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Aprilia scooter (manual) - part 11

• REAR TOP BOX LIGHT SWITCH TEST

• Raise the saddle and check continuity across the two terminals with a multimeter set to the Ohm range.

  Correct reading when switch is released (saddle raised) : 0 ohm

  Correct reading with switch pressed (saddle closed): 

  ohm

  1. LIGHT CIRCUIT

     1. LIGHT CIRCUIT

  
   

  

  Key:

  2. High beam light

  1. Parking lamp light

  2. Dashboard backlighting bulbs

  15. Complete dashboard

  18. Left switch

  21. Key-operated switch

  27. Parking light/left brake light

  29. Parking light /right brake light

  32. Number plate light

  38. Main fuses

  1. Battery

  2. Auxiliary fuses

  1. High beam lamp

  2. Low beam lamp

  3. Parking light

  4. Complete headlight

  
   

  

  TROUBLESHOOTING

  • Check battery condition, 2.4.1.

  • Check fuse condition, 8.12.1.

    

  • Check the light switch

  • Check the bulbs, 8.11.1.

    SWITCH TEST

• Check switch continuity using a multimeter.

• Change any switch that operates other than as specified in the relevant diagram.

  
   

  Light switch	Wires
  	V	N	Bi	V
  PAS

  
   

  
   

  

  1. VISUAL AND ACOUSTIC SIGNALS

     1. VISUAL AND ACOUSTIC SIGNALLING SYSTEM

  
   

  

  Key:

  1. Right indicator light

  2. Left indicator light

  15. Complete dashboard

  1. Warning horn

  2. Horn button

  3. Key-operated switch

  4. Direction indicator switch

  26. Rear left direction indicator

  30. Rear right direction indicator

  38. Main fuses

  1. Battery

  2. Auxiliary fuses

  45. CDI control unit

  54. Front right direction indicator

  
   

  

  DIRECTION INDICATOR TROUBLESHOOTING

• Check that the bulbs are in good condition, 8.11.1.

• When one bulb is burnt out, the other bulb will flash at doubled frequency.

• Check the direction indicator switch.

  

• Check the CDI control unit and replace if needed,

  7.2.2.

  The flasher is incorporated into the CDI control unit.

  
   

  

  

  WARNING HORN TEST

• Feed 12 Volts to the two connectors of the waning horn.

• If the horn does not operate, adjust through the adjuster.

• Replace the horn if necessary.

  
   

  SWITCH TEST

• Check switch continuity using a multimeter.

• Change any switch that operates other than as specified in the relevant diagram.

  
   

  Direction indicator switch	Wires
  	B/N	Az	r
  Left direction indicator
  Right direction indicator

  
   

  Horn button	Wires
  	Gr	V
  ON
  OFF

  1. BULB REPLACEMENT

     

     

     1. BULB REPLACEMENT Read 1.2.1., 1.7.1. carefully.

   WARNING

  Before proceeding to change a bulb, rotate the

  

  ignition switch to “ ”.Wear clean gloves or use a clean, dry cloth to handle bulbs. Do not put your fingerprints on a bulb, as this may cause overheating leading to failure. If you touch a bulb with your fingers, remove any fingerprints with alcohol to avoid early failure. DO NOT PULL ON THE WIRING.

  
   

  

• Place the vehicle on the stand.

  

  NOTE Check the fuses before changing a bulb, 8.12.1.

  PARKING LIGHT BULB

  
   

  

  To replace:

• Remove the front cover, 7.1.10.

  
   

   WARNING

  Proceed carefully.

  Do not damage the tabs and/or their recesses.

  
   

• Rotate and extract the bulb holder working from the rear end of the bulb holder.

• Extract the bulb.

  
   

  NOTE Make sure the locating pegs locate properly into the holder when fitting the bulb.

• Fit a new bulb of equal rating.

  
   

  

  HIGH AND LOW BEAM BULBS

  
   

  To replace:

  Open the glove compartment (1) and unhook the side guides pressing moderately down.

  
   

  
   

  

  

• Grasp the bulb connector (2) and pull to disconnect.

