furthermore, a spare crankcase cannot be combined with a crankshaft with mixed categories. Spare shafts have half-shafts of the same category.

CATEGORIESCRANKCASE HALVES Cat. 1 Cat. 2 Cat. 1 Cat. 2 NOTE DO NOT TAKE THE MEASUREMENT ON THE 2 HALFSHELLS COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION. NOTE SPARE CRANKCASES ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED WITH CATEGORY C (YELLOW) BUSHINGS ENGINE HALF-SHAFT Cat. 1 Cat. 2 Cat. 2 Cat. 1 BUSHING E B C C

CharacteristicCrankshaft-bushing maximum clearance allowed: 0.08 mm Crankcase diameter without bushing CAT. 1: 32.959 32.965 mmCAT. 2: 32.953 32.959 mm

Cylinder head250 cm - 300 cm Versions Clean all the coupling surfaces thoroughly before servicing the head. Pay attention to the position of the springs and valves so as not to change the original position upon refitting them - Using a trued bar and a thickness gauge, check that the cylinder head surface is not worn or distorted.

CharacteristicMaximum run-out allowed: 0.1 mm

- In case of irregularities, replace the head. CHAR - 27

Characteristics


- Check the sealing surfaces for the inlet and exhaust manifold. - Check that the camshaft and the rocker pin bearings show no signs of wear. - Check that the head cover show no signs of wear. - Check that the coolant sealing buffer is not rusted. Measure the camshaft seat bearings and rocking lever support pins with a bore meter

HEAD BEARINGS

Specification bearing A bearing B bearing C

Desc./Quantity 12.000 12.018 20.000 20.021 37.000 37.025

Measure the unloaded spring length

CharacteristicStandard length 40.2 mm Limit allowed after use 38.2 mm

- Remove any carbon deposits from the valve seats. - Check the width of the mark on the valve seat V with Prussian blue.

CharacteristicStandard value: 1 1.3 mm Limit allowed: 1.6 mm - If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45 milling cutter and then grind. - Replace the head in case of excessive wear or damage.

CHAR - 28


Characteristics

VALVE STANDARD LENGTHSpecification Valve check: standard length Valve check: standard length Desc./Quantity Inlet: 94.6 mm Outlet: 94.4 mm

- Measure the diameter of the valve stem at the three positions indicated in the diagram.

STANDARD DIAMETERSpecification Inlet: Outlet: Desc./Quantity 4.987 4.972 mm 4.975 4.960 mm

MINIMUM DIAMETER ALLOWEDSpecification Inlet: Outlet: Desc./Quantity 4.96 mm 4.945 mm

- Calculate the clearance between the valve and its guide. - Check the deviation of the valve stem by resting it on a V shaped support and measuring the extent of the deformation using a dial gauge.

CharacteristicLimit value allowed: 0.1 mm

CHAR - 29

Characteristics


- Check the concentricity of the valve head by placing a dial gauge at a right angle with respect to the valve head and rotating it on the V shaped support.

CharacteristicLimit allowed: 0.03 mm Measure the valve guides.

CharacteristicValve guide: 5+0.012 mm

- After measuring the valve guide diameter and the valve stem diameter, check the clearance between guide and stem.

INLETSpecification Standard clearance: Limit allowed: Desc./Quantity 0.013 0.04 mm 0.08 mm

EXHAUSTSpecification Standard clearance: Limit allowed: Desc./Quantity 0.025 0.052 mm 0.09 mm

- Check that there are no signs of wear on the faying surface with the set screw articulated terminal.

CHAR - 30


Characteristics

- If no anomalies are found during the above checks, the same valves can be reused. For better sealing results, it is advisable to grind the valve seats. Grind the valves gently with fine-grained lapping compound. Upon grinding, keep the cylinder head in horizontal position. This will prevent the lapping compound residues from penetrating between the valve stem and the guide (see figure).CAUTION

TO AVOID SCORING THE FAYING SURFACE, DO NOT ROTATE THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.CAUTION

DO NOT CHANGE THE VALVE FITTING POSITION (RH - LH). - Check the camshaft bearings for signs of abnormal wear or scores. - Using a micrometer, measure the camshaft bearings.

STANDARD DIAMETERSpecification Camshaft check: Standard diameter Camshaft check: Standard diameter Desc./Quantity Bearing A : 36.95 36.975 mm Bearing B : 19.959 19.98 mm

MINIMUM DIAMETER ADMITTEDSpecification Camshaft check: Minimum diameter admitted Camshaft check: Minimum diameter admitted Desc./Quantity Bearing A : 36.94 mm Bearing B : 19.950 mm

CHAR - 31

Characteristics


- Using a gauge, measure the height of the cams.

STANDARD HEIGHTSpecification Camshaft check: Standard height Camshaft check: Standard height Desc./Quantity Inlet: 30.285 mm Outlet: 29.209 mm

Check the axial clearance of the camshaft

CAMSHAFT AXIAL CLEARANCESpecification Camshaft check: Standard axial clearance: Camshaft check: Maximum axial clearance admitted: Desc./Quantity 0.11 0.41 mm 0.42 mm

- Check the outside diameter of the rocking lever pins - Check there are no signs of wear or scoring on the rocker pins. - Check the internal diameter of each rocker arm. - Check there are no signs of wear on the contact pads with the cam and on the jointed adjustment plate.

