Aprilia scooter (manual) - part 13

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Aprilia scooter (manual) - part 13

 

 

 

    1. THROTTLE BODY

      1. REMOVING THE THROTTLE BODY

image

  • Remove engine inspection cover, see (REMOVING THE HELMET COMPARTMENT).

  • Place a cloth under fuel supply hoses (1) to avoid any fuel spilling.

  • Disconnect fuel supply hoses (1) delivering and returning toIfrom injector.

  • Loosen and remove securing screw (2) of fuel hoses clamps.

  • Disconnect electric connection (3) controlling the injector.


     

  • Loosen clamp of air box intake manifold. image

    image

  • Disconnect electric connection (4) of stepper motor.

  • Disconnect electric connection (5) of throttle positioning sensor.

    image

  • Loosen and remove the three securing screws (6) of intake manifold (7) to the head.

  • Remove intake manifold (7) with throttle body (8).


     

    image

  • Disconnect electric connection (9) of air temperature sensor.


     

    image

  • Loosen both securing nuts (10) of hose guides to carburettor support.

  • Withdraw hose guide and its retainer (11) of forward stroke control on carburettor.

  • Withdraw hose guide and its retainer (12) of return stroke control on carburettor.


     

    image

  • Loosen and remove the three securing screws (13) of throttle body (8) to intake manifold (7).

  • Disassemble throttle body (8) from intake manifold (7).

  • Loosen and remove securing screw (14) of injector

    (15) to intake manifold.

  • Remove injector (15) of intake manifold (7).

      1. ENGINE

        1. REMOVING THE ENGINE image WARNING

          Before performing following operations, engine

          shall be removed from the frame from the back side; then provide and arrange all necessary tools.

          NOTE Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly to avoid disturbing any parts unless strictly necessary.


           

          image

          The operations to disassemble engine from frame are listed below.

  • Remove helmet compartment, see (REMOVING THE HELMET COMPARTMENT).

  • Disconnect fuel delivery hoses (1).

  • Release and remove clamps screw (2).

  • Disconnect the injector connector (3).


     

    image

  • Disconnect connector of stepper motor (5).

  • Disconnect connector of throttle position sensor (4).

  • Disconnect air sensor on throttle body. image

    image

  • Loosen both securing nuts (6) of hose guides to carburettor support.

  • Withdraw hose guide and its retainer (7) of forward stroke control on carburettor.

  • Withdraw hose guide and its retainer (8) of return stroke control on carburettor.


     

  • Disconnect coolant temperature sensor. image

    image

  • Unscrew and remove securing screw of timing sensor.

  • Close sensor seat with a cloth to prevent that any foreign matter get into cylinder head.

    image

  • Cut clamps and release timing sensor cable.

  • Remove timing sensor from crankcase and place it in a safe position.


     


     

    image

  • Remove the spark plug cap. image

    image

  • Unscrew and remove securing screw and collect ground cables.

    image

  • Unscrew and remove connection nut on starter motor.

  • Withdraw the cable from starter motor.


     

  • Disconnect oil pressure sensor. image

  • Cut the clamps. image

    image

  • Loosen the clamp and remove exhaust silencer.

  • Unscrew and remove the three screws (9). image

    image

  • Unscrew and remove both securing screws of brake calliper (10) and the screw (11) of hose guide.

  • Move the rear brake calliper.


     

  • Loosen the clamp. image

    image

  • Withdraw upper hose from coolant pump and collect the coolant in a suitable container.

    image

  • Loosen the clamp.

  • Withdraw the hose from thermostatic valve.


     

    image

  • Fasten the A frame belt to the frame lower side as shown in the figure and lift slightly the bike rear side.

  • Unscrew and remove lower securing screw in both shock absorbers.


     

  • Unscrew and remove securing nut of crankcase pin. image

    image

  • Unscrew and remove the screw and loosen ring nut.

    image

  • Take out engine pin from the right side.

  • Move frame forward and release crankcase.

        1. REASSEMBLING THE ENGINE ON THE FRAME

    image

  • Position crankcase near engine pin fitments on the frame

  • Insert engine pin from the right side.


     

  • Position ring nut properly and tighten securing screws. image

  • Tighten securing nut of engine pin. image

    image

  • Lower the frame as shown in the figure until shock absorber fitments are matching.

  • Tighten lower securing screw in both shock absorbers.

    image

  • Fit the hose on thermostatic valve.

  • Tighten clamp.


     

    image

  • Position upper hose on coolant pump and tighten clamp.

  • Fill the cooling system, see (ATLANTIC 125 200 WORKSHOP MANUAL)


     

    image

  • Refit brake calliper

  • Tighten both securing screws of brake calliper (1) and the screw (2) of hose guide.


     

    image

  • Position exhaust tail pipe and tighten the three securing screws (3)

  • Tighten the clamp image

    image

  • Position oil pressure sensor.

  • Fit clamps to ensure a perfect fixing of oil pressure sensor cable.


     

    image

  • Position cables on starter motor.

  • Tighten securing nut.


     

    image

  • Position ground cables.

  • Tighten securing nut.

  • Position the spark plug cap. image

    image

  • Fit timing sensor in its seat.

  • Tighten securing screw of timing sensor.

  • Fit clamps to ensure a perfect fixing of timing sensor cable.


     

  • Position coolant temperature sensor. image

    image

  • Position hose guide and its retainer (4) of return stroke control on throttle body.

  • Position hose guide and its retainer (5) of forward stroke control on throttle body.

  • Tighten both securing nuts (6) of hose guides to throttle body support.

