APRILIA SPORTCITY ONE 125 User manual

APRILIA SPORTCITY ONE 125 User manual
SERVICE STATION MANUAL
854184
SPORTCITY ONE 125
SERVICE STATION
MANUAL
SPORTCITY ONE 125
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 models
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 MANUAL
SPORTCITY ONE 125
- 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 scooters. 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
CHAR
TOOLING
TOOL
MAINTENANCE
MAIN
ELECTRICAL SYSTEM
ELE SYS
ENGINE FROM VEHICLE
ENG VE
ENGINE
ENG
SUSPENSIONS
SUSP
BRAKING SYSTEM
CHASSIS
PRE-DELIVERY
BRAK SYS
CHAS
PRE DE
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Characteristics
SPORTCITY ONE 125
Safety rules
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.
FUEL
FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND CAN
BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE OPERATIONS IN A WELL VENTILATED AREA
WITH THE ENGINE OFF. DO NOT SMOKE WHILE REFUELLING OR WHEN CLOSE TO FUEL
VAPOURS, AVOID CONTACT WITH NAKED FLAMES, SPARKS OR ANY OTHER SOURCE THAT
MAY CAUSE FUEL TO CATCH FIRE OR EXPLODE.
CAUTION
DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.
CAUTION
KEEP OUT OF THE REACH OF CHILDREN.
HIGH-TEMPERATURE COMPONENTS
The engine and the components of the exhaust system can get very hot and remain hot for some time
even after the engine has been switched off.
Before handling these components, make sure that you are wearing insulating gloves or wait until the
engine and the exhaust system have cooled down.
TRANSMISSION OIL AND USED FORK OIL
CAUTION
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
CHAR - 6
SPORTCITY ONE 125
Characteristics
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.
CAUTION
KEEP OUT OF THE REACH OF CHILDREN.
BRAKE FLUID
CAUTION
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.
COOLANT
The coolant contains ethylene glycol which, under certain conditions, can become flammable. When it
burns, ethylene glycol produces invisible flames which, however, can cause burns.
CAUTION
MAKE SURE NOT TO POUR THE COOLANT ON HOT ENGINE OR EXHAUST SYSTEM COMPONENTS; IT MAY CATCH FIRE PRODUCING INVISIBLE FLAMES. WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN IF IT IS TOXIC,
THE COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS.
NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS
AS THEY MAY DRINK IT.
CAUTION
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS
UNDER PRESSURE AND MAY CAUSE BURNS.
HYDROGEN GAS AND BATTERY ELECTROLYTE
CAUTION
HYDROGEN GAS AND BATTERY ELECTROLYTE
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.
CHAR - 7
Characteristics
SPORTCITY ONE 125
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,
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.
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle follow the recommendations reported below
carefully.
CAUTION
THE USE OF NAKED FLAMES IS FORBIDDEN FOR ANY KIND 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 ANY OTHER SCOOTER PARTS WITH YOUR
MOUTH: SCOOTER COMPONENTS ARE NOT EDIBLE, ON THE CONTRARY SOME OF THEM
ARE HARMFUL AND EVEN TOXIC. UNLESS OTHERWISE INDICATED, REFIT THE UNITS FOLLOWING REMOVAL OPERATIONS 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 MATTPAINTED SURFACES WITH POLISHING PASTE. 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 BATTERY NEGATIVE LEAD (-) IF YOU INTEND TO CARRY OUT
ELECTRICAL WELDING WORK. WHEN TWO OR MORE PEOPLE WORK AT THE SAME TIME,
MAKE SURE ALL SAFETY MEASURES ARE OBSERVED EACH OF THEM.
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.
REASSEMBLING COMPONENTS
CAUTION
CHAR - 8
SPORTCITY ONE 125
Characteristics
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 reassembling 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 junction surfaces, oil guard rims and washers before refitting them. Smear a light
layer of lithium-based grease on the oil guard rims. Reassemble the oil guards and the
bearings 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.
•
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.
NOTE
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAY
ROUND.
CHAR - 9
SPORTCITY ONE 125
Characteristics
•
Then fit the two connectors making sure that they couple correctly (if the relevant hooks are
provided, you will hear them "click" into place).
CAUTION
TIGHTENING TORQUE
DO NOT FORGET THAT TIGHTENING TORQUES FOR ALL FIXING ELEMENTS ON WHEELS,
BRAKES, WHEEL BOLTS AND ANY 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 REFIT 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.
Vehicle identification
Quote the chassis number when purchasing spare parts.
NOTE
DO NOT OBLITERATE OR ALTER THE VEHICLE IDENTIFICATION NUMBERS. DOING SO IS
CONSIDERED AN OFFENCE IN ALL COUNTRIES. FURTHERMORE, ALTERING THE IDENTIFICATION NUMBERS INVALIDATES THE WARRANTY.
Chassis number
The chassis number is marked on the chassis central steel tube. Remove the cover «1» to read it.
Engine number
The engine number «2» is marked near the lower
support of the rear shock absorber.
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification
Max. length
CHAR - 10
Desc./Quantity
1.950 mm
SPORTCITY ONE 125
Characteristics
Specification
Max. width (to brake levers)
Max. height (to the rear-view mirrors)
Saddle height
Wheelbase
Minimum ground clearance
Kerb weight in running order
Vehicle max load (rider + passenger + luggage)
Desc./Quantity
740 mm
1.270 mm
775 mm
1.358 mm
125 mm
126 kg
286 kg
Engine
ENGINE
Specification
Engine model
Type
Valve quantity
Cylinder quantity
Overall engine capacity
Bore / stroke
Compression ratio
Start-up
Engine revs at idle speed
Clutch
Gear
Lubrication system
Cooling
Valve clearance
Maximum power
Maximum torque
SUPPLY
Desc./Quantity
M8AM
Horizontal single-cylinder
2
1
124 cm³
57.0 mm / 48.6 mm
10.6 ± 0.5 : 1
electric
1,700 ± 100 rpm
Centrifugal
automatic
Wet sump with pump
Forced air circulation cooling
Inlet 0.10 / Outlet 0.15
7.0 kW at 8,000 rpm
10.04 Nm at 7,000 rpm
By carburettor and with automatic petrol vacuum-operated
cock.
KEIHIN CVK 26
Premium unleaded premium (4 stars) petrol, DIN 51607, with
minimum octane rating of 95 (NORM) and 85 (NOMM)
CDI / inductive
Variable from 0° to 30°
CHAMPION RG6YC
NGK CR7EB
0.6 mm
Standard carburettor
Fuel
Ignition type
Ignition advance
Spark plug
Alternative spark plug
Spark plug electrode gap
Transmission
TRANSMISSION
Specification
Variator
Primary drive
Secondary
Engine/wheel total ratio
Minimum ratio for continuos transmission
Maximum ratio for continuos transmission
Desc./Quantity
continuous, automatic
V-belt
Gear reduction unit in oil bath
1: 11.24
2.701: 1
0.809: 1
Capacities
CAPACITY
Specification
Fuel (reserve included)
Fuel reserve
Engine oil (Engine oil change and engine filter replacement)
Transmission oil
Desc./Quantity
7l
1.5 l
1.100 cm³
200 cm³
CHAR - 11
SPORTCITY ONE 125
Characteristics
Specification
Depth of fork oil level from the rim - without spring - fork included
Seats
Desc./Quantity
85 mm
2
Electrical system
ELECTRICAL SYSTEM
Specification
Battery
Fuse
(Permanent magnet) Generator
Desc./Quantity
12V - 9 Ah
20 - 7.5 - 15 Ah
175 W
BULBS AND WARNING LIGHTS
1
2
3
4
5
6
7
8
9
10
11
Specification
Low-beam bulb
High-beam bulb
Tail light bulb
Front turn indicator bulbs
Rear turn indicator bulbs
Rear position light /stop light bulb
License plate light bulb
Instrument panel light bulbs
Oil pressure warning light
Turn indicator warning light
High-beam warning light
Desc./Quantity
12 V - 35 W (Halogen) H8
12 V - 35 W (Halogen) H8
12V - 3W
12 V - 21 W (Halogen) H21W
12V - 16W
12V - 5/21W
12V - 5W
12V - 1.2W
12V - 1.2W
12V - 1.2W
12V - 1.2W
Frame and suspensions
CHASSIS AND SUSPENSIONS
Specification
Chassis type
Steering inclination angle
Trail
A
B
Front suspension
Front suspension travel
Rear suspension
Rear suspension travel
CHAR - 12
Desc./Quantity
High strength steel tube chassis with reinforcements.