PINS AND ROCKING LEVER DIAMETERSpecification Rocking levers inside diameter: Standard diameter Rocking lever pins diameter: Standard diameter Desc./Quantity 12.000 12.011 mm 11.977 11.985 mm

CHAR - 32


Characteristics

Slot packing system250 cm - 300 cm Versions

CharacteristicCompression ratio 10.5 11.5 : 1

Distance "A" to be measured is a value of piston recess, it indicates by how much the piston crown descends below the plane formed by the cylinder crown. The further the piston enters into the cylinder, the thinner the base gasket to be used should be (to compensate the compression ratio) and vice versa.NOTE

DISTANCE A SHOULD BE MEASURED WITH NO GASKET FITTED BETWEEN THE CRANKCASE AND THE CYLINDER AND AFTER RESETTING THE DIAL GAUGE, WITH SUPPORT, ON A GROUND PLANE CHAR - 33

Characteristics


SHIMMING FOR 300 ENGINESName Shimming Shimming Shimming Measure A 3.70 - 3.60 3.60 - 3.40 3.40 - 3.30 Thickness 0.4 0.05 0.6 0.05 0.8 0.05

ProductsRECOMMENDED PRODUCTS TABLEProduct AGIP RACING 4T, SAE 10W-40 AGIP GEAR SYNTH SAE 75W-90 AGIP FORK 7.5W AGIP FILTER OIL AGIP BRAKE 4 SPECIAL AGIP PERMANENT fluid Description Engine oil Gearbox oil Fork oil Oil for air filter sponge Brake fluid Coolant Specifications 10W-40 API GL4, GL5 FMVSS DOT4+ Biodegradable coolant, ready for use, with "long life" technology and characteristics (pink). Freezing protection up to -40. According to CUNA 956-16 standard. NLGI 2

AGIP GREASE SM2

NEUTRAL GREASE OR PETROLEUM JELLY

Lithium grease with molybdenum for bearings and other points needing lubrication Battery poles

Neutral grease or petroleum jelly.

CHAR - 34

INDEX OF TOPICS

TOOLING

TOOL

Tooling


SPECIAL TOOLSStores code AP8140259 Description Universal tool for clutch assemblies

AP8140665

Adapter for clutch assembly removal

AP8140535

Front pulley fitting/removal

AP8140181

Fuel pressure check tool

AP8140266

Comparator door

AP8140729

Chain cover fitting/removal

TOOL - 36


Tooling

Stores code AP8140301

Description Flywheel extractor

AP8140659

Valve oil seal punch

AP8140662

Punch for roller casing

020425Y

Shaft oil seal punch

020376Y

Adapter handle

020455Y

10-mm guide for oil seal on water pump shaft

020412Y

Clutch oil seal punch D 15 mm

TOOL - 37

Tooling


Stores code 020439Y

Description Shaft 2 oil seal punch 17 mm

020359Y

42 x 47 mm punch

020363Y

Crankshaft oil seal punch D 20 mm

020456Y

24 mm punch

020364Y

25 mm Adaptor

020414Y

28 mm punch

020357Y

32x35 mm punch

TOOL - 38


Tooling

Stores code 020375Y

Description 28x30 mm punch

020360Y

52x55 mm punch

AP8140917

Tool for valve pressure plate

AP8140661

Lock wrench for clutch bell

AP8140300

55 mm wrench

020627Y

Flywheel lock wrench

AP8140179

Support for valve fitting/removal

TOOL - 39

Tooling



Description Piston fitting ring

AP8140664

Guide to mount the movable driven pulley

020483Y

30 mm guide

020477Y

37-mm Adaptor

002095Y

Engine support

AP8140919

Valve oil seal extractor

TOOL - 40


Tooling


Description Tool for pin rings

AP8140922

Crankcase splitting strip

AP8140921

Oil seal punch

001467Y035

Bell for OD 47-mm bearings

020481Y

Adaptor cable harness

AP8140915

Crankcase check

TOOL - 41

Tooling



Description Hub cover support

AP8140252

Multipurpose wrench

AP8140595

Axone + battery charger (230V 50Hz)

AP8202311

Axone + battery charger (110V 60Hz)

TOOL - 42

INDEX OF TOPICS

MAINTENANCE

MAIN

Maintenance


Maintenance chartROUTINE MAINTENANCE TABLEI: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Replace every 2 years km x 1,000 Safety locks Spark plug driving belt Throttle control Air filter Air filter in belt compartment Engine oil filter Valve clearance Electrical system and battery Brake fluid * Coolant level * Engine oil Hub oil Sliding blocks / variable speed rollers Vehicle and brake test - test drive Wheels/tyres Suspensions Steering Break pad wear 1 I 5 10 I 15 20 R R A C C R A I I I R R R I I I I I 25 30 I 35 40 R R A C C R A I I I R R R I I I I I 45 50 I 55 60 R R A C C R A I I I R R R I I I I I

A

R I I I R R I I I I

A C C R I I I R R R I I I I I



I

I

I

I

I

I

I

I

I

I

I

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Spark plugCAUTION

WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD. Check and/or replace the spark plug at the intervals shown in the scheduled maintenance table. To reach the spark plug: Remove the central cover of the chassis. Undo the indicated screw and remove the spark plug inspection cover. Disconnect the tube. Unscrew the spark plug.

CharacteristicSpark plug electrode gap 0.7 -0.8 mm Spark plug NGK CR7EB

To refit, carry out removal operations but in reverse order MAIN - 44


Maintenance

Hub oilRide a few kilometres until the regular working temperature is reached, then shut off the engine.NOTE

USE RECOMMENDED OIL ONLY. REFER TO THE RECOMMENDED PRODUCTS TABLE.

Check Park the vehicle on firm and level ground. Rest the vehicle on its centre stand. Unscrew and pull out the measuring cap-dipstick. Clean the area in contact with oil with a clean cloth. Screw the cap-dipstick fully down into its tube. Pull out the cap-dipstick again and read the level the oil reaches on the dipstick. The level is correct when it is close to the first notch above the little round mark. CAUTION WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD.

Top-up if necessary.

TOP-UP NOTE

Pour a small quantity of oil through the fill opening and wait about one minute so that the oil flows evenly into the crankcase. Check the oil level and top up, if required. Top-up with small quantities of oil, until the recommended level is reached. At the end of the operation, screw and tighten the cap-dipstick.