  • Disconnect air sensor on throttle body. image

    image

  • Disconnect connector of throttle position sensor (7).

  • Disconnect connector of stepper motor (8).


     

    image

  • Connect the injector connector (9).

  • Tighten the clamps screw (10).

  • Connect the injector connector (11).

      1. CHASSIS

        1. REMOVING THE BATTERY COVER

          image

  • Raise the seat.

  • Loosen and remove the four screws.

  • Lift battery cover.


     

  • Remove under seat light bulb from its seat. image

    image

  • Disconnect power outlet connector.

  • Remove battery cover.

        1. REMOVING THE TAIL GUARD

          image

  • Remove luggage rack, see (ATLANTIC 125 200 WORKSHOP MANUAL)

  • Remove both under seats, see (ATLANTIC 125 200 WORKSHOP MANUAL)

  • Working on either side, loosen and remove the three upper screws.


     

    image

  • Working on either side, loosen and remove the lower screw.


     

  • Unscrew and remove the lower centre screw. image

    image

  • Release and remove the two lower side screws.

  • Move tail guard and disconnect rear light connector. image

  • Disconnect the seat releasing cable. image

    image

  • Withdraw the two electric components from the hooks

  • Remove complete tail guard.

        1. REMOVING THE HELMET COMPARTMENT

          image

  • Remove the tail guard, see (REMOVING THE TAIL GUARD).

  • Remove the seat, see (ATLANTIC 125 200 WORKSHOP MANUAL).

  • Remove the battery cover, see (REMOVING THE BATTERY COVER).

  • Remove the battery.

  • Loosen and remove the two front screws.


     

  • Loosen and remove the two rear screws. image

    image

  • Loosen and remove the four CPU screws.

  • Move the CPU and collect the ground cable.


     

    image

  • Remove the bank angle sensor.

    image

  • Unscrew and remove the five securing screws and collect the nut.


     

    image

  • Loosen and remove the two screws.

  • Remove helmet compartment casing.


     

    image

  • Unscrew and remove the seven securing screws of engine inspection cover.

  • Remove engine inspection cover.


     

    image

  • Remove primary and auxiliary fuse carrier from the hooks.

  • Remove helmet compartment.

        1. REMOVING THE SHOCK ABSORBER

    image

  • Remove the tail guard, see (REMOVING THE TAIL GUARD).

  • Unscrew and remove upper securing screw.


     

    image

  • Unscrew and remove lower securing screw.

  • Remove shock absorber.

 

 

 

 

    1. ELECTRIC SYSTEM

      1. WIRING DIAGRAM


 

image

Key:

  1. Multiple connectors

  2. Low fuel light

  3. High beam warning light

  4. Parking light warning light

  5. Instrument panel backlighting

  6. EFI light

  7. Right direction indicator warning light

  8. Left direction indicator warning light

  9. Oil pressure light

  10. ABS light (not in use)

  11. Side stand light

  12. Antitheft system LED

  13. Fuel level gauge

  14. Water temperature gauge

  15. Complete instrument panel

  16. Oil pressure sensor

  17. Warning horn

  18. Repeater

  19. Direction indicator switch

  20. Left dimmer switch

  21. Horn button

  22. Rear brake switch

  1. Complete headlight

  2. Radio power supply

  3. Auxiliary fuses label

  4. Protection diode for alarm

  5. Fuel level


 

AUXILIARY FUSES:

  1. 15 A INJECTION, BRAKE LIGHTS, STARTING.

  2. 3A LOGIC I ENGINE KILL

  3. 15A LIGHTS, HORN, INSTRUMENT PANEL, FAN RELAY, REPEATERIDIRECTION INDICATORS, INSTRUMENT PANEL, RADIO, FUEL LEVEL ECU

  4. 15A POWER SOCKET

  5. 3A ECU PERMANENT POWER SUPPLY

  6. SPARE

  7. 15A SPARE FUSE H 3A SPARE FUSE I SPARE


 

WIRE COLOUR CODING


 

23.

Fan relay

    

Ar

Orange

24.

Starter button

    

Az

Light blue

25.

Engine kill switch

    

B

Blue

26.

Front brake switch

    

Bi

White

27.

Bank angle sensor

    

G

Yellow

28.

Key operated switch

    

Gr

Grey

29.

Compartment light

    

M

Brown

30.

Compartment light switch

    

N

Black

31.

Right parkingIstop lights

    

R

Red

32.

Left parkingIstop lights

    

Ro

Pink

33.

Number plate light

    

V

Green

34.

Rear left turn indicator

    

Vi

Violet

35.

Rear right turn indicator

        

36.

Antitheft system control unit

        

37.

Auxiliary fuses

        

38.

Starter motor

        

39.

Starter relay

        

40.

Battery

        

41.

Main fuses

        

42.

Power outlet

        

43.

Flywheel

        

44.

Voltage regulator

        

45.

Fan

        

46.

Instrument panelIengine

water

temperature

    
 

thermistor

        

  1. Instrument panel air temperature thermistor

  2. Throttle sensor

  3. Oxygen sensor (not as standard)

  4. Side stand switch

  5. Auxiliary injection relay

  6. Main injection relay (polarised)

  7. Fuel level sensor

  8. Fuel pump

  9. Fuel injector

  10. Coil

  11. Spark plug

  12. Stepper motor

  13. RPM sensor

  14. ECU diagnosis socket

  15. ECU

  16. Front left turn indicator

  17. Parking light

  18. High beam lamp

  19. Low beam lamp

  20. Front right turn indicator

 

 

 

 

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