28.5°
90 mm
522 mm
416 mm
Hydraulic action telescopic fork
86 mm
Hydraulic single shock absorber with preloading adjustable to
four positions
84 mm
SPORTCITY ONE 125
Characteristics
Brakes
BRAKES
Specification
Front brake
Rear brake
Desc./Quantity
Ø 220-mm disc brake with hydraulic transmission
Ø 140-mm drum brake with mechanic transmission
Wheels and tyres
WHEEL RIM
Specification
Rims
Front wheel
Rear wheel
Desc./Quantity
alloy
3.00 x 14"
3.50 x 14"
TYRES
Specification
Front tyre
Rear tyre
Front tyre standard inflation pressure
Rear tyre standard inflation pressure
Front tyre standard inflation pressure with passenger
Rear tyre standard inflation pressure with passenger
Desc./Quantity
120/70 - 14" 52K Tubeless
120/70 - 14" 52K Tubeless
180 kPa (1.8 bar)
200 kPa (2.0 bar)
190 kPa (1.9 bar)
220 kPa (2.2 bar)
Tightening Torques
FRAME ASSEMBLY
Name
License plate holder support fixing screw
Torque in Nm
10
ENGINE LINK ROD UNIT
Name
Nut fixing the chassis-side swinging arm and the engine-side
swinging arm
Engine-side swinging arm retaining nut
Chassis-side swinging arm retaining nut
Buffer plate to chassis retaining nut
Torque in Nm
42.5
42.5
52.5
40
STAND UNIT
Name
Central stand to chassis fixing screw
Torque in Nm
42.5
FRONT SUSPENSION
Name
Stems-plate fixing screw
Stems-sleeve fixing screw
Wheel pin hub fixing screw
Upper ring nut
Lower ring nut
Torque in Nm
40
30
10
37.5
13
REAR SUSPENSION UNIT
Name
Nut fixing shock absorber bracket on engine
Upper part of the shock absorber retaining nut
Lower part of the shock absorber retaining nut
Torque in Nm
22.5
22.5
42.5
CHAR - 13
SPORTCITY ONE 125
Characteristics
ENGINE UNIT
Name
Air cleaner cover fixing screw
Air cleaner and mudguard fixing screw
Rear brake lever transmission fixing screw
Throttle control to engine transmission fixing screw
Clutch assembly lock-nut on driven pulley
Driven pulley shaft nut
Crankshaft pulley nut
Transmission cover screws
hub cover screws
Pick-up screws
Stator screws
Flywheel nut
Starter motor screws
Head-cylinder stud bolt nuts:
Rocking lever axle and camshaft bearing screw
Chain tensioner pad screw
Camshaft pulley screw
Head cover screw
Timing chain tensioner screw
Timing chain tensioner central screw
Spark plug
Intake manifold screw
Crankcase halves union screws:
Engine oil pre-filter cap:
Timing chain/oil pump compartment cover screws
Central screw
Cover screws
Oil pump screws
Oil sump screws
Torque in Nm
3
10
10
10
55 ÷ 60
40 ÷ 44
18 ÷ 20 + 90°
11 ÷ 13
24 - 26
3÷4
3÷4
52 ÷ 58
11 ÷ 13
6 ÷ 7 +135° +90° upon first assembly; upon refitting, tighten
again at 6 ÷ 7 90° +90°
3÷4
5÷7
12 ÷ 14
8 ÷ 10
8 ÷ 10
5÷6
12 ÷ 14
7÷9
8 ÷ 10
25 ÷ 28
4÷5
12 ÷ 14
0.7 ÷ 0.9
5÷6
8 ÷ 10
EXHAUST SYSTEM UNIT
Name
Silencer protection fixing screw
Muffler plate-engine fixing screw
Nut fixing exhaust manifold to engine
Silencer clamp to exhaust manifold fixing screw
Torque in Nm
6
25.5
15
25.5
FRONT WHEEL UNIT
Name
Brake disc fixing screw
Wheel pin to fork fixing nut
Front brake cable guide on plate fixing screw
Odometer cable guide on plate fixing screw
Torque in Nm
9
46.5
6
6
REAR WHEEL UNIT
Name
Rear wheel to hub fixing nut
Torque in Nm
115
BRAKING SYSTEM UNIT
Name
Left control lever fixing screw
Left lever fixing screw
Brake pump to handlebar fixing screw
Front brake calliper to fork fixing screw
Brake pipe to calliper fixing screw
Brake pipe to brake pump fixing screw
Brake pad locking screws
Rear brake adjustment nut
CHAR - 14
Torque in Nm
8
8
8.05
25.5
21.5
18
15 ÷ 20
5
SPORTCITY ONE 125
Characteristics
HANDLEBAR UNIT
Name
Handlebar to headstock fixing nut
Throttle control fixing screw
Opening throttle control transmission fixing nut
Mirror fixing screw
Torque in Nm
52.5
3.5
3.5
25
ELECTRICAL SYSTEM UNIT
Name
Horn fixing screw
Voltage regulator fixing screw
Control unit fixing screw
Coil fixing screw
Start-up relay fixing screw
Torque in Nm
10
10
10
5
10
LIGHTS AND INSTRUMENT PANEL UNIT
Name
Front headlamp fixing screw
Rear light fixing screw
Rear light fixing screw
Nut fixing license plate lamp
Instrument panel fixing screw
Torque in Nm
3
6
3
3
3
FUEL TANK UNIT
Name
Fuel tank to chassis lateral fixing screw
Fuel tank to chassis rear fixing screw
Torque in Nm
10
10
SADDLE UNIT
Name
Saddle plate fixing nut
Torque in Nm
10
BODYWORK UNIT
Name
Helmet compartment fixing screw
Helmet compartment fixing screw
Passenger handgrip profiles fixing screw
Passenger handgrip fixing screw
Battery cover fixing screw
Front head fixing screw
Front head fixing screw
Rear head fixing screw
Front wheel well fixing screw
Front wheel well fixing screw
Front mudguard fixing screw
Mats kit fixing screw
Mats kit fixing screw
Footrest fixing screw
Shield upper lock fixing screw
Lid hinge fixing screw
Internal shield fixing screw
Internal shield fixing screw
Under-footrest fixing screw
Central lock fixing screw
Right side lock to right passenger footrest fixing screw
Left side lock to left passenger footrest fixing screw
Right fairing right passenger footrest fixing screw
Left fairing left passenger footrest fixing screw
Right and left fairings to headlamp support fixing screw
Pre-assembled tail section to vehicle fixing screw
Inspection cover fixing screw
Mudflap fixing screw
Torque in Nm
6
3
3
20.5
6
6
3
3
6
3
6
6
3
6
6
3
6
3
6
3
3
3
6
6
3
6
6
6
CHAR - 15
SPORTCITY ONE 125
Characteristics
Name
Bag hook fixing screw
Rear mudguard fixing screw
Torque in Nm
3
6
LABELS / TRANSFER UNIT
Name
License plate fixing nut
Torque in Nm
6
Overhaul data
Assembly clearances
Cylinder - piston assy.
COUPLING BETWEEN PISTON AND CAST IRON CYLINDER (125)
Name
Coupling
Coupling
Coupling
Coupling
Coupling 1st oversize
Coupling 1st oversize
Coupling 1st oversize
Coupling 1st oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 2nd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Coupling 3rd oversize
Initials
M
N
O
P
M1
N1
O1
P1
M2
N2
O2
P2
M3
N3
O3
P3
Cylinder
56.997 ÷ 57.004
57.004 ÷ 57.011
57.011 ÷ 57.018
57.018 ÷ 57.025
57.197 ÷ 57.204
57.204 ÷ 57.211
57.211 ÷ 57.218
57.218 ÷ 57.225
57.397 ÷ 57.404
57.404 ÷ 57.411
57.411 ÷ 57.418
57.418 ÷ 57.425
57.597 ÷ 57.604
57.604 ÷ 57.611
57.611 ÷ 57.618
57.618 ÷ 57.625
Piston
56.944 ÷ 56.951
56.951 ÷ 56.958
56.958 ÷ 56.965
56.965 ÷ 56.972
57.144 ÷ 57.151
57.151 ÷ 57.158
57.158 ÷ 57.165
57.165 ÷ 57.172
57.344 ÷ 57.351
57.351 ÷ 57.358
57.358 ÷ 57.365
57.365 ÷ 57.372
57.544 ÷ 57.551
57.551 ÷ 57.558
57.558 ÷ 57.565
57.565 ÷ 57.572
Play on fitting
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
0.046 - 0.060
Initials
A
A
A
A
Quantity
0.15 ÷ 0.30
0.10 ÷ 0.30
0.10 ÷ 0.35
0.15 ÷ 0.30
Piston rings
SEALING RINGS (125)
Name
Compression ring
Oil scraper ring
Oil scraper ring
Compression ring 1st
Oversize
CHAR - 16
Description
Dimensions
57 x 1
57x1
57x2.5
57.2 x 1
SPORTCITY ONE 125
Name
Oil scraper ring 1st
oversize
Oil scraper ring 1st
oversize
Compression ring 2nd
oversize
Oil scraper ring 2nd
oversize
Oil scraper ring 2nd
oversize
Compression ring 3rd
oversize
Oil scraper ring 3rd
oversize
Oil scraper ring 3rd
oversize
Description
Characteristics
Dimensions
57.2x1
Initials
A
Quantity
0.10 ÷ 0.30
57.2x2.5
A
0.10 ÷ 0.35
57.4x1
A
0.15 ÷ 0.30
57.4x1
A
0.10 ÷ 0.30
57.4x2.5
A
0.10 ÷ 0.35
57.6x1
A
0.15 ÷ 0.30
57.6x1
A
0.10 ÷ 0.30
57.6x2.5
A
0.10 ÷ 0.35
Maximum clearance after use: 1 mm
Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD (125)
Name
Half shaft, transmission
side
Half shaft, flywheel side
Connecting rod with PP
Crankpin width
Description
Dimensions
16.6 +0-0.05
Initials
A
Quantity
D = 0.20 ÷ 0.50
16.6 +0-0.05
18 -0,10 -0,15
51,400
B
C
E
D = 0.20 ÷ 0.50
0.20 ÷ 0.50
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS
(125)
Name
Crankshaft
Crankshaft
Crankcase
Crankcase
Crankshaft half-bearings
Crankshaft half-bearings
Crankshaft half-bearings
Crankshaft type 1Crankcase type 1
Crankshaft type 1 Crankcase type 2
Crankshaft type 2 Crankcase type 1
Crankshaft type 2 Crankcase type 2
Description
Dimensions
Initials
Class 1
Class 2
Class 1
Class 2
B Type - blue
Quantity
28.998 ÷ 29.004
29.004 ÷ 29.010
32.953 ÷ 32.959
32.959 ÷ 32.965
1.973 ÷ 1.976
C Type - yellow
1.976 ÷ 1.979
E Type - green
1.979 ÷ 1.982
E-E
C-C
C-C
B-B
CHAR - 17
SPORTCITY ONE 125
Characteristics
Characteristic
Crankshaft/crankcase axial clearance «A»:
0.15 ÷ 0.40
Slot packing system
SHIMMING SYSTEM
Measure taken
0 ÷ 0.1
0.1 ÷ 0.3
0.3 ÷ 0.4
Characteristic
Compression ratio
10.6 ± 0.5 : 1
CHAR - 18
Gasket thickness
0.8 ± 0.05
0.6 ± 0.05
0.4 ± 0.05
SPORTCITY ONE 125
Characteristics
Products
RECOMMENDED PRODUCTS TABLE
Product
AGIP CITY HI TEC 4T
AGIP GEAR SYNTH SAE 75W-90
AGIP FORK 7.5W
AGIP GREASE SM2
AGIP BRAKE 4
AGIP FILTER OIL
Description
Specifications
Engine oil
SAE 5W/40, API SL, ACEA A3, JASO MA
Gearbox oil
API GL4, GL5
Fork oil
Lithium grease with molybdenum for
NLGI 2
bearings and other points needing lubrication
Brake fluid
FMVSS DOT4+
Oil for air filter sponge
-
CHAR - 19
INDEX OF TOPICS
TOOLING
TOOL
SPORTCITY ONE 125
Tooling
TOOLS
Stores code
020423Y
Description
Driven pulley lock wrench
001467Y009
Bell for OD 42-mm bearings
001467Y013
Calliper to extract 15-mm diameter bearings
008564Y
Flywheel extractor
020074Y
Support base for checking crankshaft
alignment
020150Y
Air heater support
TOOL - 21
SPORTCITY ONE 125
Tooling
TOOL - 22
Stores code
020151Y
Description
Air heater
020262Y
Crankcase splitting strip
020263Y
Sheath for fitting the driven pulley
020306Y
Punch for fitting the valve sealing rings
020335Y
Dial gauge magnetic support
SPORTCITY ONE 125
Tooling
Stores code
020357Y
Description
32 x 35 mm adaptor
020359Y
42 x 47-mm adaptor
020360Y
Adaptor 52x54 mm
020363Y
20 mm guide for oil seal
020364Y
25-mm Guide
020368Y
driving pulley lock wrench
TOOL - 23
SPORTCITY ONE 125
Tooling
TOOL - 24
Stores code
020375Y
Description
28x30 mm punch
020376Y
Adapter handle
020382Y
Tool for removing valve cotters fitted with
part 012
020382Y011
adaptor for valve removing tool
020412Y
15-mm Oil seal guide
020424Y
Punch for fitting driven pulley roller casing
SPORTCITY ONE 125
Tooling
Stores code
020425Y
Description
Shaft oil seal punch
020426Y
Piston fitting fork
020427Y
Piston fitting ring
020428Y
Support to check piston position
020431Y
Valve oil seal extractor
020439Y
17-mm guide for oil seal
TOOL - 25
SPORTCITY ONE 125
Tooling
Stores code
020565Y
TOOL - 26
Description
Flywheel lock calliper spanner
INDEX OF TOPICS
MAINTENANCE
MAIN
SPORTCITY ONE 125
Maintenance
Maintenance chart
ROUTINE MAINTENANCE TABLE
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
* Check level every 3,000 km
** Replace every 2 years
km x 1,000
Driven pulley roller casing
Safety locks
Spark plug
driving belt
Throttle control
Air filter
SAS filter
Oil mesh filter
Engine oil filter
Valve clearance
Electrical system and battery
Cooling system
Brake control levers
Brake fluid **
Engine oil*
Hub oil
Headlight aiming adjustment
Brake pads
Sliding blocks / Variable speed rollers
Tyre pressure and wear
Vehicle road test
Idle speed
Odometer gear
Suspensions
Steering
Transmissions
1
6
I
I
I
A
C
C
R
I
C
R
A
I
L
I
R
R
I
R
I
I
I
I
A
I
I
I
I
I
12
L
I
R
R
A
C
C
C
R
I
L
I
R
I
A
I
R
I
I
A
L
I
I
L
18
I
I
C
C
R
A
I
I
R
I
I
I
I
I
24
L
I
R
R
A
C
C
C
R
30
I
C
L
I
R
R
A
I
R
I
I
A
L
I
I
L
I
I
I
C
C
R
I
R
I
I
I
I
I
Carburettor
Check idle speed according to the indications in
the maintenance table. To reach the set screw:
•
Remove the inspection cover from the
inside of the helmet compartment.