RIDING THE VEHICLE WITH INSUFFICIENT LUBRICATION OR CONTAMINATED OR NOT RECOMMENDED LUBRICANTS ACCELERATES THE WEAR AND TEAR OF MOVING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE

Replacement Park the vehicle on firm and level ground.

MAIN - 45

Maintenance


Rest the vehicle on its centre stand. Stop the engine and let it cool down. This will allow the oil to settle into the crankcase and cool down.

CAUTION

WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD. Unscrew and pull out the measuring cap-dipstick.

Place a +300 cm (18.3 cu.in) capacity container under the drain screw. Unscrew and remove the drain screw and let the oil drain off completely.

Screw and tighten the drain screw. Add oil through the transmission oil fill opening. Screw and tighten the measuring capdipstick. Start the engine and let it run for several minutes. Stop the engine and let it cool down.

CAUTION

Check the transmission oil level.

USED OIL CONTAINS SUBSTANCES THAT ARE HARMFUL TO THE ENVIRONMENT. DISPOSE OF USED OIL ACCORDING TO THE REGULATIONS IN FORCE.

Air filterClean and check the air filter following the indications specified in the scheduled maintenance table. Carry out the maintenance procedures more frequently if the vehicle is used in rainy or dusty areas, or off road. In this case, the air filter can be partially cleaned after travelling along these kinds of roads.CAUTION

PARTIAL AIR FILTER CLEANING DOES NOT EXCLUDE NOR POSTPONE AIR FILTER REPLACEMENT. DO NOT START THE ENGINE WITHOUT THE AIR FILTER. DO NOT USE PETROL OR SOLVENTS TO CLEAN THE FILTERING ELEMENT; THE FUEL SUPPLY SYSTEM MAY CATCH FIRE POSING A GREAT RISK FOR PEOPLE AND THE VEHICLE ITSELF. MAIN - 46


Maintenance

Remove the filter. Wash the filtering element with clean, non-flammable or high-volatility solvents, and let it dry properly.

Apply a specific filter oil over all the surface.

CAUTION PARTIAL AIR FILTER CLEANING DOES NOT EXCLUDE NOR POSTPONE AIR FILTER REPLACEMENT. DO NOT START THE ENGINE WITHOUT THE AIR FILTER. DO NOT USE PETROL OR SOLVENTS TO CLEAN THE FILTERING ELEMENT; THE FUEL SUPPLY SYSTEM MAY CATCH FIRE POSING A GREAT RISK FOR PEOPLE AND THE VEHICLE ITSELF.

Check the lower part of the bleed pipes 1 for dirt.

Remove any deposit coming from the filter housing found inside the bleed pipe. Proceed as follows: WARNING

Remove the caps 2. Drain the content in a container; then, send it to a recycling bank.

NEVER REUSE A FILTER. Replace the air filter with a new one of the same type.

Engine oil Replacement Rest the vehicle on its centre stand. Shut off the engine and let it cool down, so that the crankcase oil drains out and cools off. Unscrew and pull out the cap-dipstick 1. Place a container under the filter to collect the engine oil.NOTE PARK THE VEHICLE ON SAFE AND LEVEL GROUND. CAUTION WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD.

MAIN - 47

Maintenance


Unscrew and remove the cartridge engine oil filter 4. Unscrew and remove the oil drainage plug 3 and then drain all the engine oil into the collecting container.

Fit a new oil cartridge filter 4 and take special care to lubricate the filter sealing O-rings with oil.

CAUTION

Screw and tighten the engine oil drainage plug 3. Add oil through the transmission engine oil fill opening. Screw and tighten the measuring capdipstick 1. Start the engine and let it run for several minutes. Stop the engine and let it cool down. Check the engine oil level.

USED OIL CONTAINS SUBSTANCES THAT ARE HARMFUL TO THE ENVIRONMENT. DISPOSE OF USED OIL ACCORDING TO THE REGULATIONS IN FORCE.

Check CAUTION

Park the vehicle on firm and level ground. Rest the vehicle on its centre stand.

WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD. Stop the engine and let it cool down. This will allow the oil to settle into the crankcase and cool down.NOTE

FAILURE TO FOLLOW THESE OPERATIONS MAY RESULT IN AN INCORRECT READING OF THE ENGINE OIL LEVEL.

MAIN - 48


Maintenance

Unscrew and take out the measuring cap-dipstick 1. Clean the area in contact with oil with a clean cloth. Screw the cap-dipstick 1 fully down into its tube 2. Pull out the cap-dipstick again 1 and read the level the oil reaches on the dipstick:

MAX = maximum level. MIN = minimum level. The level is correct when it is close to "MAX" level, marked on the measuring dipstick. WARNING DO NOT GO BEYOND THE "MAX" OR BELOW THE "MIN" LEVEL MARKS TO AVOID SEVERE ENGINE DAMAGE.

Top up if necessary.

ENGINE OIL TOP-UP NOTE

Pour a small quantity of oil through the fill opening 2 and wait about one minute so that the oil flows evenly into the crankcase. Check the oil leveland top-up,if required. Top-up with small quantities of oil, until the recommended level is reached. At the end of the operation, screw and tighten the cap-dipstick 1.

RIDING THE VEHICLE WITH INSUFFICIENT LUBRICATION OR CONTAMINATED OR NOT RECOMMENDED LUBRICANTS ACCELERATES THE WEAR AND TEAR OF MOVING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE.NOTE

DO NOT EXCEED THE "MAX" MARK WHEN TOPPING-UP ENGINE OIL.

Cooling system Level checkCAUTION

WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING-UP THE COOLANT LEVEL.CAUTION

MAIN - 49

Maintenance


PARK THE VEHICLE ON SAFE AND LEVEL GROUND. Shut off the engine and wait until it cools off. Undo the indicated screw on both sides and remove the front case.

Make sure that the liquid level in the expansion tank is between "MIN" and "MAX" references.

Otherwise, top-up.

DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE OIL.