• Twist the bulb holder (3) anticlockwise and extract from the reflector seat.

• Extract the bulb.

  
   

  On refitting:

  NOTE Insert the bulb into the reflector seat and ensure that the three pegs on the bulb match the slots in the reflector seat.

• Position the bulb holder (3) into the reflector seat and twist clockwise.

• Connect the bulb connector (2).

  
   

  

  TAIL LIGHT BULBS

  
   

  The tail lights accommodate:

  • Two parking light/brake light bulbs (4).

  • Two rear direction indicator bulbs (5).

  NOTE The following procedure applies to both indicators.

  
   

  

  To replace:

  
   

• Unscrew the two retaining screws (6) and remove the lens (7).

  
   

   WARNING

  Proceed carefully.

  Do not damage the tabs and/or their recesses.

  
   

  

• Rotate anticlockwise and extract the bulb (4, parking/brake light) or (5, direction indicator).

• Fit a new bulb of equal rating.

  NOTE On refitting, ensure the lens (7) locates properly into its seat.

   WARNING

  Proceed carefully.

  Do not damage the tabs and/or their recesses.

  
   

• Tighten the screws (6) gradually. Do not overtighten or you will damage the lens (7).

  

  FRONT DIRECTION INDICATOR BULBS

  
   

  

• Remove the front cover, 7.1.10.

• Working from the front end of the vehicle, rotate the holder (8) with the bulb (9) clockwise and extract both.

• Press the bulb (9) moderately and twist anticlockwise.

• Extract the bulb.

  NOTE Make sure the locating pegs locate properly into the holder when fitting the bulb.

• Fit a new bulb of equal rating.

  
   

  

  TAIL LIGHT BULB

  
   

• Grasp the bulb holder (10), pull and extract.

• Remove the bulb and fit a new bulb of equal rating.

  
   

  

  

  DASHBOARD BULBS

• Remove the dashboard, 7.2.6.

• Rotate the bulb holder clockwise and extract.

• Extract the bulb – which is the bayonet type – and replace it.

• Insert the bulb holder and rotate clockwise to lock it in place.

  
   

  

  CLOCK BATTERY REPLACEMENT

  

• Remove the dashboard to give access to the rear end,

  7.2.6.

• Release the click-opening door.

• Change the button battery.

• Refit the click-opening door.

  
   

  

  1. REPLACING THE FUSES

     1. REPLACING THE FUSES  WARNING

  Never attempt to repair a defective fuse.

  Never use a fuse of a rating other than specified.

  This could damage the electrical system or cause a short circuit, with the risk of fire.

  NOTE When the fuses fitted in a particular position keep blowing frequently, there might be a short circuit or overloading.

  Checking the fuses is recommended whenever an electrical component fails to operate or is malfunctioning, or when the engine does not start.

  

  Check the 3-A and 15-A fuses first and then the 30-A fuses.

  
   

  

• Set the ignition switch to “ ”. This will prevent accidental short circuits.

  Main fuses:

  

• Perform the first four steps described at paragraph

  2.4.3.

  

  Auxiliary fuses:

• Remove the front cover, 7.1.10.

  
   

  Inspection:

• Extract all fuses one by one and check for blown fuses. A blown fuse is identified by the link bar in the centre being divided.

• When you find a blown fuse, determine and rectify the cause (if possible) before fitting a new fuse.

  

• Replace any failed fuse with a fuse of equal current rating.

  NOTE When you use one of the spare fuses, remember to add a new fuse of equal rating to the fuse box.

  
   

  Layout of auxiliary fuses (front cover):

  
   

  - 15-A fuse (1)

  From ignition switch to: lights, horn, brake lights.

  - 7.5-A fuse (2)

  From ignition switch to: starting interlock relay, automatic starter.

  - 7.5-A fuse (3)

  Spare.

  - 15-A fuse (4)

  Spare.

  

  Layout of main fuses (battery compartment):

  
   

  - 20-A fuse (5)

  From battery to: ignition switch, helmet compartment light.

  - 15-A fuse (6)

  From battery to: power socket.

  - 15-A fuse (7)

  Spare.