CAUTION
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS
AND IN ORDER TO AVOID BURNS, LEAVE ENGINE AND
MUFFLER TO COOL OFF TO AMBIENT TEMPERATURE.
•
Operate on the screw «1» until the pre-set idle speed is obtained.
Characteristic
Engine revs at idle speed
1,700 ± 100 rpm
MAIN - 28
36
L
I
R
R
A
C
C
C
R
A
I
L
I
R
I
A
I
R
I
I
A
L
I
I
L
42
I
I
C
C
R
I
I
R
I
I
I
I
I
48
L
I
R
R
A
C
C
C
R
I
C
L
I
R
R
A
I
R
I
I
A
L
I
I
L
54
I
I
C
C
R
A
I
I
R
I
I
I
I
I
60
L
I
R
R
A
C
C
C
R
I
L
I
R
I
A
I
R
I
I
A
L
I
I
L
SPORTCITY ONE 125
Maintenance
Spark plug
Check the spark plug according to the indications in the maintenance table. To reach it:
•
Remove the side fairings.
CAUTION
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS,
LEAVE ENGINE AND MUFFLER TO COOL OFF TO AMBIENT TEMPERATURE.
•
Disconnect the cap.
•
Clean off any trace of dirt from the
spark plug base by blowing compressed air.
•
Unscrew the spark plug and remove it from its seat, making sure no dust or dirt gets into the
cylinder.
•
Check that spark plug electrode and central porcelain insulator do not have carbon deposits
or corrosion; if necessary, remove them.
•
Use a thickness gauge to check the electrode gap and, if necessary, adjust it.
•
Make sure the washer is in good conditions.
•
Fit the washer and then finger tighten the spark plug.
•
Tighten to the specified torque.
Characteristic
Spark plug electrode gap
0.7 mm
Locking torques (N*m)
Spark plug 12 ÷ 14
Hub oil
Check
NOTE
USE RECOMMENDED OIL ONLY. REFER TO THE RECOMMENDED PRODUCTS TABLE.
MAIN - 29
Maintenance
•
SPORTCITY ONE 125
Ride some kilometres until reaching
the regular operating temperature;
then, stop the engine.
•
Rest the scooter on its stand.
•
Remove the tap-dipstick «2» and clean
it with a cloth.
•
Reinsert the tap-dipstick «2» into its
tube and then pull it out again to check
the oil level.
•
The oil level is correct if it reaches the
indicated mark.
CAUTION
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
CAUTION
WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD.
To ensure long-lasting and optimal scooter performance, change oil following the frequency indicated in the scheduled maintenance tables.
For change:
•
Ride a few kilometres until the regular
working temperature is reached, then
stop the engine.
•
Park the vehicle on its centre stand.
•
Place a container with 200 cm³ minimum capacity under the drainage plug
«1».
•
Unscrew the filler cap «2» and the oil
drainage plug «1».
MAIN - 30
SPORTCITY ONE 125
•
Maintenance
Let the oil drain off completely from the
crankcase.
•
Tighten the drainage plug «1» and
pour 200 cm³ of the recommended oil.
•
Check the hub oil level.
•
Tighten the filler cap «2».
CAUTION
SCREW THE FILLER CAP AND THE DRAINAGE PLUG
TIGHTLY AND MAKE SURE THAT OIL DOES NOT SEEP
THROUGH.
CHECK REGULARLY THAT THERE ARE NO LEAKS IN THE
CRANKCASE COVER GASKET.
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.
Air filter
CAUTION
CLEAN AND CHECK THE AIR FILTER CONDITIONS MONTHLY OR FOLLOWING THE INDICATIONS IN THE SCHEDULED MAINTENANCE TABLES. THIS WILL DEPEND ON USE CONDITIONS.
IF THE SCOOTER IS USED ON DUSTY OR WET ROADS, CLEAN AND CHANGE THE FILTER
MORE FREQUENTLY.
Removing the air filter
•
Rest the scooter on its centre stand.
•
Undo and remove the six screws «1».
•
Slide off the air filter cover «2».
•
Slide off the filtering element «3».
Cleaning
MAIN - 31
Maintenance
SPORTCITY ONE 125
CAUTION
DO NOT USE PETROL OR FLAMMABLE SOLVENTS TO CLEAN THE FILTERING ELEMENT TO
AVOID RISK OF FIRE OR EXPLOSION.
•
Wash the filtering element «3» with clean non-inflammable or high-volatility solvents and let
it dry thoroughly.
•
Apply a specific filter oil over all the surface.
Engine oil
Replacement
NOTE
USE RECOMMENDED OIL ONLY. REFER TO THE RECOMMENDED PRODUCTS TABLE.
NOTE
PARK THE VEHICLE ON SAFE AND LEVEL GROUND.
•
Park the vehicle on firm and level ground.
•
Rest the vehicle on its centre stand.
•
Unscrew and take out the measuring
tap-dipstick «1».
•
Place a container to collect the oil under the engine oil filter.
•
Unscrew and remove the engine oil
cartridge filter «2».
CAUTION
USED OIL CONTAINS SUBSTANCES THAT ARE HARMFUL TO THE ENVIRONMENT. DISPOSE OF USED OIL ACCORDING TO THE REGULATIONS IN FORCE.
•
Unscrew and remove the oil drainage plug «3» and drain off the engine oil.
•
Fit a new oil cartridge filter «2» and lubricate the filter sealing O-rings with oil.
•
Screw and tighten the engine oil drainage plug «3».
•
Pour approx. 1000 cm³ (61 cu.in) of engine oil through the fill opening.
MAIN - 32
SPORTCITY ONE 125
Maintenance
•
Screw and tighten the cap-dipstick «1».
•
Start the engine and let it run for several minutes. Stop the engine and let it cool down.
•
Check the engine oil level.
Check
NOTE
USE RECOMMENDED OIL ONLY. REFER TO THE RECOMMENDED PRODUCTS TABLE.
NOTE
PARK THE VEHICLE ON SAFE AND LEVEL GROUND.
•
Rest the vehicle on its centre stand.
CAUTION
WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD.
•
Stop the engine and let it cool off so
that the oil in the crankcase flows down
and cools as well.
NOTE
FAILURE TO FOLLOW THESE OPERATIONS MAY RESULT IN AN INCORRECT READING OF THE ENGINE OIL
LEVEL.
•
Unscrew and pull out the measuring
cap-dipstick «1».
•
Clean the area in contact with oil with
a clean cloth.
•
Screw the cap-dipstick «1» fully into its
tube.
•
Remove the tap-dipstick «1» again and
read the level the oil reaches on the
dipstick:
MAX = maximum level;
MIN = minimum level.
•
The level is correct when it is close to
the «MAX» level marked on the measuring dipstick.
CAUTION
MAIN - 33
Maintenance
SPORTCITY ONE 125
IN ORDER TO AVOID DAMAGING THE ENGINE, OIL LEVEL
MUST NEVER EXCEED THE «MAX» MARK OR FALL BELOW THE «MIN» MARK.
•
Top-up if required.
TOP-UP
Do not exceed the «MAX» mark level when topping-up engine oil.
•
Pour a small quantity of oil through the tube 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.
•
Once this operation is finished, screw and tighten the cap-dipstick «1».
CAUTION
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.
Fuel filter
Cleaning the fuel filter
•
Empty the fuel tank.
•
Unscrew the clamp «1».
•
Remove the pipe «2».
•
Slide off the petrol flange «3».
•
Unscrew the filter «4» from the flange
«3».
NOTE
BLOW THE FILTER WITH COMPRESSED AIR AND REFIT.
MAIN - 34
SPORTCITY ONE 125
Maintenance
Transmissions
Check that the throttle grip works correctly
CAUTION
DO NOT USE THE SCOOTER IF THE THROTTLE GRIP CABLE IS DAMAGED, TWISTED OR
COILED. THIS MAY INTERFERE WITH THE THROTTLE GRIP NORMAL OPERATION.
THE THROTTLE GRIP MAY GET LOCKED AND THIS MAY RESULT IN LOSS OF VEHICLE CONTROL.
Make sure the front fork rotation does not press the throttle grip and engage gears. Furthermore, make
sure that the throttle grip goes back to idle position smoothly and automatically when released.
If this does not occur:
NOTE
USED THE SPECIFIC LUBRICANT AVAILABLE IN THE MARKET TO LUBRICATE THE COMPONENTS.
Check the position and lubrication of the following
components:
•
throttle grip cable sheath;
•
throttle grip regulator «2»;
•
cable terminals;
•
throttle grip.
Check the throttle grip adjustment.
NOTE
APPLY A GOOD QUANTITY OF SCOOTER CABLE
GREASE TO LUBRICATE THE THROTTLE GRIP SYSTEM
COMPONENTS.
Throttle grip adjustment
NOTE
BEFORE CARRYING OUT ANY TYPE OF OPERATIONS, MAKE SURE THE THROTTLE GRIP
WORKS PROPERLY.
The throttle grip cable backslash must be between
2 - 3 mm (0.08 - 0.12 in), measured at the throttle
trim, as shown in the figure.
MAIN - 35
Maintenance
SPORTCITY ONE 125
To adjust the cable:
•
Rest the scooter on its centre stand.
•
Loosen clamping nut «1».
•
Turn regulator «2» so as to restore the
specified value.
•
After adjusting, tighten the closing nut
«1» and check backlash again.
CAUTION
AFTER ADJUSTING THE THROTTLE GRIP, TURN THE
HANDLEBAR FULLY TO THE LEFT AND THEN FULLY TO
THE RIGHT WITH THE ENGINE AT IDLE SPEED.
CHECK THAT THE NOISE PRODUCED WITH THE ENGINE
AT IDLE DOES NOT CHANGE WHILE CARRYING OUT
THESE OPERATIONS. ALSO CHECK THAT THE THROTTLE GRIP CLOSES SMOOTHLY AND TOTALLY WHEN RELEASED.
Braking system
CAUTION
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER
REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO THE REGULAR USE CONDITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED.
Level check
NOTE
CARRY OUT THESE OPERATIONS ONLY WITH THE VEHICLE ON A FLAT AND STABLE SURFACE, SUCH AS A GARAGE CONCRETE FLOOR.
•
Rest the vehicle on its centre stand.
MIN = minimum level.
•
Turn the handlebar so that the fluid in
the brake fluid reservoir is parallel to
the «MIN» reference mark.
•
Make sure that the fluid level in the reservoir is above the «MIN» reference
mark.
MAIN - 36
SPORTCITY ONE 125
Maintenance
Top-up
•
Remove the mirror and the pump cover.
CAUTION
TO REMOVE THE TWO SCREWS «1» THAT FIX THE RESERVOIR COVER «2», TURN THE HANDLEBAR SO THAT
THE FLUID INSIDE THE BRAKE FLUID RESERVOIR IS
PARALLEL TO «MIN» REFERENCE MARK. IF THIS PROCEDURE IS NOT CARRIED OUT, THE BRAKE FLUID WILL
SPILL OUT OF THE RESERVOIR.
•
Turn the handlebar so that the fluid in the brake fluid reservoir is parallel to the «MIN» reference mark.
•
Undo the two screws «1».
•
Remove cover «2».
•
Remove cover guide «4».
WARNING
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.
CAUTION
TO AVOID SPILLING BRAKE FLUID WHILE TOPPING-UP, KEEP THE FLUID LEVEL IN THE RESERVOIR PARALLEL TO THE RESERVOIR EDGE AND DO NOT SHAKE THE VEHICLE.
•
Remove the gasket «5».
NOTE
TO REACH THE MAXIMUM LEVEL, TOP-UP UNTIL COVERING THE SIGHT GLASS COMPLETELY BUT LEAVE A
5-6 MM (0.20-0.23 IN) MARGIN FROM THE RESERVOIR
EDGE.