TOP-UP CAUTION

Loosen but do not remove the coolant reservoir cap. Wait for some seconds so that possible pressure may be purged. Unscrew and remove the cap Top up with the recommended product until the liquid approximately reaches the "MAX" level. Refit the fuel tank cap.

IF THERE IS AN EXCESSIVE CONSUMPTION OF COOLANT OR WHEN THE EXPANSION TANK REMAINS EMPTY, CHECK THAT THERE ARE NO LEAKS IN THE CIRCUIT. Radiator cleaning NOTE

Remove the front case. Wash the radiator with a pressurised water jet. Blow the radiator with compressed air.

IT IS NOT NECESSARY TO REMOVE THE RADIATOR

Braking systemThe following operations refer to both braking systems.CAUTION

PURGE THE AIR IN THE SYSTEM IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER, EXCESSIVE ELASTICITY OR AIR BUBBLES IN THE CIRCUIT. DO NOT USE OR MIX DIFFERENT SILICON- OR PETROLEUM-BASED COOLANT TYPES. MAIN - 50


Maintenance

PAY UTMOST ATTENTION THAT NO WATER OR DUST INADVERTENTLY GETS INTO THE CIRCUIT.

Level check Park the vehicle on its centre stand. Turn the handlebar so that the fluid in the brake fluid reservoir is parallel to the MIN reference mark indicated on the sight glass 1. Check that the level in the reservoir is over the MIN reference mark indicated on the sight glass 1. MIN = minimum level. If the fluid does not reach at least the MIN reference mark:CAUTION BRAKE LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN.

Check brake pads and disc for wear. If the pads and/or the disc do not need replacing, top-up the fluid.

Top-up Remove the front handlebar cover. Undo and remove the four screws indicated.CAUTION RISK OF BRAKE FLUID SPILLS. DO NOT PULL THE FRONT BRAKE LEVER WHEN THE SCREWS ARE LOOSE OR, MAINLY, WHEN THE BRAKE FLUID RESERVOIR COVER HAS BEEN REMOVED. PLACE A CLOTH UNDER THE BRAKE FLUID RESERVOIR TO PROTECT IT FROM ANY FLUID LEAKS.

Remove the cover and top up the reservoir with the recommended liquid until the correct level is reached

CAUTION DO NOT SHAKE THE VEHICLE TO AVOID BRAKE FLUID SPLASHING DURING TOP-UP. CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE.

MAIN - 51

Maintenance


CAUTION DO NOT FILL UP THE TANK TO THE MAXIMUM, BUT JUST OVER THE ''MIN'' LEVEL. TOP-UP TO MAXIMUM LEVEL MARK ONLY WHEN BRAKE PADS ARE NEW. BRAKE LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN. IT IS ADVISABLE NOT TO TOP-UP TO THE MAX LEVEL MARK WHEN THE BRAKE PADS ARE WORN BECAUSE YOUR RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS.

Headlight adjustmentFor a quick check of the correct direction of the front light beams, place the vehicle ten metres from a vertical wall and make sure the ground is level. Turn on the low-beam light, sit on the vehicle and check that the light beam projected to the wall is a little below the headlight horizontal straight line (about 9/10 of the total height). To adjust the light beam: Use a screwdriver to act on the corresponding screws 1 on the front wheel housing. SCREW it (clockwise) to raise the light beam. UNSCREW it (anticlockwise) to lower the light beam.

MAIN - 52

INDEX OF TOPICS

ELECTRICAL SYSTEM

ELE SYS

Electrical system


KEY 1. Multiple connectors 2. fall sensor 3. ECU diagnosis 4. Fan 5. Instrument panel 6. MODE button 7. Speed sensor 8. Turn indicators 9.Left light switch 10. Horn 11. Key switch 12. Front stop switch 13. Rear stop switch 14. Turn indicator switch 15.Rear light 16.Rear left turn indicator 17. Tail light/stop light twin bulbs 18. Rear right turn indicator 19. License plate light ELE SYS - 54


Electrical system

20. Stop light relay 21.Start-up relay 22. Starter motor 23. Battery 24. Plug socket 25. Main fuses 26. Auxiliary fuses 27.Voltage regulator 28.Generator 29. Pick-up 30. Oil sensor 31.Injection relay 32. Lambda Probe 33. Fuel pump 34.Fuel probe 35.Fuel injector 36.Spark plug 37. HV coil 38.Fan relay 39. ENGINE TEMPERATURE SENSOR 40. CDI control unit 41. Front right turn indicator 42. Front headlamp 43. High-beam bulb 44. Front headlamp tail light 45. Low-beam bulb 46.Front left turn indicator 47. Starter button 48. Engine stop switch 49. Horn button 50. Light switch CABLE COLOURS Ar orange Az sky blue B blue Bi white G yellow Gr grey ELE SYS - 55

Electrical system


M brown N black R red V green Vi purple Ro pink

Components arrangement

1. CDI control unit Remove the inspection cover placed in the helmet compartment to reach it.

ELE SYS - 56


Electrical system

2. Horn 3. Start-up relay Remove the front wheel housing to reach it.

4. Remote control switches Remove the front wheel housing to reach it. A. Fan relay B. Injection relay C. Stop light relay

5. Auxiliary fuses 6. Battery 7. Main fuses Remove the battery cover placed on the footrest to reach them.

8. Voltage regulator Remove the lower cover to reach it.

ELE SYS - 57

Electrical system


9. HV coil Remove the helmet compartment to reach it.

10. Fuel probe Open the saddle to reach it.

Electrical system installation Front sideHANDLEBAR AREA

ELE SYS - 58


Electrical system

Key 1.Through the hole 2.(98x2.5) Clamp 3.(290x4.5) Clamp 4.Through the hole ELE SYS - 59