  
   

  

  
   

  10 m

   

  8.13. BEAM SETTING

  
   

  This is a quick beam inspection procedure. Place the vehicle ten metres away from a vertical wall. It is important that the motorcycle be on level ground.

  Switch on the low beam and sit astride the vehicle. The light spot on the wall should be just below the horizontal line of the headlight (about nine/tenths of overall height).

  
   

  

  To set beam height:

• Open the glove compartment (1) and unhook the side guides by pressing moderately downwards.

• Use a screwdriver and rotate the lower adjuster screws

(2) of both beams:

TIGHTEN (turn clockwise) to lower the beam. SLACKEN (turn anticlockwise) to raise the beam.

8.13.2. BEAM HORIZONTAL SETTING

To adjust the horizontal position of the beam:

• Open the glove compartment (1) and unhook the side guides by pressing moderately downwards.

  
   

  

• Use a screwdriver and rotate the upper adjuster screws (2) of both beams:

TIGHTEN (turn clockwise) to move the beam to the right (viewed in the direction of travel);

SLACKEN (turn anticlockwise) to move the beam to the left; (viewed in the direction of travel).

1. WIRING DIAGRAM

   1. WIRING DIAGRAM

Key:

WIRE COLOUR CODING

UPDATES 9

SUMMARY

1. UPDATE 3

   1. REFERENCE MANUALS 3

   2. TECHNICAL DATA 4

   3. LUBRICANT CHART 6

   4. ROUTINE MAINTENANCE TABLE 7

   5. CARBURETTOR SPECIFICATIONS 8

   6. CHECKING AND TOPPING UP TRANSMISSION OIL LEVEL 9

1. UPDATE

   1. REFERENCE MANUALS Version 125 cc

      

      SPARE PARTS CATALOGUES

      aprilia part# (description) 6642 rel.03

      
       

      Version 250 cc

      
       

      

      SPARE PARTS CATALOGUES

      aprilia part# (description) 6642 rel.03

      
       

      

      SPECIAL TOOLS CATALOGUES

      aprilia part# (description) 001 M

      

      SPECIAL TOOLS CATALOGUES

      aprilia part# (description) 001 M

      
       

      

      OWNER'S MANUALS

      aprilia part# (description)
      8104853
      8104854
      8104856

      
       

      ENGINE TECHNICAL MANUAL

      

      OWNER'S MANUALS

      aprilia part# (description)
      8104853
      8104854
      8104856

      
       

      ENGINE TECHNICAL MANUAL

      aprilia part# (description)

      8140680

      8140681

      8140682

      8140683

      8140684

      aprilia part# (description)

      8140797

      8140798

      8140799

      8140800

      8140801

       

   2. TECHNICAL DATA

      

      DIMENSIONS

      Max. length 2085 mm (82.086 in)

      Max. width 785 mm (30.905 in)

      Max. height (front part of the fairing included) 1370 mm (53.937 in) Seat height 790 mm (31.102 in)

      Wheel base 1460 mm (57.480 in)

      Wheel base 1480 mm (58.267 in)

      Min. ground clearance 190 mm (7.480 in)

      Unladen weight (in the direction of travel) 162 kg (357.148 lb)

      Unladen weight (in the direction of travel) 170 kg (374.785 lb) ENGINE

      Make M 245 M

      Make M 237 M

      Type Single-cylinder, four-stroke with four valves, wet forced lubrication, overhead camshaft.

      Number of cylinders 1

      Total displacement 124 cm3 (7.567 in3)

      Total displacement 244 cm3 (14.890 in3)

      Bore/stroke 57 x 48,6 mm (2.244 x 1.913 in)

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

      Compression ratio 12,0 ± 0,5: 1

      Compression ratio 11,0 ± 0,5: 1

      Starting Electric

      Engine idling rpm 1600 ± 100 giri/min

      Clutch Centrifugal type

      Gearbox Automatic

      Cooling system Liquid-type (50% water + 50% coolant), with forced circulation

      Valve clearances Intake 0.10 / Exhaust 0.15 CARBURETOR

      Model CVK 7 30 KEIHIN

      Model WVF 7 0 29 WALBRO

      FUEL SUPPLY

      Type Vacuum pump

      Fuel Premium-grade petrol, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.)