CAUTION
DO NOT EXCEED THE ''MAX'' LEVEL REFERENCE MARK
WHEN TOPPING-UP. TOP-UP TO THE ''MAX'' LEVEL REFERENCE MARK ONLY WHEN NEW PADS ARE FITTED.
WARNING
NEVER FILL THE RESERVOIR UP TO THE 'MAX'' LEVEL
REFERENCE MARK IF THE PADS ARE WORN; THIS
WOULD CAUSE THE FLUID TO LEAK OUT FROM THE
RESERVOIR WHEN THE NEW PADS ARE FITTED. USE
RECOMMENDED PRODUCT ONLY. NEVER REUSE OLD
BRAKE FLUID.
MAIN - 37
Maintenance
•
Top-up the reservoir with brake fluid up
to the ''MAX'' level.
•
Refit gasket «5» correctly in its position.
•
Refit cover guide «4» correctly in its
position.
•
Refit cover «2».
•
Insert and tighten the two screws «1».
•
Refit the front handlebar cover.
CAUTION
AFTER CARRYING OUT BRAKE MAINTENANCE, ALWAYS
CHECK THAT BRAKES OPERATE PROPERLY. EXCESSIVE BRAKE LEVER CLEARANCE OR POOR BRAKING
PERFORMANCE MAY INDICATE THAT CIRCUIT NEEDS
PURGING. THIS MAY ALSO BE DUE TO ANY OTHER
PROBLEM IN THE BRAKING SYSTEM.
Headlight adjustment
CAUTION
NEVER USE THE SCOOTER IF THE HEADLAMPS DO NOT
WORK PROPERLY.
NEVER USE THE SCOOTER IF THE HEADLAMPS ARE
NOT CORRECTLY ADJUSTED; YOU MAY DAZZLE THE
VEHICLE RIDING TOWARDS YOUR DIRECTION. THIS MAY
ALSO REDUCE THE POSSIBILITY OF SEEING AN OBSTACLE AHEAD OF YOU ON THE ROAD WHEN RIDING AT
NIGHT.
IT IS ALWAYS ADVISABLE TO REDUCE SPEED WHEN
RIDING AT NIGHT SO AS TO HAVE ENOUGH TIME TO
AVOID POTENTIAL OBSTACLES AND TO ADAPT YOURSELF TO LOW VISIBILITY CONDITIONS RESULTING
FROM DARKNESS.
NOTE
THE PROCEDURE DESCRIBED HEREIN COMPLIES WITH
THE ITALIAN STANDARDS REGARDING MAXIMUM
HEIGHT OF THE LIGHT BEAM.
IF THE SCOOTER IS USED IN OTHER COUNTRIES, NATIONAL REGULATIONS MUST BE OBSERVED.
•
For 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
MAIN - 38
SPORTCITY ONE 125
SPORTCITY ONE 125
Maintenance
headlight horizontal straight line (about
9/10 of the total height).
To adjust the light beam:
•
Park the vehicle on its centre stand on
safe and level ground.
•
Hold the knob «4» operating inside the
wheel well.
SCREW it (clockwise) to raise the light beam.
UNSCREW it (anticlockwise) to lower the light
beam.
NOTE
IN COMPLIANCE WITH LOCAL LEGISLATION, SPECIFIC
PROCEDURES MUST BE FOLLOWED WHEN ALIGNING
THE LIGHTS.
MAIN - 39
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
SPORTCITY ONE 125
Electrical system
KEY
1. Multiple connectors
2. Horn
3. Horn button
4. Fuel level probe
5. Diagnosis
6. Oil level warning light
7. Instrument panel lighting bulbs
8. High-beam warning light
9. Turn indicator warning light
10. Fuel level instrument
11. Instrument panel
12. NTC temperature sensor
13. Blinker
14. Low-beam/High-beam/Passing switch
15. Key switch
16. Turn indicators switch
17. Starter button
18. Front stop switch
19. Rear stop switch
ELE SYS - 41
Electrical system
SPORTCITY ONE 125
20. Rear left turn indicator
21. Rear light
22. License plate light
23. Rear right turn indicator
24. Start-up relay
25. Starter motor
26. Battery
27. Main fuse
28. Auxiliary fuses
29. Coil
30. Spark plug
31. Throttle sensor
32. CDI control unit
33. Automatic starter
34. PTC heater
35. Regulator
36. Oil pressure sensor
37. Pick-up
38. Generator
39. Front right turn indicator
40. High-beam light
41. Front position light
42. Low-beam light
43. Front left turn indicator
44. Front headlamp
45. Ground point on chassis
CABLE COLOURS
Ar:Orange Az:Sky blue B: Blue Bi: White G: Yellow Gr:Grey M: Brown N: Black R: Red V: Green
Vi:Purple Ro: Pink
ELE SYS - 42
SPORTCITY ONE 125
Electrical system
Components arrangement
ELE SYS - 43
Electrical system
1. Instrument panel
•
To reach the connector, remove the
front handlebar cover.
2. Battery
•
To reach it, remove the appropriate
cover placed under the saddle.
3. Main fuse
•
Remove the battery cover to reach it.
4. Starter motor
•
Remove the helmet compartment to
reach it.
ELE SYS - 44
SPORTCITY ONE 125
SPORTCITY ONE 125
Electrical system
5. Temperature sensor
•
Remove the helmet compartment to
reach it.
6. Voltage regulator
•
Remove the rear central cover to reach
it.
Characteristic
Battery recharging voltage:
13 ÷ 14.5 V at 4000 rpm
7. Auxiliary fuses
•
To reach them, open the front glove
compartment.
8. Control unit
•
To reach it, remove the legshield.
ELE SYS - 45
Electrical system
9. Key switch
•
To reach it, remove the legshield.
10. Throttle valve position sensor
•
To reach it, remove the inspection
compartment placed in the helmet
compartment.
11. Turn indicators
•
To reach them, remove the legshield.
12. Horn
•
Remove the shield back plate to reach
it.
ELE SYS - 46
SPORTCITY ONE 125
SPORTCITY ONE 125
Electrical system
13. Coil
•
Remove the rear central cover to reach
it.
Characteristic
Coil primary resistance value:
~ 0.5 Ω
Coil secondary resistance value:
3000 ± 300 Ω
14. Pick-Up/Current generator/Oil pressure
sensor
•
The connector is placed under the vehicle right fairing.
Characteristic
Pick-up resistance value:
~ 130 Ω
Generator phases resistance values:
1±1Ω
Generated current:
13A at 6000 rpm
15. Automatic starter
•
To reach the connector, remove the
right side fairing.
16. Start-up remote control switch
•
Remove the right side fairing to reach
it.
ELE SYS - 47
Electrical system
17. Fuel level probe
•
Placed on the fuel tank.
Characteristic
Resistance value with empty tank
~ 101 Ω
Resistance value with full tank
~ 7.4 Ω
18. Diagnostics socket
•
Remove the battery cover to reach it.
Ground points
Ground point on chassis
•
Remove the rear central cover to reach
it.
Ground point on engine
•
Remove the helmet compartment to
reach it.
Checks and inspections
ELE SYS - 48
SPORTCITY ONE 125
SPORTCITY ONE 125
Electrical system
Ignition circuit
CAUTION
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.
Pick-Up Check
•
With engine off disconnect the control
unit connector.
•
Measure the resistance present between terminals No. 10 (Blue-Yellow
cable) and No. 12 (Blue cable).
•
If the value measured is incorrect, repeat the check directly on the component.
•
Disconnect the Pick-Up connector and
measure the resistance between the
pin corresponding to the Blue-Yellow
cable of the wiring and the ground connection on the engine.
•
If the value measured is correct, check
wiring continuity.
Characteristic
Pick-up resistance value:
~ 130 Ω
ELE SYS - 49
Electrical system
SPORTCITY ONE 125
Coil primary check:
•
Disconnect the connector of the control
unit.
•
Measure the resistance present between terminals No. 4 (White-Purple
cable) and No. 12 (Blue cable).
•
If the measured value is incorrect, repeat the check between the positive
and negative terminals of the coil.
•
If a correct value is measured, check
wiring continuity.
Characteristic
Coil primary resistance value:
~ 0.5 Ω
Coil secondary check
•
Disconnect the spark plug cap from the
coil cable and measure the resistance
between the cable end and the coil
negative terminal.
Characteristic
Coil secondary resistance value:
3000 ± 300 Ω
Battery recharge circuit
With engine running at high revs, measure the voltage present at the battery poles.
Characteristic
Battery recharging voltage:
13 ÷ 14.5 V at 4000 rpm
ELE SYS - 50
SPORTCITY ONE 125
Electrical system
Stator check
•
Disconnect the connector from the
voltage regulator and check if there is
continuity between a yellow cable and
the other two cables.
•
Check that all yellow cables are insulated from the ground connection.
Characteristic
Generator phases resistance values:
1±1Ω
•
If non-conforming values are measured, repeat the checks directly on the
stator. If a correct value is measured,
check wiring continuity.
Recharge system voltage check
•
Connect the ammeter induction clamp
to the voltage regulator positive terminal (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.
Characteristic
Generated current:
13A at 6000 rpm
Start up system check
CAUTION
ELE SYS - 51
Electrical system
SPORTCITY ONE 125
THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED.
•
Check continuity of the Green-Red cable between the 7.5A fuse B and stop buttons.
•
Check the stop buttons contacts.
•
Check continuity between the starter button Green-Red cable and the stop button GreenYellow cables.
•
Check the starter button contacts.
•
Check continuity between the Yellow-Red cable between the starter button and the start-up
remote control switch.
•
Check the start-up remote control switch.
•
Check continuity of the Red cable between remote control and the battery and between the
remote control and the starter motor.
•
Check that the starter motor is earthed.
Horn control
CAUTION
THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED.
•
Check continuity of the Green cable which connects the horn button to 15A fuse C .
•
Check that the horn switch works properly.
•
Check continuity of the Grey cable which connects the switch to the horn.
Turn signals system check
CAUTION
THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED.
•
Check that bulb operates properly.
•
Check continuity of the Green cable which connects turn indicators to the 15A fuse C .
•
With key switch set to «ON» check if there is intermittent voltage between the Blue-Black
cable and the turn indicators blinker Blue cable.
•
Check continuity of the Blue-Black cable between the turn indicators blinker and the turn
indicators switch.
•
Check that the turn indicator switch works properly.
•
Check continuity of the Red and Blue cables which connect the switch to the bulbs.
ELE SYS - 52
SPORTCITY ONE 125
Electrical system
level indicators
CAUTION
THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED.
•
Check continuity of the Green cable which connects the instrument panel to the 15A fuse
C.
•
Check continuity of the Grey-Green cable which connects the instrument panel to the probe
checking fuel level.
•
Measure resistance present between the Grey-Green cable and the Blue cable of the fuel
level probe by moving the arm with the float to different positions.
•
If the values measured are correct but the instrument panel value displayed is incorrect,
check wiring continuity.
Characteristic
Resistance value with empty tank
~ 101 Ω
Resistance value with full tank
~ 7.4 Ω
Lights list
BULBS AND WARNING LIGHTS
Specification
Low-beam bulb
High-beam bulb
Tail light bulb
Front turn indicator bulbs
Rear turn indicator bulbs
Rear position light /stop light bulb
License plate light bulb
Instrument panel light bulbs
Oil pressure warning light
Turn indicator warning light
High-beam warning light
1
2
3
4
5
6
7
8
9
10
11
Desc./Quantity
12 V - 35 W (Halogen) H8
12 V - 35 W (Halogen) H8
12V - 3W
12 V - 21 W (Halogen) H21W
12V - 16W
12V - 5/21W
12V - 5W
12V - 1.2W
12V - 1.2W
12V - 1.2W
12V - 1.2W
CAUTION
THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DISCONNECTED.