Electrical system


STEERING AREA

Key 1.(180x4.5) Clamp

ELE SYS - 60


Electrical system

Key 1.Clamp too long FOOTREST AREA

Key 1. (290x4.5) Clamp ELE SYS - 61

Electrical system


Key 1. (290x4.5) Clamp

Key 1. Through the hole

ELE SYS - 62


Electrical system

ELE SYS - 63

Electrical system



Back sideENGINE AREA

ELE SYS - 64


Electrical system

Key 1. (290x4.5) Clamp 2. Main cable harness

ELE SYS - 65

Electrical system


Key 1. Strap 2. Cable guide 3. (180x4.5) Clamp

ELE SYS - 66


Electrical system

Key 1. Lambda probe cable inside the metal cable guide

ELE SYS - 67

Electrical system


Key 1. Corrugated hose covering the starter motor cable. SPEED SENSOR

ELE SYS - 68


Electrical system


ELE SYS - 69

Electrical system


Key 1. (98x2.5) Clamp 2. Plastic cable guide

ELE SYS - 70


Electrical system

Key 1. (290x4.5) Clamp MAIN CABLE HARNESS

Key 1. (290x4.5) Clamp ELE SYS - 71

Electrical system


Key 1. (290x4.5) Clamp REAR LIGHT AND LICENSE PLATE LIGHT

ELE SYS - 72


Electrical system



ELE SYS - 73

Electrical system


Conceptual diagrams Ignition

KEY 11.Key switch 23.Battery 25. Main fuses 26.Auxiliary fuses 29. Pick-up 31.Injection relay 36. Spark plug 37.HV coil 40. CDI control unit

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Electrical system

Battery recharge and starting

KEY 11. Key switch 12.Front stop switch 13. Rear stop switch 21. Start-up relay 22.Starter motor 23.Battery 25. Main fuses 26. Auxiliary fuses 27. Voltage regulator 28.Generator 40. CDI control unit 47. Starter button

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Electrical system


Level indicators and enable signals section

KEY 2.fall sensor 5. Instrument panel 7.Speed sensor 11.Key switch 23.Battery 25. Main fuses 26.Auxiliary fuses 30.Oil sensor 31.Injection relay 32.Lambda Probe 34.Fuel probe 35.Fuel injector 39. ENGINE TEMPERATURE SENSOR 40. CDI control unit 48. Engine stop switch

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Electrical system

Devices and accessories

KEY 4.Fan 5.Instrument panel 6.MODE button 10.Horn 11.Key switch 23.Battery 24.Plug socket 25.Main fuses 26. Auxiliary fuses 31. Injection relay 33.Fuel pump 38.Fan relay 40. CDI control unit 49.Horn button

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Electrical system


Lights and turn indicators

KEY 5.Instrument panel 8.Turn indicators 11.Key switch 12. Front stop switch 13. Rear stop switch 14. Turn indicator switch 15.Rear light 16.Rear left turn indicator 17.Tail light/stop light twin bulbs 18.Rear right turn indicator 19. License plate light 20.Stop light relay 23.Battery 25. Main fuses 26.Auxiliary fuses 41. Front right turn indicator 42. Front headlamp

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Electrical system

43. High-beam bulb 44. Front headlamp tail light 45. Low-beam bulb 46. Front left turn indicator 50. Light switch

Checks and inspections Ignition circuit No spark plugCAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED. Check spark plug for correct conditions, clean it and remove deposits. Replace it, if necessary.

Coil primary check: Disconnect the connector of the coil. Measure the resistance present between the two terminals (OrangeWhite cable and Red-Brown cable).

Electric characteristicPrimary resistance 0.210% Ohm at 20 C (68 F)

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Electrical system


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 (Orange-White cable).

Electric characteristicSecondary resistance 290010% Ohm at 20 C (68 F)

Battery recharge circuitWith engine running at high revs, measure the voltage present at the battery poles.

Electric characteristicNo-load recharge voltage 13 15 V at 5000 rpm

Stator checkChecking the stator windingWARNING

THE CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED. 1) Remove the lower cover. 2) Disconnect the stator connector from the voltage regulator. 3) Measure the resistance between each of the yellow terminals and the other two. 4) Check that there is insulation between the each yellow cable and the earth.

Electric characteristicStator winding resistance 0.11 Ohm at 20 C (68 F)

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Electrical system

Recharge system voltage check Connect the ammeter induction clamp to the voltage regulator positive terminals (Red-Orange). Measure the battery voltage and turning on the vehicle lights, with engine off, wait for the voltage to set at about 12 V. Start the engine and measure the current generated by the system with lights on and a high running engine.

CharacteristicGenerated current: 13A at 6000 rpm

Start up system check

KEY: 1.CDI control unit 2. Key switch 3.Engine stop switch 4.Front stop switch ELE SYS - 81

Electrical system


5.Rear stop switch 6. Starter button 7. Start-up relay 8. Starter motor 9.Battery 10. Main fuses 11. Auxiliary fusesCAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED. 1) Check fuses No. 1 and 4. 2) Check the contacts of the key switch and the engine stop switch. 3) Check the contacts of the stop switches and the starter button. 4) Make an attempt to start the engine and check whether there is voltage between the Yellow-Red and the Blue-Yellow cables of the start-up relay (see figure). 5) If no voltage is detected, check cable harness continuity. 6) Check the start-up relay. 7) Check the integrity and the connections of the Red cable that connects the battery to the start-up relay. 8) Repeat the check on the Red cable that connects the start-up relay and the starter motor (see figure).

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Electrical system

Horn control

KEY: 1. Horn button 2. Key switch 3. Horn 4.Battery 5.Main fuses 6.Auxiliary fusesCAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED. 1) Check fuses No. 1 and 3. 2) Check key switch and horn button contacts. 3) With the key switch set to ON, check for voltage between the Green cable of the horn button and ground. If voltage is not detected, check cable harness continuity. 4) Check the integrity and the connections of the Grey cable of the horn and the horn ground lead (Blue cable). ELE SYS - 83

Electrical system


Turn signals system check

KEY: 1. Instrument panel 2. Blinker 3.Turn indicator switch 4.Key switch 5. Rear left turn indicator 6.Rear right turn indicator 7.Battery 8.Main fuses 9.Auxiliary fuses 10.Front right turn indicator 11.Front left turn indicatorCAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED. 1) Check that both the bulbs and their ground connection work properly (Blue cables). 2) Check fuses No. 1 and 3. 3) Check the contacts of the key switch.

