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Aprilia scooter (manual) - part 7

BODYWORK

1. BODYWORK

   
    

   

   1. Light unit

   2. Front cover

   3. Left mirror

   4. Rear brake lever

   5. Rear brake master cylinder

   6. Left switch

   7. Glove compartment

   8. Legshield

   9. Central tunnel

   10. Saddle lock

   11. Luggage rack

   12. Tail

   13. Tail light

   14. Number plate holder

   15. Mudguard

   16. Air filter

   17. Transmission oil level

   18. Engine oil level

   19. Centre stand

   20. Passenger footrests

   21. Side stand

   22. Rider footrests

   23. Warning horn

   24. Front brake calliper

   25. Front brake disc

   26. Front fork

   27. Front mudguard

   28. Left side fairing

       
        

       
        

       

       

       

       7 - 4

       
        

       

       
        

       

       
        

   29. Saddle

   30. Rear side panel

   31. Battery

   32. Throttle control

   33. Right switch

   34. Front brake lever

   35. Right mirror

   36. Windshield screen

   37. Auxiliary fuses

   38. Proportioning valve

   39. Right side fairing

   40. Front wheel

   41. Front brake master cylinder

   42. Splashguard

   43. Fuel tank

   44. Main fuses

   45. Expansion reservoir

   46. Exhaust

   47. Rear brake disc

   48. Rear wheel

   49. Rear brake calliper

   50. Engine Control Unit

   
    

   

   

   

   7 - 5

   
    

   

   
    

   
    

   

2. SADDLE REMOVAL

   • Place the vehicle on the centre stand.

   • Insert the ignition key into the saddle lock.

   • Press and turn the key anticlockwise.

   • Raise the saddle.

     
      

     

   • Release and remove the four screws.

   • Remove the saddle.

     
      

     

     
      

     
      

     

3. REMOVING THE REAR SIDE PANELS

   NOTE The procedures described below apply to both side panels.

   

   • Raise the saddle, 7.1.2.

   • Release and remove the two screws (1).

     
      

     

   • Remove the side panel.

4. LUGGAGE RACK REMOVAL

   TORQUE WRENCH SETTINGS

   Screws (1) 10 Nm (1.0 kgm)

   Screws (2) 24 Nm (2.4 kgm)

   
    

   

   • Raise the saddle, 7.1.2.

   • Remove the luggage rack cover.

     
      

     
      

     

   • Release and remove the two screws (1) and collect the two washers.

     
      

   • Release and remove the two screws (2). 

     

   • Remove the luggage rack.

     
      

     

5. TAIL REMOVAL

   

   • Remove the luggage rack, 7.1.4.

   • Remove both rear side panels, 7.1.3.

   • Release and remove the three upper screws (1) on both sides.

     
      

   • Release and remove the lower screw (2) on both sides. 

   • Shift the tail and disconnect the tail light connector. 

     

   • Disconnect the saddle releasing cable.

   • Remove the complete tail.

     
      

     

6. REMOVING THE NUMBER PLATE HOLDER

   • Release and remove the four screws (1) on both sides.

     
      

     

   • Shift the number plate holder.

   • Release and remove the two screws of the bulb holder (2).

   • Remove the number plate holder.

     
      

     

7. REMOVING THE CENTRAL TUNNEL

   

   • Remove the saddle, 7.1.2.

   • Remove the tail, 7.1.5.

   • Remove the legshield, 7.1.9.

     
      

      WARNING

     Proceed carefully. Do not damage the tab

     and/or its recesses.

     
      

     

   • Lift and remove the mat on both sides with your hands.

   • Release and remove the five screws (1) on both sides.

     
      

   • Release and remove the six screws (2) on both sides. 

   • Insert the ignition key into the tank lock.

   • Press and turn the key anticlockwise.

   • Lift the filler cap flap.

     

   • Remove the rubber gaiter placed underneath the fuel filler cap.

     NOTE Place a clean cloth into the filler cap opening.

     
      

     

      WARNING

     Proceed carefully. Do not damage the tab

     and/or its recesses.

     
      

   • Remove the central tunnel pulling in a rearward motion.

     
      

     

8. AIR DAM REMOVAL

   • Place the vehicle on the centre stand.

   • Lift and remove the front mat with your hands on both sides.

     
      

     

   • Lift and remove the rear mat with your hands on both sides.

   • Release and remove the six screws (1) on both sides.

     
      

     
      

     

     

   • Release and remove the screw (2) at the rear end on both sides.

     

   • Release and remove the three screws (3) at the front end.

   • Lower the side stand.

   • Remove the air dam.

9. LEGSHIELD REMOVAL

   • Place the vehicle on the centre stand.

   • Release and remove the eight screws (1) at the sides.

     
      

     
      

     

   • Insert the ignition key into the fuel tank lock.

   • Press and turn the key anticlockwise.

   • Lift the filler cap flap.

   • Release and remove the two screws (2).

     
      

     

   • Lift the front cover.

   • Release and remove the two screws (3) on both sides.

     
      

      WARNING

     Proceed carefully. Do not damage the tab

     and/or its recesses.

     
      

   • Remove the legshield.

     
      

     

10. FRONT COVER REMOVAL

    • Release and remove the screw (1) at the rear end on both sides.

      
       

      

    • Release and remove the two screws (2) at the front end.

      
       

      

    • Release and remove the two screws (3) at the lower end.