Check tail lights and panel lightning
•
Check that bulb operates properly.
•
Check continuity between the Green cable of 15A fuse C and the Yellow cables of the tail
lights bulbs.
•
Also check continuity of the Green cable of the instrument panel connector.
ELE SYS - 53
SPORTCITY ONE 125
Electrical system
•
High/low-beam light check
•
Check that bulb operates properly.
•
Check continuity of the Green cable between 15A fuse C and light switch.
•
Check that the light switch operate properly.
•
Check continuity of the Black cable between the light switch and the low-beam bulb.
•
Check continuity of the White cable between the light switch and the high-beam bulb.
Fuses
CAUTION
DO NOT REPAIR FAULTY FUSES.
USE RECOMMENDED FUSES ONLY. USING FUSES OF UNSUITABLE CAPACITY MAY SERIOUSLY DAMAGE THE ELECTRICAL SYSTEM OR CAUSE A SHORT CIRCUIT, WHICH MAY
TOTALLY DESTROY YOUR SCOOTER AS WELL AS INJURE YOU.
The vehicle has one fuse located in the battery compartment and two fuses located in the front glove
compartment.
FUSE CHART
1
Specification
Fuse A
2
Fuse B
3
Fuse C
ELE SYS - 54
Desc./Quantity
Capacity: 20 A
Protected circuits: Recharge circuit, oil pressure sensor, oil pressure warning light .
Capacity: 7.5 A
Protected circuits: Start-up circuit, starter motor, stop
light bulb, ECU power supply.
Capacity: 15 A
Protected circuits: Rear light bulb, license plate light
bulb, turn indicator bulb, turn indicator warning light, fuel
gauge, instrument panel lighting bulb, horn, low-beam
bulb, high-beam bulb, high-beam warning light.
SPORTCITY ONE 125
Electrical system
Sealed battery
Commissioning sealed batteries
If the scooter is provided with a sealed battery, the only maintenance required is to check if it is charged
and to recharge it, if necessary. 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 scooter
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 14.40÷14.70V
•
Initial charge current equal to 0.3÷0.5 of the battery rated capacity
•
Charge time:
•
10 to 12 h recommended Minimum 6 h Maximum 24 h
5. Constant-current battery charge mode
6.
•
Charge current equal to 1/10 of the battery rated capacity
Dry-charge battery
WARNING
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.
ELE SYS - 55
Electrical system
SPORTCITY ONE 125
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
MILK, FOLLOWED BY MAGNESIUM MILK, BEATEN EGG OR VEGETABLE OIL. SEEK MEDICAL
ATTENTION IMMEDIATELY.
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° Bé, at a minimum
temperature of 15°C 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 a
density of about 1/10 of the battery
nominal capacity and until the acid
density is about 1.27, corresponding to
31º Bé, and these values are 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.
ELE SYS - 56
SPORTCITY ONE 125
Electrical system
With the battery charged, a density of 30÷32 Bé, corresponding to a specific weight of 1.26÷1.28, must
be at a minimum temperature of 15° C.
A density reading below 20° Bé 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) earth wire marked (-) is connected
to the - negative terminal whereas the other two red wires marked (+) are connected to the + positive terminal.
Battery recharge
WARNING
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.
ELE SYS - 57
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
SPORTCITY ONE 125
Engine from vehicle
Exhaust assy. Removal
•
Rest the vehicle on its centre stand.
•
Undo and remove the two screws «1»
fixing the muffler to the engine.
CAUTION
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS, LET THE ENGINE AND THE MUFFLER TO COOL
OFF AT AMBIENT TEMPERATURE TO AVOID POTENTIAL
BURNS.
Locking torques (N*m)
Nut fixing exhaust manifold to engine 15
•
Undo and remove the screws «2».
•
Remove the muffler.
NOTE
UPON REFITTING, REPLACE THE GASKET BETWEEN
THE EXHAUST MANIFOLD AND THE MUFFLER WITH A
NEW ONE.
Locking torques (N*m)
Muffler plate-engine fixing screw 25.5
Removal of the engine from the vehicle
•
Rest the vehicle on its centre stand.
•
Remove the side fairings.
•
Take out the spark plug tube.
•
Disconnect the starter motor power
connector «1» and the ground lead
«2».
•
Disconnect the generator connector
«3».
ENG VE - 59
Engine from vehicle
•
Disconnect the connector of the automatic starter «4» and the connector of
the temperature sensor «5» and release the wiring.
•
Remove the low-pressure pipe «6»
from the cylinder head.
•
Disconnect the carburettor pipe «7»
from the carburettor.
•
Remove the throttle grip transmission
from the carburettor by acting on the
appropriate set screws and release the
transmission from the engine.
ENG VE - 60
SPORTCITY ONE 125
SPORTCITY ONE 125
•
Engine from vehicle
Unscrew the rear brake set screw «8»
and the two screws «9» and free the
engine from the rear brake transmission.
Locking torques (N*m)
Rear brake adjustment nut 5
CAUTION
SUPPORT THE SCOOTER FIRMLY.
•
Undo the shock absorber lower screw
«10» with washer.
Locking torques (N*m)
Lower part of the shock absorber retaining
nut 42.5
•
Undo the two screws «11»
Locking torques (N*m)
Buffer plate to chassis retaining nut 40
•
Remove the Seeger ring «12».
•
Remove the plate.
ENG VE - 61
Engine from vehicle
•
Undo and remove the engine-rod fulcrum nut «13».
•
Operating on the chassis, lift the vehicle rear part.
•
Completely slide off the engine-rod fulcrum pin.
•
Slide off the engine towards the back.
Locking torques (N*m)
Engine-side swinging arm retaining nut 42.5
ENG VE - 62
SPORTCITY ONE 125
INDEX OF TOPICS
ENGINE
ENG
Engine
Automatic transmission
Transmission cover
- To remove the transmission cover it is necessary
to remove the rear plastic cover first by inserting a
screwdriver in the corresponding slotted holes.
Using the clutch bell lock wrench, remove the driven pulley axle locking nut and recover the washer.
- Remove the cap/dipstick from the engine oil filling
hole.
- Remove the 10 screws and the earth cable fastened under one of them.
- Remove the transmission cover. If this operation
is performed directly on the vehicle, it is necessary
to remove the cooling air coupling and the three air
filter housing retainers.
Specific tooling
020423Y Driven pulley lock wrench
Air duct
- Unscrew the Torx screws fixing the air manifold
bulkhead and remove the bulkhead.
- Remove the 3 screws, then take out the manifold
as well as the filter.
ENG - 64
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
Air duct filter
- Unscrew the 2 fixing screws and slide off the filter.
- Clean with water and milid soap.
Removing the driven pulley shaft bearing
- Remove the clip from the inside of the cover.
- Use the specific tools to remove the bearing from
the crankcase.
CAUTION
USE AN APPROPRIATE REST SURFACE TO AVOID DAMAGING THE COVER PAINT.
Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
ENG - 65
Engine
Refitting the driven pulley shaft bearing
- Heat up the crankcase inside with the hot air gun.
- Insert the bearing in its housing, refit the Seeger
ring.
NOTE
ALWAYS REPLACE THE BEARING WITH A NEW ONE
UPON REFITTING.
Specific tooling
020151Y Air heater
020376Y Adaptor handle
020357Y 32 x 35 mm adaptor
020412Y 15 mm guide
Removing the driven pulley
- Remove the spacer, the clutch bell and the whole
driven pulley unit.
NOTE
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
PULLEY MOUNTED.
Inspecting the clutch drum
- Check that the clutch bell is not worn or damaged.
- Measure the clutch bell inside diameter.
Characteristic
Max. value clutch bell
Max. value: Ø 134.5 mm
Clutch bell standard value
Standard value: Ø 134 - 134.2 mm
ENG - 66
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
Checking the bell working surface eccentricity
- Install the bell on a driven pulley shaft using 2 bearings (inner 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 in 3 positions (Central, internal, external).
- If faults are found, replace the bell.
Specific tooling
020074Y Support base for checking crankshaft alignment
020335Y Magnetic support for dial gauge
Characteristic
clutch bell inspection: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm
ENG - 67
Engine
SPORTCITY ONE 125
Inspecting the clutch
- Check the thickness of the clutch mass friction material.
- The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals.
NOTE
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST
NOT BE DIFFERENT FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN
SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
ENG - 68
SPORTCITY ONE 125
Engine
Removing the clutch
- By means of a calliper spanner, block the clutch
assembly rotation. - With a 46 mm spanner remove the clutch lock nut. - Remove the clutch and
the spring.
CAUTION
UPON REMOVING THE CLUTCH ASSEMBLY LOCK NUT,
PAY ATTENTION TO KEEP THE ASSEMBLY IN ITS SEAT
SO THAT IT DOES NOT COME OUT DUE TO THE SPRING
THRUST
Specific tooling
020565Y Flywheel lock calliper spanner
Pin retaining collar
- Remove the collar with the aid of 2 screwdrivers.
- Remove the 3 guide pins and the movable halfpulley.
Removing the driven half-pulley bearing
- Remove the retaining ring using two flat blade
screwdrivers.
- Using a hammer and pin, knock the ball bearing
out as shown in the figure.
- Remove the roller bearing using the specific extractor.
NOTE
REST THE HALF-PULLEY ON A WOOD SURFACE TO
AVOID DAMAGING THE THREADED RINGLET OF THE
DRIVEN PULLEY UPON REMOVING IT.
Specific tooling
020375Y 28 x 30 mm adaptor
020376Y Adaptor handle
020439Y 17 mm guide
ENG - 69
Engine
Inspecting the driven fixed half-pulley
- Measure the external diameter of the pulley bushing.
Characteristic
Minimum diameter permitted
Ø 40.96 mm
Standard diameter
Ø 40.965 mm
Inspecting the driven sliding half-pulley
- Remove the 2 inner sealing rings and the two Orings.
- Measure the inside diameter of the mobile halfpulley bushing.
Characteristic
Minimum admissible diameter
Ø 41.08 mm
Standard diameter
Ø 41.035 mm
ENG - 70
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
Refitting the driven half-pulley bearing
- Assemble a new roller case using the specific
punch, fit the bearing with the label facing outward
and insert it completely up to the punch on the halfpulley.
NOTE
REST THE HALF-PULLEY ON A WOOD SURFACE TO
AVOID DAMAGING THE THREADED RINGLET OF THE
DRIVEN PULLEY UPON REMOVING IT.
Specific tooling
020424Y Driven pulley roller casing fitting
punch
- To assemble the new ball bearing insert it completely down in its housing with the specific punch
and finally assemble the Seeger ring.
Specific tooling
020375Y 28 x 30 mm adaptor
020376Y Adaptor handle
020439Y 17 mm guide
Refitting the driven pulley
- Check that the faying surfaces between the 2
half-pulleys and the belt do not show any signs of
wear, scoring and grease.
- Insert the new oil seals and O-rings on the movable half-pulley.
- Assemble the half-pulley on the ringlet with the
appropriate protection sheath.
- Make sure the pins and collar are not worn, reassemble the pins and collar.
- Use a greaser with a curved spout to lubricate the
driven pulley unit with around 6 g of grease. This
operation must be done through one of the holes
inside the bushing until grease comes out of the
opposite hole. This operation is necessary to avoid
the presence of grease beyond the O-rings.
Specific tooling
ENG - 71
Engine
020263Y Sheath for driven pulley fitting
Recommended products
AGIP GREASE SM 2 Grease for the tone wheel
revolving ring
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN
KF2K-20
Inspecting the clutch spring
- Measure the unloaded length of the spring of the
movable driven half-pulley.
Characteristic
Standard length:
106 mm
Refitting the clutch
Versione 125
- Refit the clutch assembly following the removal
operations but in reverse order, use the calliper
spanner and lock the nut to the prescribed torque.