      CAPACITY

      Fuel (with reserve) 9,5 liters

      Fuel reserve 1,5 liters

      Engine oil

      • changing engine oil only 1000 cm3 (61.024 in3)

      • changing engine oil and engine oil filter 1100 cm3 (67.126 in3)

      • changing for engine overhaul 1150 cm3 (70.177 in3)

      Transmission oil 150 cm3 (9.154 in3)

      Coolant 1.200 cm3 (73.228 in3)

      Seats 2

      Vehicle max. load (rider + passenger + luggage) 210 kg (462.970 lb) TRANSMISSION

      Variator Continuous automatic

      Primary With V-belt

      Secondary Gear-type

      Engine/wheel total ratio

      - short 1:29,40

      - long 1:8,78

      Engine/wheel total ratio

      - short 7:19,30

      - long 1:6,80

      
       

      FRAME
      Type	Single-beam with twin overlapped cradle
      Steering inclination angle	27°
      Trail	104 mm (4.094 in)
      SUSPENSIONS
      Front	telescopic fork with hydraulic operation
      Stroke	105 mm (4.134 in)
      Rear	n. 1 Hydraulic monoshock
      Stroke	105 mm (4.134 in)
      BRAKES
      Front	Hydraulic disc brake - 0 240 mm (9.449 in)
      Rear	Hydraulic disc brake - 0 190 mm (7.480 in) (combine with front brake)
      WHEELS
      Front	E - 13 x 3,00 DOT - D
      Rear	E - 13 x 3,50 DOT - D
      TYRES
      Type	Tubeless
      Front	110 / 90 - 13" 56 P
      Rear	130 / 70 - 13" 63 P
      Front
      Rear	200 kPa (2,0 bar)
      INFLATION PRESSURES FOR CARRYING A	220 kPa (2,2 bar)
      PASSENGER
      Front	230 kPa (2,0 bar)
      Rear	250 kPa (2,2 bar)
      IGNITION
      Type	Capacitive discharge, variable spark advance
      Timing advance	Variable, controlled by the ECU5°/min - 24°/>4000 rpm
      Timing advance	Variable, controlled by the ECU4°/min - 15°/4000 -6000 rpm
      SPARK PLUG
      Standard	NGK CR 8 EB
      As an alternative	NGK CR 7 EB
      	NGK CR 9 EB
      	CHAMPION RG 6 YC
      	CHAMPION RG 4 HC
      Electrode gap	0,7 - 0,8 mm (0.028 - 0.031 in)
      ELECTRIC SYSTEM
      Battery	12 V - 12 Ah
      Fuses	20 - 15 - 7,5 A
      Generator (with permanent magnet)	12 V - 180 W
      Generator (with permanent magnet)	12 V - 235 W
      BULBS
      Low beam	12 V - 55 W
      High beam	12 V - 55 W
      Parking light	12 V - 16 W
      Direction indicators	12 V - 10 W
      Tail lights/Number plate light/ Stop light	12 V - 5 W / 21 W
      WARNING LIGHTS
      Instrument panel lights	12 V - 1,2 W
      Direction indicators	12 V - 1,2 W
      Engine oil pressure	12 V - 1,2 W
      Low beam	12 V - 1,2 W
      High beam	12 V - 1,2 W
      Fuel reserve	12 V - 1,2 W

       

      d

      
       

      

      
       

      

      
       

      

      

      

      

      

      

      

      

   3. LUBRICANT CHART

      
       