    • Remove the front cover.

11. SCREEN REMOVAL

    

    • Remove the front cover, 7.1.10.

    • Remove both mirrors, 7.1.12.

    • Release and remove the two front screws (1).

    • Remove the windshield screen.

12. REAR-VIEW MIRROR REMOVAL

    TORQUE WRENCH SETTINGS

    Screws (2) 10 Nm (1.0 kgm)

    
     

    NOTE The procedures described below apply to both mirrors.

    • Slip off the rubber gaiter.

    • Release and remove the two screws (1).

      
       

    • Remove the outer cover. 

      

    • Release and remove the two screws (2).

    • Remove the mirror.

      
       

      

13. REMOVING THE SIDE FAIRINGS

    NOTE The procedures described below apply to both fairings.

    

    • Remove the front cover, 7.1.10.

    • Remove the legshield, 7.1.9.

    • Release and remove the upper screw (1) on both sides.

      
       

    • Release and remove the screw (2) on both sides. 

      

    • Release and remove the four screws (3) on the inside.

    • Remove the side fairing.

14. FRONT MUDGUARD REMOVAL

    TORQUE WRENCH SETTINGS

    Screws (1) 7 Nm (0.7 kgm)

    
     

    • Place the vehicle on the centre stand.

    • Release and remove the two screws (1) at both sides.

    • Remove the front mudguard.

      
       

      

15. REAR MUDGUARD REMOVAL

    TORQUE WRENCH SETTINGS

    Airbox screws (1) 8 Nm (0.8 kgm)

    Screws (2) 12 Nm (1.2 kgm)

    
     

    • Unscrew the two retaining screws (1) of the airbox.

      
       

      

    • Unscrew the three retaining screws (2) and collect the cable retainer.

    • Remove the rear mudguard.

16. HELMET COMPARTMENT REMOVAL

    

    • Remove the tail, 7.1.5.

    • Remove the saddle, 7.1.2.

      

    • Remove the battery and extract the main fuse carrier,

      7.2.1.

    • Release and remove the two screws (1) at the front end.

      
       

      

    • Release and remove the two screws (2) at the rear end.

      
       

      

    • Lift the helmet compartment.

    • Release and remove the two retaining screws (3) of the expansion reservoir.

    • Shift the expansion reservoir, but leave it connected to the coolant hoses.

      
       

      

    • Disconnect the two power socket connectors (4).

    • Remove the helmet compartment.

17. HANDLEBAR COVER REMOVAL

    • Release and remove the two screws (1).

    • Remove the upper cover.

      
       

      

    • Release and remove the screw (2) at the front end on both sides.

      
       

      

    • Release and remove the screw (3) at the lower end on both sides.

      
       

      

    • Release and remove the three screws (4).

      

    • Remove the upper handlebar cover.

    • Release and remove the two screws (5).

    • Remove the lower handlebar cover.

18. SPLASHGUARD REMOVAL

    

    • Remove the complete headstock, 7.8.1.

    • Remove the central tunnel, 7.1.7.

    • Shear the tie (1) on both sides.

    • Withdraw both air scoops from the radiator.

      
       

    • Release and remove the four screws (2) at both sides. 

      

    • Release and remove the centre screw (3).

    • Remove the splashguard.

      
       

      

19. BATTERY REMOVAL

    

    • Perform the first four operations described at paragraph 2.4.2.

    • Disconnect the negative (-) cable first and then the

      positive (+) cable.

    • Disconnect the breather hose from the battery.

    • Remove the battery.

      
       

      

20. ENGINE CONTROL UNIT REMOVAL

    

    • Remove the tail, 7.1.5.

    • Disconnect the ECU connector (1).

    • Release and remove the two screws (2).

    • Remove the ECU.

      
       

      

21. VOLTAGE REGULATOR REMOVAL

    

    • Remove the tail, 7.1.5.

    • Disconnect the voltage regulator connector (1).

    • Release and remove the two screws (2).

    • Remove the voltage regulator.

      
       

      

22. REMOVING THE RIGHT SWITCH

    • Release and remove the three screws (1) at the lower end.

    • Release and remove the screw (2).

    • Remove the switch lower cover.

      
       

    • Disconnect the engine kill switch connector. 

      

    • Disconnect the starter connector.

    • Remove the switch upper cover.

      
       

      

23. REMOVING THE LEFT SWITCH

    • Release and remove the three screws (1) at the lower end.

    • Release and remove the screw (2).

    • Remove the switch lower cover.

      
       

      

    • Disconnect the light connector (3).

    • Disconnect the direction indicator connector (4).

    • Disconnect the horn connector (5).

    • Remove the switch upper cover.

24. DASHBOARD REMOVAL

    

    • Remove the windshield, 7.1.11.

    • Release and remove the dashboard retaining screw (1) on both sides.

      
       

    • Lift the dashboard. 

    • Disconnect the speedometer cable. 

      

    • Disconnect the three dashboard connectors (2-3-4). Proceed gently or the flexible printed circuit might damage.

      
       

      

    • Remove the dashboard.

      
       

      

25. HEADLIGHT REMOVAL

    

    • Remove both side fairings, 7.1.13.

    • Release and remove the two upper screws (1).

    • Release and remove the two lower screws (2).

      
       

      

    • Disconnect the two direction indicator connectors on both sides.

      
       

      

    • Disconnect the headlight connector.

    • Remove the headlight.

      
       

      

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