CAUTION
USE A BOX-SPANNER WITH SMALL CHAMFER SO AS
NOT TO DAMAGE THE CLUTCH NUT. UPON FITTING THE
CLUTCH ASSEMBLY LOCK NUT, MAKE SURE THE ASSEMBLY IS WELL SECURED IN IT SEAT UNTIL SOME
SCREW THREADS HOLD IT IN PLACE.
Locking torques (N*m)
Locking torque 55 ÷ 60 Nm
ENG - 72
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
Refitting the driven pulley
- Reassemble the clutch bell and spacer.
Drive-belt
During the wear checks foreseen in the scheduled
maintenance, check that the rim bottom of the
toothing does not show signs of incisions or cracks
(see figure): the rim bottom of the tooth must not
have incisions or cracks; if it does, change the belt.
- Check that the driving belt is not damaged.
- Check the width of the belt.
BELT SIZE
Specification
Minimum width
Standard width
Desc./Quantity
21.5 mm
22.5 ± 0.2 mm
ENG - 73
SPORTCITY ONE 125
Engine
Removing the driving pulley
- Lock the driving pulley with the specific tool as
shown in the figure. - Disassemble the central nut
and the Belleville washer, remove the drive and
the 2 washers. - Remove the stationary half pulley
and the steel washer.
Specific tooling
020368Y driving pulley lock wrench
- Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling
free assembled rollers.
- Remove the return rollers plate with the relative
guide pads.
Inspecting the rollers case
- Check that the internal bushing is not abnormally worn and measure inner diameter.
NOTE
DO NOT LUBRICATE OR CLEAN THE BUSHING.
BUSHING ROLLER CONTAINER
Specification
Maximum allowable diameter
Standard diameter
Desc./Quantity
Ø 26.121 mm
Ø 26+0 +0.021 mm
BUSH SLIDE PULLEY
Specification
Minimum diameter permitted
Standard diameter
Desc./Quantity
Ø 25.950 mm
Ø 26-0.020 -0.041 mm
VARIABLE SPEED ROLLERS
Specification
Minimum diameter permitted
Standard diameter
ENG - 74
Desc./Quantity
Ø 18.5 mm
Ø 26±0.1 mm
SPORTCITY ONE 125
Engine
- Check the guide shoes for the variator back-plate
are not worn.
- Check there is no wear in the roller housing, and
the surfaces in contact with the belt on either of the
pulley halves.
- Pre-assemble the movable half-pulley with the
roller contrast plate by placing the rollers as shown
in the figure, that is, during insertion, the closed
side should be on the left side of the pulley thrust.
- Mount the complete bushing unit on the driving
shaft.
ENG - 75
Engine
SPORTCITY ONE 125
- Open the rear pulley and insert the belt observing
the correct direction of rotation.
WARNING
IT IS MOST IMPORTANT THAT WHEN FITTING THE FRONT
PULLEY UNIT, THE BELT IS FREE INSIDE SO AS TO AVOID
A WRONG TIGHTENING OF THE DRIVING HALF-PULLEY.
Refitting the driving pulley
- Reassemble the parts of the unit (internal lining,
fixed half-pulley, external lining, drive and nut),
spread threadlock on the thread and screw the nut
to the prescribed torque.
-Avoid the half-pulley rotation using a calliper
spanner
NOTE
REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT
Specific tooling
020368Y driving pulley lock wrench
Recommended products
Loctite 243 Medium-strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
Locking torque 75 ÷ 83
Refitting the transmission cover
- Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the
oil sump on the transmission cover.
- Replace the cover tightening the 10 screws at the specified torque.
- Refit the oil loading cap/bar.
- refit the steel washer and the driven pulley nut.
- Tighten the nut to the prescribed torque using the lock wrench and the torque wrench tools.
- Replace the plastic cover.
Specific tooling
020423Y Driven pulley lock wrench
Locking torques (N*m)
Transmission cover screws 11 ÷ 13 Driven pulley shaft nut 54 ÷ 60
ENG - 76
SPORTCITY ONE 125
Engine
End gear
Removing the hub cover
- Empty the rear hub through the oil drainage tap
located inside the hub cover
- Remove the brake shoe and relevant spring
- Remove the 7 flanged screws as shown in the
figure.
- Remove the rubber cover and the brake pad lever
sliding unscrewing the relevant retaining screw to
reach the rear of the cover
- Take off the hub cover and relevant gaskets
Removing the wheel axle
Remove the intermediate gear and the complete
hub cover.
ENG - 77
Engine
SPORTCITY ONE 125
Removing the hub bearings
- Check the state of the bearings being examined
(wear, clearance and noisiness). If faults are detected, do the following.
- Use the specific bearing extractor to remove the
three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).
Specific tooling
001467Y009 Bell for OD 42-mm bearings
001467Y013 Calliper to extract 15-mm diameter bearings
Removing the wheel axle bearings
- Take out the clip on the outside of the gearbox
cover.
- Remove the bearing with the adequate tools adequately supporting the hub cover, as shown in the
figure.
Specific tooling
020376Y Adaptor handle
020364Y 25-mm guide
With the appropriate tools, remove the oil seal as
shown in the figure.
Specific tooling
020376Y Adaptor handle
020359Y 42x47-mm adaptor
Removing the driven pulley shaft bearing
If it is necessary to remove the driven pulley shaft, from the relevant bearing and oil seal, remove driven
pulley.
- Extract the driven pulley shaft from its bearing.
- Remove the oil guard using a screwdriver, working from inside the bearing and being careful not to
damage the housing, make it come out of the belt transmission side.
- Remove the seeger ring shown in the figure
ENG - 78
SPORTCITY ONE 125
Engine
With the sectional punch, remove the driven pulley
shaft bearing.
Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020363Y 20 mm guide
See also
Inspecting the hub shaft
- Check the three shafts for wear or distortion of
the toothed surfaces, the bearing housings, and
the oil seal housings.
- In case of anomalies, replace the damaged components.
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted. - Check the capacity of the bearings and the
brake camshaft. - If faults are found, replace the hub cover.
Refitting the driven pulley shaft bearing
- Heat up the parts using the specific heat gun
Specific tooling
020150Y Air heater support
020151Y Air heater
- Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside of
the hub cover using the adequate tools
Specific tooling
020376Y Adaptor handle
ENG - 79
SPORTCITY ONE 125
Engine
- Refit the Seeger ring with the opening facing the
bearing as shown in the figure and fit a new oil
guard flush with the crankcase.
Refitting the wheel axle bearing
- Heat up the parts using the specific heat gun
Specific tooling
020151Y Air heater
020150Y Air heater support
-The wheel axle bearing on the cover, should be assembled with the specific tools
Specific tooling
020364Y 25-mm guide
020360Y Adaptor 52 x 55 mm
020376Y Adaptor handle
•
Assemble the Seeger ring.
•
Assemble the oil seal flush with the internal surface as shown in the figure to
the hub using the adequate tools and
with the seal lip towards the inside of
the hub.
Specific tooling
020376Y Adaptor handle
020360Y Adaptor 52 x 55 mm
Refitting the hub cover bearings
- For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the
specific heat gun.
Specific tooling
020150Y Air heater support
020151Y Air heater
ENG - 80
SPORTCITY ONE 125
Engine
- The three 15 mm bearings must be fitted using
the appropriate tools.
Refitting the hub bearings
- Insert the cover prepared in the crankcase taking
care of inserting the gear of the pulley shaft on the
intermediary gear.
Refitting the ub cover
- Fit a new gasket together with the centring dowels.
- Fit the gearbox cover, making sure the breather
pipe is in the correct position.
- Screw the 7 screws to the specified torque, positioning the support plate of the pipe in the position shown in the figure.
- Remove the control pin of the shoe taking care
so as the long tooth coincides with the groove on
the control lever.
Locking torques (N*m)
Locking torque 24 ÷ 27
Flywheel cover
ENG - 81
Engine
SPORTCITY ONE 125
Cooling hood
-Remove the housing acting on the 4 retaining
screws.
CAUTION
DURING REMOVAL SLIDE THE HOUSING CONNECTOR
ON THE HOUSING.
- Loosen the clamp and remove the carburettor
from the manifold.
-Remove the complete manifold acting on the 2
retainers as shown in the figure.
- Remove the 2 self threading screws, left and right
and the lateral base retaining screw on the crankcase base.
- Take off the housings.
- Remove the gasket seal of the housing on the
head.
NOTE
IF THE FLYWHEEL HOUSING IS NOT REMOVED, IT IS ALSO NECESSARY TO REMOVE THE TWO KNOB SCREWS.
On the vehicles equipped with the engines mentioned if they are losing a full circle at full gas, we suggest
to intervene on the vacuum socket inserting on the inlet manifold widening the hole from 0.4 mm to 1.5
mm. Remember that such operation must have performed on a disassembled manifold which must be
cleaned afterwards.
Cooling fan
- Remove the cooling fan by acting on the three
fixings indicated in the figure.
ENG - 82
SPORTCITY ONE 125
Engine
- Refit the parts in reverse order of the removal
operation.
- Make sure that there are spacers with the two
rear retainers of the housing.
- The long spacers should be in a high position.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL
CONNECTOR.
Removing the stator
- Remove the electric terminal of the minimum oil
pressure switch.
- Remove the two Pick-Up screws and the one for
the wiring harness bracket as well as the two stator
fixing screws shown in the figure.
- Remove the stator and its wiring.
Refitting the stator
- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.
- Place the cable harness as shown in the figure.
NOTE
THE PICK-UP WIRE SHOULD BE POSITIONED BETWEEN
THE UPPER SCREW AND THE REFERENCE PIN AS
SHOWN IN THE DETAIL DRAWING.
Locking torques (N*m)
Stator screw 3 ÷ 4
ENG - 83
Engine
SPORTCITY ONE 125
Flywheel and starting
Removing the flywheel magneto
- Lock the rotation of the flywheel using the calliper
spanner.
- Remove the nut.
CAUTION
THE USE OF A CALLIPER SPANNER OTHER THAN THE
ONE SUPPLIED COULD DAMAGE THE STATOR COILS
Specific tooling
020565Y Flywheel lock calliper spanner
- Extract the flywheel with the extractor.
Specific tooling
008564Y Flywheel extractor
Inspecting the flywheel components
- Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate.
Refitting the flywheel magneto
- Fit the flywheel being careful to insert the key
properly.
- Lock the flywheel nut to the prescribed torque
- Check that the Pick-Up air gap is between 0.34
÷ 0.76 mm.
The air gap cannot be modified when assembling
the Pick-Up.
Different values result from deformations visible
on the Pick-Up support.
NOTE
A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE
IGNITION SYSTEM IDLE SPEED
Locking torques (N*m)
ENG - 84
SPORTCITY ONE 125
Engine
Flywheel nut 52 ÷ 58
Refitting the starter motor
- Fit a new O-ring on the starter and lubricate it.
- Fit the starter on the crankcase, locking the two
screws to the prescribed torque.
NOTE
REFIT THE REMAINING PARTS AS DESCRIBED IN THE
CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL
AND TRANSMISSION CHAPTERS.
Locking torques (N*m)
Starter motor screws 11 ÷ 13
Cylinder assy. and timing system
Removing the timing system drive
- Remove the parts listed below first: transmission
cover, belt driving pulley, oil pump pulley cover and
pinion separator washer.
- Remove the tappet cover.
- Remove the central screw fastener and the automatic valve-lifter retaining cover, as shown in the
figure.
- Remove the return spring of the automatic valve
lifter assembly and the automatic valve lifter assembly and its end of stroke washer.
- Loosen the central screw on the tensioner first.
- Remove the two fixings shown in the figure.
- Remove the tensioner with its gasket.
ENG - 85
Engine
- Remove the internal hex screw and the counterweight shown in the figure.
- Remove the camshaft command pulley and its
washer.