      LUBRICANT	PRODUCT
      Engine oil	RECOMMENDED: SUPERBIKE 4, SAE 5W - 40 or  4T FORMULA RACING, SAE 5W - 40. As an alternative to the recommended oils, it is possible to use select oilshaving properties in compliance with or even above A.P.I. SJspecifications.
      Transmission oil	RECOMMENDED: F.C., SAE 75W 90 or  GEAR SYNTH, SAE 75W - 90. As an alternative to the recommended oil, use select oils having propertiesin compliance with or even above A.P.I. GL3 specifications
      Fork oil	RECOMMENDED: F.A. 5W or F.A. 20W, as an alternative  FORK 5W or FORK 20W. Should you wish to reach an average behavior between those offered by  F.A. 5W and by  F.A. 20W or  FORK 5W and by FORK 20W, mix the products as follows: SAE 10W = F.A. 5W 67% of the volume, + F.A. 20W 33% of thevolume.  FORK 5W 67% of the volume +  FORK 20W33% of the volume. SAE 15W = F.A. 5W 33% of the volume, + F.A. 20W 67% of thevolume.  FORK 5W 33% of the volume +  FORK 20W67% of the volume.
      Bearings and other lubrication points	RECOMMENDED: BIMOL GREASE 481 +  GREASE SM2. As an alternative to the recommended product, use select oil for rollingbearings, useful temperature range -30°C.+140°C (-22°F.+284°F), dripping point 150°C.230°C (302°F.446°F), highly anticorrosive, water and oxidization resistant.
      Battery terminals	Neutral grease or vaseline.
      Brake fluid	RECOMMENDED: F.F. DOT 4 (DOT 5 compatible) -  BRAKE 5.1 DOT 4 (DOT 5 compatible). As an alternative to the recommended fluid, use fluids having properties incompliance with or even above SAE J1703, NHTSA 116 DOT 4, ISO 4925specifications. NOTE Before mixing different makes or types of oil, check theircompatibility.
      Engine coolant	RECOMMENDED: ECOBLU - 40° C (-40°F) +  COOL. As an alternative to the recommended fluid, use fluids having properties incompliance or even above basic ethylene glycol CUNA NC 956-16specifications. NOTE Use only nitrite-free anti-freeze and corrosion inhibitors with afreezing point of -35°C (-31°F) as a minimum.

      

   4. ROUTINE MAINTENANCE TABLE

      
       

      Parts After running-in

      [1000 km (621 mi)]

      
       

      Every 6000 km

      (3728 mi) or 8 months

      
       

      Every 12000 km

      (7456 mi) or 16 months

      Idle misture (CO) - 1 -

      Belt, converter rollers and plastic guides - 1 3

      Converter belt - 3 -

      Steering bearings 1 1 -

      Wheel bearings - 1 -

      Converter cover air filter - 2 -

      Secondary air scoop filter - 2 -

      Clutch shoes - - 1

      Valve clearance - 1 -

      Brake fluid 1 1 1 / every 2 years: 3

      Front fork oil 1 1 3

      Engine oil filter mesh and magnetic screw 1 1 -

      Converter rollers and plastic guides - 1 3

      Wheels/tyres - 1 -

      Nuts and bolts torque 1 1 -

      Cylinder head nuts torque 1 - -

      Brake bleeding 1 - -

      Battery terminals tightening 1 - -

      Fuel line - 1 every 2 years: 3

      Rear shock absorbers 1 1 -

      Battery - Battery fluid level 1 1 -

      Spark plug 1 1 3

      Carburettor - idle rpm 4 - 1

      Air cleaner - 2 -

      Engine oil filter 3 3 -

      Throttle operation 1 1 -

      Brake operation 1 1 -

      Converter grease - 3 -

      Brake light switch - 1 -

      Coolant 1 every 1000 km (621 mi): 1 / every 16

      months: 3

      Engine oil 3 every 1000 km (621 mi): 1 / every 6000

      km (3728 mi): 3

      Transmission oil 3 every 6000 km (3728 mi): 1 / every 24000

      km (14913 mi): 3

      Beam setting/operation - 1 -

      Tyres/inflation pressure every month: 1

      Battery terminals tightening 1 - -

      Front fork 1 1 -

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

      
       

      1 = check and clean, adjust, lubricate or change, if necessary; 2 = clean; 3 = change; 4 = adjust.

      Perform the maintenance operations more often if the vehicle is used in rainy or dusty areas, on uneven surfaces or on racetracks.

      
       

      

      ( ) = OPERATIONS TO BE MADE ALSO BY THE USER

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