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Electrical system

4) With the key switch set to ON, check whether there is intermittent voltage between the Blue-Black cable of the turn indicator switch and the ground connection. 5) If no voltage is detected, check cable harness continuity. 6) Check the contacts of the turn indicator switch. 7) Check the integrity and the connections of the bulbs cable harnesses (Sky blue and Red cables) to the turn indicator switch.

level indicators

KEY: 1.Fuel Level Sensor 2.Instrument panelCAUTION

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED.

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Electrical system


1) Measure the resistance in the fuel level sensor ends in the different conditions. 2) If the resistance values are correct, but the indication on the instrument panel is incorrect, check the integrity and the connections of the cable harnesses (Brown cable with pin 7 of the instrument panel connector and Grey-Green cable with pin 12 of the instrument panel connector.)

Electric characteristicFull tank 10010% Ohm Empty tank 120010% Ohm

Lights list

KEY: 1.Instrument panel 2. Light switch 3.Key switch 4.Twin tail light/stop light bulb 5.License plate light ELE SYS - 86


Electrical system

6. Battery 7. Main fuses 8.Auxiliary fuses 9. High-beam bulb 10. Front headlamp tail lights 11.Low-beam bulb

BULBS/WARNING LIGHTS1 2 3 4 5 6 7 8 9 10 11 12 CAUTION Specification High-/low-beam bulb Tail light bulb Front turn indicator bulbs Rear turn indicator bulbs Rear tail light /stop light bulb License plate light bulb Instrument panel lighting bulb Turn indicator warning light High-beam warning light Low fuel warning light Engine oil pressure warning light / EFI warning light High coolant temperature gauge warning light Desc./Quantity 12 V - 55 W - H7 12V - 5W 12 V - 10 W (Amber) 12 V - 10 W (White) 12 V - 5/21 W (Red) 12V - 5W LED LED LED LED LED LED

THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED. Tail lights line check 1) Check that bulbs and their ground connection are in working conditions (Blue cables). 2) Check fuses No. 1 and 3. 3) Check key switch contacts. 4) Check the integrity and the connections of the bulbs cable harnesses (Green cables) with fuse No. 3. High-beam/low-beam lights line check 1) Check that bulbs and their ground connection are in working conditions (Blue cables). 2) Check fuses No. 1 and 3. 3) Check key switch and light switch contacts. 4) With the key switch set to ON, check for voltage between the light switch Green cables and ground. If voltage is not detected, check cable harness continuity. 5) Check that the connections between bulb cable harnesses (White cable and Black cable) and the light switch are in good conditions.

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Electrical system


FusesCAUTION

DO NOT REPAIR FAULTY FUSES. NEVER USE FUSES OTHER THAN THE ONES SPECIFIED. A SHORT CIRCUIT MAY DAMAGE THE ELECTRICAL SYSTEM OR EVEN CAUSE A FIRE. NOTE IF THE SPARE FUSE IS USED, REPLACE WITH ONE OF THE SAME TYPE IN THE CORRESPONDING FITTING.

FUSE DISTRIBUTION1 Specification Fuse No. 1 Desc./Quantity Capacity: 20A Protected circuits: Key switch, instrument panel, recharge circuit, fan and ECU. Capacity: 15 A Protected circuits: From battery to plug socket. Capacity: 15 A Protected circuits: From key switch to tail lights, stop lights, high-beam light, low-beam light, instrument panel, turn indicators and horn. Capacity: 15 A Protected circuits: From key switch to start-up circuit, injection remote control switch, injection load, fan remote control switch and ECU.

2 3

Fuse No. 2 Fuse No. 3

4

Fuse No. 4

Dashboard

KEY 1. High-beam warning light, blue 2. Turn indicator warning light, green 3. Fuel gauge ELE SYS - 88


Electrical system

4. Low fuel warning light, orange 5. Speedometer 6. Coolant high temperature warning light 7. Coolant temperature indicator 8. Engine oil pressure warning light / electronic injection control warning light, red 9. ABS warning light (Active only in models with ABS) 10. Multifunction indicator: total odometer (ODO) / two trip odometers (ODO I - ODO II) / battery voltage 11. Not active warning light 12. Digital clock

Km or miles selection Quickly press the MODE button, select the battery voltage measurement function. Hold down the MODE button for more than 10 seconds to change from km to mile reading for the odometer. For the first 5 seconds the button is held down, there will be no instrument panel indication, but for the next 5 seconds, the legend of the unit of measurement (km or miles) currently in use will flash at a frequency of 1 Hz. If the button is released before 10 seconds elapse, the unit of measurement does not vary.

Data check functionWARNING

THE SERVICE WARNING LIGHT IS NOT ACTIVE. WHEN THE KEY IS INSERTED, THE SERVICE COUPONS ICON SHALL BE ON FOR TWO SECONDS ONLY AFTER REACHING 50,000 KM. CARRY OUT THE RESET SERVICE TO ELIMINATE THE SERVICE COUPONS ICON IGNITION. RESET Hold the MODE button down.

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Electrical system


Turn the key to ''ON'' and wait 10 seconds. During this operation the service icon flashes at a 1 Hz frequency.