- Remove the command sprocket wheel and the
timing chain.
- Remove the screws indicated in the figure, the
spacer bar and the tensioner pad.
The chain tensioning pad must be removed from
the transmission side. As regards the lower chain
guide pad, it may only be removed after the head
has been removed.
NOTE
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
See also
Electric fan
Removing the cam shaft
- Remove the two screws and the cam shaft retainer shown in the diagram.
- Remove the cam shaft.
ENG - 86
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
- Remove the pin of the rocking levers from the
flywheel side holes.
- Remove the rocking levers and the elastic washer.
NOTE
MARK THE ROCKING LEVERS ASSEMBLE POSITION, SO
AS TO AVOID THE INVERSION OF INLET WITH THE OUTLET.
Removing the cylinder head
- Remove the spark plug.
- Remove the 2 side fixings shown in the figure.
- Loosen the 4 head-cylinder fastening nuts in two
or three stages and in criss-cross fashion.
- Remove the head, the two centring dowels and
the gasket.
NOTE
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH
THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING
BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE DRIVING SHAFT
CHAIN TIGHTENER.
Removing the valves
- Using the specific tool fitted with the element
shown in the figure, remove the cotters, the plates
and the spring between the valves.
Specific tooling
020382Y Tool for removing valve cotters fitted
with part 012
020382Y011 adapter for valve removal tool
ENG - 87
Engine
- Remove the oil seals with the appropriate tool.
- Remove the lower spring supports.
Specific tooling
020431Y Valve oil seal extractor
Removing the cylinder - piston assy.
- Remove the chain guide pad.
- Remove the cylinder base gasket.
CAUTION
TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE
REMOVING THE CYLINDER.
- Remove the two stop rings, the wrist pin and the
piston.
- Remove the 3 piston rings from the piston.
NOTE
BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DURING REMOVAL.
Inspecting the small end
- Measure the internal diameter of the small end
using an internal micrometer.
NOTE
IF THE DIAMETER OF THE ROD SMALL END EXCEEDS
THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF
WEAR OR OVERHEATING REPLACE THE CRANKSHAFT
AS DESCRIBED IN THE "CRANKCASE AND CRANKSHAFT" CHAPTER".
Characteristic
Rod small end check-up: Maximum diameter
15.030 mm
ENG - 88
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
Rod small end check-up: Standard diameter
15 +0.015+0.025 mm
Inspecting the wrist pin
- Check the outer diameter of the gudgeon pin.
Characteristic
Standard pin diameter
14.996 ÷ 15 mm
Minimum diameter permitted
Ø 14.994 mm
- Calculate the piston pin coupling clearance.
NOTE
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.
FOR THIS REASON MEASUREMENT OF THE DIAMETER
MUST BE CARRIED OUT ACCORDING TO THE AXIS OF
THE PISTON.
Characteristic
Piston pin bore - standard diameter
Ø 15+0.001 +0.006
- Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis.
- Measure 36.5 mm from the piston crown's shown
in the figure.
NOTE
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.
FOR THIS REASON MEASUREMENT OF THE DIAMETER
MUST BE CARRIED OUT ACCORDING TO THE AXIS OF
THE PISTON.
- Using a bore meter, measure the inner cylinder
diameter at three different points according to the
directions shown in the figure.
- Check that the coupling surface with the head is
not worn or misshapen.
- Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).
Characteristic
ENG - 89
SPORTCITY ONE 125
Engine
Maximum allowable run-out:
0.05 mm
- The cylinder rectifying operation should be carried out with a surfacing that respects the original
angle.
- The cylinder surface roughness should be 0.9
micron.
- This is indispensable for a good seating of the
sealing rings, which in turn minimises oil consumption and guarantees optimum performance.
- The pistons are oversized due to cylinder rectification and are subdivided into three categories
1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. They
are also classified into 4 categories A-A, B-B, CC, D-D.
Inspecting the piston
- Carefully clean the seal housings.
- Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as
shown in the diagram.
- If the clearance is greater than that indicated in the table, replace the piston.
STANDARD COUPLING CLEARANCE
Name
Top piston ring
Middle piston ring
oil scraper
Description
Dimensions
0.025 ÷ 0.070
0.015 ÷ 0.060
0.015 ÷ 0.060
Initials
Quantity
MAXIMUM ADMITTED CLEARANCE AFTER USE
Name
Top piston ring
Middle piston ring
oil scraper
ENG - 90
Description
Dimensions
0.080 mm
0.070 mm
0.070 mm
Initials
Quantity
SPORTCITY ONE 125
Engine
Inspecting the piston rings
NOTE
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAPTER.
See also
Interventions rules
Removing the piston
- Install piston and wrist pin onto the connecting
rod, aligning the piston arrow the arrow facing towards the exhaust.
- Fit the pin stop ring onto the appropriate tool.
Specific tooling
020430Y Pin lock fitting tool
- With the opening in position indicated on the tool,
take stop ring in the closed position using the
punch.
- Fit the wrist pin stop using the plug as shown in
the figure
NOTE
THE TOOL FOR INSTALLING THE STOP RINGS MUST BE
USED MANUALLY.
CAUTION
USING A HAMMER TO POSITION THE RINGS CAN DAMAGE THE LOCKING HOUSING.
Choosing the gasket
- Provisionally fit the piston into the cylinder, without any base gasket.
- Assemble a dial gauge on the specific tool.
- Set the dial gauge to zero at a contrast plane with
an average preload, for example 5 mm. Keeping
the zero setting position, fit the tool on the cylinder
and lock it with 2 nuts, as shown in the figure.
- Rotate the crankshaft up to the TDC (the inversion point of the dial gauge rotation)
ENG - 91
Engine
- Calculate the difference between the two measurements.
- By means of the table, see the SPECIFICATIONS chapter, identify the cylinder base gasket
thickness to be used upon refitting. Correctly identify the cylinder base gasket thickness to keep the
correct compression ratio.
- Remove the special tool and the cylinder.
Specific tooling
020428Y Support to check piston position
Refitting the piston rings
- Place the oil scraper spring on the piston.
- Refit the oil scraper ring with the join of spring
ends on the opposite side from the ring gap and
the word 'TOP' towards the crown of the piston.
The tapered side of the middle piston ring should
always be facing away from the crown of the piston.
- Fit the middle piston ring with the identification
letter facing the crown of the piston. In any case,
the step must be facing opposite the piston top.
- Fit the top piston ring with the word 'top' or the
reference mark facing the crown of the piston.
- Offset the piston ring gaps on the three rings by
120° to each other as shown in the figure.
- Lubricate the components with engine oil.
NOTE
SO AS TO OBTAIN THE BEST CONFIGURATION THE 2
SEALING RINGS ARE MADE WITH A CONTACT CONICAL
CYLINDER SECTION.
ENG - 92
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
Refitting the cylinder
- Insert the cylinder base gasket with the thickness
determined above.
- Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure.
NOTE
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW
OUT THE LUBRICATION DUCT AND OIL THE CYLINDER
BARREL.
Specific tooling
020426Y Piston fitting fork
020427Y Piston fitting band
Inspecting the cylinder head
- Using a trued bar check that the cylinder head
surface is not worn or distorted.
- Check that the camshaft and rocking lever pin
bearings show no signs of wear.
- Check that the cylinder head cover surface, the
intake manifold and the exhaust manifold are not
worn.
Characteristic
Maximum admitted unevenness: Head check
0.05 mm
STANDARD DIAMETER
Specification
Standard diameter
Standard diameter
Standard diameter
Desc./Quantity
A Ø 32.5 ÷ 32.525
B Ø 20 ÷ 20.021
C Ø 12 ÷ 12.018
ENG - 93
SPORTCITY ONE 125
Engine
Inspecting the timing system components
- Check that the guide shoe and the tensioner shoe
are not worn out.
- Ensure that the camshaft drive pulley, the chain
assembly and the sprocket wheel are not worn.
- If sings of wear are found, replace the parts. if the
chain, pinion or pulley are worn, replace the whole
assembly.
- Remove the central screw and the tensioner
spring. Check that the one-way mechanism is not
worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
assembly.
Inspecting the valve sealings
- Measure the width of the sealing surface on the valve seats.
VALVE SEAL SURFACE
Specification
Inlet valve - seal surface
Outlet valve - seal surface
Desc./Quantity
2.4 ÷ 2.8 mm
2.2 ÷ 2.6 mm
Inspecting the valve housings
- Remove any carbon formation from the valve guides.
- Measure the inside diameter of each valve guide.
- Take the measurement at three different heights in the rocker arm push direction.
ENG - 94
SPORTCITY ONE 125
Engine
Characteristic
Standard drainage guide diameter
5.012 mm
Standard inlet guide diameter
5.012 mm
- If the width of the impression on the valve seat or
the diameter of the valve guide exceed the specified limits, replace the cylinder head.
- Check width of the impression on the valve seat
«V»
Characteristic
Wear limits:
Max. 1.6 mm.
Inspecting the valves
- Measure the diameter of the valve stems in the
three positions indicated in the diagram.
- Calculate the clearance between valve and valve
guide.
Characteristic
Minimum diameter admitted - Inlet:
4.96 mm
Minimum diameter admitted - Outlet:
4.95 mm
Standard clearance - Inlet:
0.013 ÷ 0.040 mm
Standard clearance - Outlet:
0.025 ÷ 0.052 mm
Maximum clearance admitted- Inlet:
0.062 mm
Maximum clearance admitted - Outlet:
0.072 mm
ENG - 95
Engine
- Check that there are no signs of wear on the
contact surface with the articulated register terminal.
- If the sealing surface on the valves is wider than
the specified limit, damaged in one or more points
or curved, replace the valve with a new one.
Characteristic
Standard valve length - Inlet:
80.6 mm
Valve standard length: drainage
79.6 mm
- If the checks above give no failures, you can use
the same valves. For best sealing results, it is advisable to grind the valves. Grind the valves gently
with a fine-grained lapping compound. During
grinding, keep the cylinder head in a horizontal
position. This will prevent the lapping compound
residues from penetrating between the valve stem/
guide coupling.
CAUTION
TO AVOID SCORING THE CONTACT SURFACE, DO NOT
KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER
HEAD AND THE VALVES WITH A SUITABLE PRODUCT
FOR THE TYPE OF LAPPING COMPOUND BEING USED.
- Insert the valves into the cylinder head.
- Test the 2 valves alternatively.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
ENG - 96
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
Inspecting the springs and half-cones
- Check that the upper spring caps and the cotter
halves show no signs of abnormal wear.
- Check the length clearance of the springs.
Characteristic
Valve spring length
33.9 ÷ 34.4 mm
Refitting the valves
- Lubricate the valve guides with engine oil.
- Place the lower plates of the valve spring on the
head.
- Use the punch to fit the 2 sealing rings one at a
time.
Specific tooling
020306Y Punch for assembling valve seal
rings
- Fit the valves, the springs and the spring retaining
caps. Using the appropriate tool with adapter 11,
compress the springs and insert the cotters in their
seats.
Specific tooling
020382Y Tool for removing valve cotters fitted
with part 012
020382Y011 adapter for valve removal tool
Inspecting the cam shaft
- Inspect the cam shaft for signs of abnormal wear
on the cams.
Characteristic
Standard diameter Bearing A
Ø: 32.5 mm -0.025 -0.050 mm
Standard diameter Bearing B
20 -0.020 -0.041 mm
ENG - 97
Engine
Minimum admitted diameter bearing A
Ø: 32.440 mm
Minimum admitted diameter bearing B
Ø: 19.950 mm
Inlet cam height
27.512 mm
Outlet cam height
27.212 mm
- Check there is no wear on the cam shaft retaining
plate and its associated groove on the cam shaft.
- If any of the above dimensions are outside the
specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
Characteristic
Maximum axial clearance admitted
0.42 mm
- Check there are no signs of wear on the automatic valve-lifter cam, or the end-of stroke roller,
or the rubber buffer on the automatic valve-lifter
retaining cover.