Sealed batteryCommissioning sealed batteries In case the vehicle fits a sealed battery, the maintenance is limited to the loading state and to an eventual recharge. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit. Besides upon pre-delivery, it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and afterwards every 6 months. INSTRUCTIONS FOR BATTERY REFRESH AFTER OPEN CIRCUIT STORAGE 1. Voltage check 2. Before installing the battery on the vehicle, check the open circuit voltage 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 14.4014.70V Initial charge current equal to 0.30.5 of the battery rated capacity Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h

5. Constant-current battery charge mode 6. Charge current equal to 1/10 of the battery rated capacity

Dry-charge batteryWARNING

BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.

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Electrical system

IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK FOLLOWED BY MAGNESIUM MILK, BEATEN EGG 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 WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN Remove the short closed tube and the caps, then pour sulphuric acid into the cells, using the type specified for batteries, with a specific gravity of 1.26, corresponding to 30 B, at a minimum temperature of 15C until the upper level is reached. Leave to rest for at least 2 hours, then restore the level with sulphuric acid. Within the following 24 hours, recharge with the specific battery charger at an intensity of about 1/10 of the battery nominal capacity and until the acid density is about 1.27, corresponding to 31 B, and these values are stabilised. 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 vehicle ensuring that it is connected properly. 1 Hold the tube upright 2 Inspect visually 3 The float must be freed Electrolyte level check The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water to restore this level. If it is necessary to add water too frequently, check the vehicle electrical system: the battery works overcharged and is subject to quick wear. Charge status check After topping-up the electrolyte level, check its density using an appropriate densitometer.

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Electrical system


With the battery charged, a density of 3032 B, corresponding to a specific weight of 1.261.28, must be at a minimum temperature of 15 C. A density reading below 20 B indicates that the battery is completely flat and must therefore be recharged. If the vehicle is not be used for a certain time (1 month or more), the battery needs to be recharged periodically. The battery runs down completely in about three months. Should the battery be fitted on a vehicle, be careful not to invert the connections, keeping in mind that the (black) ground wire marked (-) is connected to the - negative terminal while the other two red wires marked (+) are connected to the + positive terminal. Battery rechargeWARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL. KEEP NAKED FLAMES OR SPARKS AWAY FROM THE BATTERY WHILE CHARGING. First detach 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 corresponding poles (+ to + and - to -). The battery should always be kept clean, especially its top side, and the terminals should be coated with petroleum jelly.CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.CAUTION

ORDINARY DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL TO THE BATTERY. CONSEQUENTLY, ONLY USE DISTILLED WATER.CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY BEFORE BEING PUT INTO OPERATION SHORTENS BATTERY LIFE.

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Electrical system

Connectors ECUKEY 1.Injection telltale light (Sky blue-Green) 2.Not connected 3. Not connected 4.Lambda probe negative (Green-White) 5. Permanent power supply (Green-Red) 6. Battery-powered (Red-Orange) 7.Not connected 8. Fan relay (Purple-Black) 9.Engine temperature sensor (Orange) 10. Not connected 11.Lambda probe (Sky blue-Black) 12. Engine stop switch (White-Blue) 13. Pick-up positive (Red) 14.Fuel injector (Grey-Red) 15. Pick-up negative (White) 16.Diagnosis (Brown) 17. Not connected 18. Ground (Blue-Green) 19. Not connected 20.Injection relay (Red-Blue) 21.Not connected 22.HV coil (Orange-White) 23.Not connected 24. Start-up relay (Blue-Yellow) 25.Fall sensor (Pink-Yellow) 26. Ground (Blue-Green)

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Electrical system


Dashboard1.Oil pressure sensor (Purple) 2. MODE Button (Pink) 3. Left turn indicator warning light (Sky Blue) 4. Right turn indicator warning light (Red) 5.High-beam warning light (White) 6. Not connected 7. Fuel level sensor (Brown) 8. Speed sensor negative (Yellow-White) 9. Not connected 10. Speed sensor positive (Orange-Black) 11. Not connected 12. Fuel level sensor (Yellow-Green) 13.Thermistor (White-Blue) 14. Speed sensor signal (Blue-Orange) 15. Not connected 16. Ground (Blue) 17. Ground (Blue) 18. Not connected 19. Live supply (Green) 20. Battery-powered (Red-Orange)

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INDEX OF TOPICS

ENGINE FROM VEHICLE

ENG VE

Engine from vehicle


Exhaust assy. RemovalCAUTION

ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF COMPLETELY. Silencer removal Rest the vehicle on its centre stand. Loosen the clamp (1) fixing the exhaust silencer to the manifold. Undo and remove the three fixing screws (2). Remove exhaust silencer.

CAUTION

ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF COMPLETELY. Remove the rear central cover. Unscrew and remove the two fixing nuts of the exhaust manifold.CAUTION ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF.

Disconnect the lambda probe connector.

ENG VE - 96


Engine from vehicle

Undo and remove the three fixing screws of the exhaust silencer. Remove the exhaust system.

Removal of the engine from the vehiclePreventively remove: Helmet compartment. Rear central cover. Right and left fairings. Tail section. Entire lower cover. Rear brake calliper and release the pipe. Get a container of adequate capacity to collect the fluid and place it under the cooling system pump. Remove the expansion tank cap. Loosen the clamp and remove the radiator - pump pipe and allow the coolant to drain into the collecting container. Unscrew the spark plug tube and release its cable from any retainer.

ENG VE - 97

Engine from vehicle


Disconnect the lambda probe connector.

Remove the injector connector.

Remove the fast-release fitting from the injector support.

Remove the water temperature sensor connector.

ENG VE - 98


Engine from vehicle

Remove the throttle body transmissions and release them from the engine.

Disconnect the connector of the ECU and release the cable harness.

Unscrew and remove the starter motor supply and ground nuts. Disconnect the starter motor supply and ground cables and leads.

Working from the vehicle left side, remove the generator connectors. Cut any retaining straps.

ENG VE - 99

Engine from vehicle


Remove the fuel bleeding pipe.

Hold the vehicle chassis by means of a hoister. Working from the left side, unscrew and remove the nut and slide off the fixing pin of the shock absorber.

Working from the left side, unscrew and remove the nut and slide off the fixing pin of the shock absorber.

Working on the right side, unscrew and remove the nut.

ENG VE - 100


Engine from vehicle

From the left side, slide off the pin and collect the washer and the spacer. Remove the engine by pulling it backwards.

ENG VE - 101

INDEX OF TOPICS

ENGINE

ENG


Engine

This section describes the operations to be carried out on the engine and the tools required.

Automatic transmission Transmission cover- To remove the transmission cover, it is necessary to remove the plastic cover first by inserting a screwdriver in the slotted holes. Using the clutch bell lock wrench shown in the figure, remove the driven pulley shaft lock-nut and washer.

Specific toolingAP8140661 Lock wrench for clutch bell - Pull out the cap/dipstick from the engine oil filling tube. - Remove the 10 screws. - Now remove the transmission cover.NOTE WHEN REMOVING THE TRANSMISSION COVER, BE CAREFUL NOT TO DROP THE CLUTCH BELL.

Air duct- Remove the transmission compartment air intake cover shown in the photograph.

ENG - 103

Engine


- Remove the 5 screws on the two different levels, as well as the small casing.

Removing the driven pulley shaft bearing- Remove the seeger ring from the inside of the cover. - Remove the bearing from the crankcase.

Specific tooling020376Y Adapter handle 020375Y 28x30 mm punch 020412Y Clutch oil seal punch D 15 mm

Refitting the driven pulley shaft bearing- Slightly heat the crankcase internal side so as not to damage the coated surface. - Insert the bearing in its housing. - Refit the seeger ring.CAUTION REST THE COVER ON A SUITABLE SURFACE TO AVOID DAMAGING THE COVER COAT. NOTE ALWAYS REPLACE THE BEARING WITH A NEW ONE AT EVERY REFIT

Specific tooling020376Y Adapter handle 020357Y 32x35 mm punch 020412Y Clutch oil seal punch D 15 mm ENG - 104


Engine

Baffle roller Plastic roller- Check that the roller shows no signs of abnormal wear and that it rotates freely. - Remove the special fixing screws as indicated in the photograph

- Check the roller outside diameter does not have defects that could jeopardise belt functioning - For refitting, place the roller with the belt containment edge on the engine crankcase side - Tighten the screw to the prescribed torque.

Locking torques (N*m)Belt support roller screw 1113 (8.19.6 ftlb)

Removing the driven pulley- Remove the clutch bell and the entire driven pulley assembly.NOTE THE ASSEMBLY CAN ALSO BE REMOVED EVEN IF THE DRIVING PULLEY IS MOUNTED.

ENG - 105

Engine


Inspecting the clutch drum- Make sure that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter.

CharacteristicClutch bell max. value (250 cm) 135 mm Clutch bell max. value (300 cm) 134.5 mm Clutch bell standard value 134 134.2 mm Checking the bell working surface eccentricity - Fit the bell on a driven pulley shaft with 2 bearings (inside diameter: 15 and 17 mm). - Lock with the original spacer and nut. - Place the bell/shaft assembly on the support to check the crankshaft alignment.

- Using a feeler pin gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement at 3 positions (Central, internal, external). - In case of anomalies, replace the bell.

Characteristicclutch bell check: Limit eccentricity. Admissible limit eccentricity: 0.15 mm

Specific toolingAP8140915 Crankcase check

ENG - 106


Engine

Inspecting the clutch- Check the thickness of the clutch mass friction material. - The masses must exhibit no traces of lubricants; in that case, check the driven pulley unit seals.NOTE UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. DIFFERENT CONDITIONS MAY CAUSE CLUTCH TEARING. CAUTION DO NOT USE TOOLS TO OPEN THE MASSES TO AVOID VARIATION IN THE RETURN SPRING LOAD.

CharacteristicCheck minimum thickness 1 mm

Removing the clutchFit the special driven pulley spring compressor tool: - Fit the driven pulley assembly on the tool by inserting the 3 pins in the ventilation holes on the mass holder support. - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut. - Use the special multipurpose wrench to remove the nut fixing the clutch. - Disassemble the driven pulley into its components (Clutch and spring with plastic fitting).CAUTION

THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST TOUCH THE TOOL. EXCESSIVE TORQUE MAY DEFORM THE SPECIFIC TOOL.

Specific toolingAP8140665 Adapter for clutch assembly removal AP8140259 Universal tool for clutch assemblies AP8140300 55 mm wrench

ENG - 107

Engine


Pin retaining collar- Simultaneously turn and pull the collar manually to remove it.NOTE USE 2 SCREWDRIVERS IN CASE OF ANY DIFFICULTY. NOTE BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGING THE O-RING SEAL.

- Remove the 4 torque server pins and pull the halfpulleys apart.

Removing the driven half-pulley bearing- Check there are no signs of wear and/or noise; otherwise, replace it. - Remove the snap ring using two flat blade screwdrivers. - Place pulley bushing on the threaded side adequately on a wood support. - Using a hammer and pin, knock the ball bearing out as shown in the figure. - Support the pulley properly.

Specific tooling001467Y035 Bell for OD 47-mm bearings

ENG - 108


Engine

- Remove the roller bearing using the specific punch.

Specific tooling020376Y Adapter handle 020456Y 24 mm punch 020363Y Crankshaft oil seal punch D 20 mm

Inspecting the driven fixed half-pulley Measure the outside diameter of the pulley bushing. Check the surface in contact with the belt to make sure there are no signs of abnormal wear. Check the riveted joints work properly. Check the evenness of the surface in contact with the belt.

CharacteristicHalf-pulley minimum diameter Minimum diameter allowed: 40.96 mm Half-pulley standard diameter Standard diameter: 40.985 mm wear limit 0.3 mm

ENG - 109

Engine


Inspecting the driv

Documents

Aprilia Sportcity Cube 250 - 300