- Check that the valve lifting spring has not yielded.
- Replace any defective or worn components.
- Check there are no signs of scoring or wear on
the rocking lever bolt.
Check there are no signs of wear on the pad from
contact with the cam and on the jointed adjustment
plate.
- Measure the internal diameter of each rocking
lever.
-Check that the elastic washer dedicated to the
axle clearance of the rocking levers is not worn. -
ENG - 98
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
In case of anomalies, replace the damaged components.
Characteristic
Minimum diameter permitted
Ø 11.970 mm
Maximum diameter admitted
Ø 12.030 mm
Refitting the head and timing system components
- Fit the timing chain guide pad.
- Insert the head and cylinder centring dowels, fit the head gasket and the head on the cylinder.
-Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque.
Locking torques (N*m)
Locking torque 28 ÷ 30
- Fit the two screws on the outside of the timing
chain side and tighten them to the specified torque.
NOTE
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN USING A COMPRESSED AIR JET.
Locking torques (N*m)
Locking torque 11 ÷ 13
- Fit the timing chain sprocket wheel on the crankshaft, with the chamfer facing the insertion side.
- Loop the timing chain around the sprocket on the
crankshaft.
- Fit the tensioner pad by the cylinder head.
- Fit the spacer and the screw fastener.
- Fit the pin, the outlet rocking lever, the spring
washer and the inlet rocking lever.
- Lubricate the 2 rocking levers through the holes
at the top.
- Lubricate the 2 bearings and insert the camshaft
in the cylinder head with the cams opposing the
rocking levers.
ENG - 99
Engine
- Insert the retention plate and tighten the two
screws shown in the figure to the prescribed torque.
Locking torques (N*m)
Locking torque 4 ÷ 6
- Refit the spacer on the cam shaft.
- Rotate the engine so that the piston is at top dead
centre, using the reference marks on the flywheel
and the crankcase.
- While doing so, fit the chain onto the control camshaft pulley and keep the reference 2V in correspondence with the reference mark on the head.
- Fit the pulley onto the camshaft.
- Assemble the counterweight with the corresponding fixing screw and tighten to the specified
torque.
Locking torques (N*m)
Locking torque 7 ÷ 8.5
-Fit the end-stop ring on the automatic valve-lifter
cam and fit the automatic valve-lifter cam to the
cam shaft.
- Fit the automatic valve-lifter return spring.
- During this operation the spring must be loaded
approximately 180°.
NOTE
GREASE THE END STOP RING TO PREVENT IT COMING
OUT AND FALLING INTO THE ENGINE.
ENG - 100
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
- Fit the automatic valve-lifter retaining dish, using
the counterweight screw fastener as a reference.
- Tighten the clamping screw to the prescribed torque.
Locking torques (N*m)
Locking torque 12 - 14
- Set the tensioner cursor in the rest position.
- Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed
torque.
Locking torques (N*m)
Locking torque 11 ÷ 13
- Insert the chain tensioning screw, together with the spring and washer, tightening it to the prescribed
torque.
Locking torques (N*m)
Locking torque 5 - 6
- Adjust the valve clearance.
- Fit the spark plug
Characteristic
Spark plug
Champion RG6YC
Electric characteristic
Electrode gap
0.8 mm
Locking torques (N*m)
Locking torque 12 - 14
- Assemble the casing sealing gasket on the head.
On the fitting direction, use the supplements on the
timing side as reference.
- Assemble the screw fixing the housing to the
crankcase to the specified torque and the 2 selfthreading screws joining the half-shells.
- Take care that the gasket is well inserted in its
housing during the assembly stage.
- Place the spark plug access cap.
ENG - 101
Engine
Locking torques (N*m)
Locking torque 3 ÷ 4
- Fit the inlet manifold and lock the 2 screws to the
specified torque.
- Fit the carburettor onto the inlet manifold and lock
the clamp
NOTE
FIT THE CARBURETTOR THROUGH THE SUPPLEMENT
ON THE MANIFOLD.
Locking torques (N*m)
Locking torque 11 ÷ 13
- Refit the cylinder head cover, tightening the 4
clamping screws to the prescribed torque.
- Refit the fan and the housing.
- Reassemble the oil pump control, the chain compartment cover, the by-pass and the oil sump as
described in the lubrication chapter.
- Reassemble the driving pulley, the belt and the
transmission cover as described in the transmission chapter.
Locking torques (N*m)
Locking torque 11 ÷ 13
Crankcase - crankshaft
- Precautionary remove the following units:
transmission cover, driving pulley, driven pulley
and belt, rear hub cover, gears, bearings and oil
seals as described in the transmission chapter.
- Remove the oil sump, the by-pass, the chain
compartment cover and the oil pump as in the lubrication chapter.
- Remove the flywheel cover, the fan, the flywheel
and the stator as described in the magneto flywheel chapter.
- Remove the oil filter and the oil pressure bulb.
- Remove the cylinder-piston-head unit as described in the cylinder head timing system chapter.
ENG - 102
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
- Remove the 2 retainers indicated in the figure
and the starter motor.
- Before opening the crankcase, it is advisable to
check the axial clearance of the crankshaft. To do
this, use a plate and a support with specific tool
dial gauge.
Specific tooling
020262Y Crankcase splitting strip
020335Y Magnetic support for dial gauge
Characteristic
Standard clearance
0.15 ÷ 0.40 mm
Splitting the crankcase halves
Remove the 11 coupling screws to the crankcase.
- Separate the crankcase while keeping the crankshaft in one of the two halves of the crankcase.
Remove the crankshaft.
CAUTION
IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY FALL.
- Remove the coupling gasket of the crankcase
halves.
- Remove the two screws and the internal cover
shown in the diagram.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE DRIVING SHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSHINGS. FAILURE TO OBSERVE THIS PRECAUTION CAN
DAMAGE THE MAIN BUSHINGS.
ENG - 103
Engine
- Remove the oil guard on the flywheel side.
- Remove the oil filter fitting shown in the diagram
- Check the axial clearance on the connecting rod.
Characteristic
Standard clearance
0.20 ÷ 0.50 mm
- Check the radial clearance on the connecting rod.
-Check the surfaces that limit the axial free-play
are not scored and measure the width of the crankshaft between these surfaces, as shown in the
diagram.
CAUTION
BE CAREFUL NOT TO LET THE MEASUREMENT BE AFFECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS.
Characteristic
Standard clearance
0.036 ÷ 0.054 mm
- If the axial clearance between crankshaft and
crankcase is exceeding and the crankshaft does
not have any defect, the problem must be due to
either excessive wear or wrong machining on the
crankcase.
CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH
IS WITHIN THE STANDARD VALUES AND THE SURFACES
SHOW NO SIGNS OF SCORING.
Characteristic
Distance between the shoulders
55.67 ÷ 55.85 mm
ENG - 104
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
- Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces
shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart
below.
STANDARD DIAMETER
Specification
Class 1
Class 2
Desc./Quantity
28.998 ÷ 29.004
28.004 ÷ 29.010
Inspecting the crankshaft alignment
To install the drive shaft on the support and to
measure the misalignment in the 4 points indicated
in figure.
- Check that the driving shaft cone, the tab seat,
the oil seal capacity, the toothed gear and the
threaded tangs are in good working order.
- In case of failures, replace the crankshaft.
The connecting rod head bushings cannot be replaced. For the same reason, the connecting rod
may not be replaced and, when cleaning the
crankshaft, be very careful that no impurities get in
through the shaft's lubrication holes.
In order to prevent damaging the connecting rod
bushings, do not attempt cleaning the lubrication
duct with compressed air.
- Make sure that the 2 caps on the crankpin are
properly fitted.
- A wrong installation of a cap can seriously affect
the bushing lubrication pressure.
NOTE
THE MAIN BEARINGS ARE NOT GRINDABLE
ENG - 105
Engine
Specific tooling
020074Y Support base for checking crankshaft
alignment
Characteristic
Off-line maximum admitted
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
Inspecting the crankcase halves
- Before proceeding to check the crankcase
halves, thoroughly clean the all surfaces and oil
ducts.
- On the transmission side crankcase half, take
particular care cleaning the housing and oil ducts
for the following components: the oil pump, the oil
by-pass valve, the main bushings and the cooling
jet on the transmission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the valve, which regulates the oil pressure.
NOTE
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES THE
PISTON TOP COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAK CAN CONSIDERABLY DECREASE THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
- On the flywheel side crankcase half, take particular care cleaning the oil ducts for the main bushings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the flywheel side oil seal.
NOTE
THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH
A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD
LUBRICATION; THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP. THE JET CLOGGING IMPAIRS THE HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET FAILURE CAUSES A DECREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
ENG - 106
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
- Inspect the mating surfaces on the crankcase
halves for scratches or deformation, taking particular with the surfaces that mate with the cylinder
and the mating surfaces between the crankcase
halves.
- Defects in the crankcase coupling gasket or the
surfaces indicated in the figure can cause a drop
in the oil pressure and affect the lubricating pressure for the main bushings and the connecting rod.
- Check the main bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and dimensions.
Inspecting the crankshaft plain bearings
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure
(4 bar) and a good oil flow rate; the bushings must
be correctly positioned so as not to obstruct the oil
supply channels.
- The main bushings are comprised of two halfbearings, one containing holes and channels for
lubrication and the other solid.
- The solid half-bearing is intended to stand the
thrusts caused by combustion, and for this reason
it is arranged opposed the cylinder.
- To prevent shutters in the oil feeding channels,
the matching surface of the two half-bearings must
be perfectly orthogonal to the cylinder axis, as
shown in the figure.
- The oil supply channel section is also affected by
the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
NOTE
ENG - 107
SPORTCITY ONE 125
Engine
TO KEEP THIS POSITION OF THE BUSHINGS ON THE
CRANKCASE, FITTING IS FORCED ON STEEL RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE
HALVES.
Characteristic
Standard driving depth
1.35 ÷ 1.6
- Check the inside diameter of the main bushings in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing half. see diagram.
- The standard bushing diameter after driving is variable on the basis of a coupling selection.
- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like
those for the crankshaft.
3 - The main bushings are subdivided into 3 thickness categories; see the table below:
NOTE
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE
THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.
MAIN BEARINGS
Specification
B
C
E
Refitting the crankcase halves
- Fit the internal bulkhead by locking the two
screws to the prescribed torque.
Locking torques (N*m)
Locking torque 4 ÷ 6
ENG - 108
Desc./Quantity
Blue
Yellow
Green
SPORTCITY ONE 125
Engine
- Fit the oil filter joint and tighten it to the prescribed
torque.
- Place a new gasket on one of the crankcase
halves, preferably on the transmission side, together with the locating dowels.
Locking torques (N*m)
Locking torque 27 ÷ 33
- Lubricate the main bushings and insert the crankshaft in the transmission side crankcase half.
- Reassemble the two crankcase halves.
- Fit the 11 screws and tighten them to the prescribed torque.
NOTE
WHEN FITTING THE HALF CASING AND THE CRANKSHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREADED TANGS.
Locking torques (N*m)
Locking torque 11 ÷ 13
- Lubricate the flywheel oil seal.
- Use the appropriate tool to assemble the oil seal.
- Fit a new O-ring on the pre-filter and lubricate it.
- Insert the pre-filter on the engine with its corresponding cover to the specific torque.
NOTE
REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER PLANE, TO ENSURE
BETTER SEALING PERFORMANCE.
NOTE
FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN
AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEALING.
Specific tooling
020425Y Punch for flywheel-side oil seal
Locking torques (N*m)
Locking torque 24 ÷ 30
Lubrication
ENG - 109
Engine
Conceptual diagrams
ENG - 110
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
Oil pressure check
- After removing the cover protections as described in the "Flywheel" chapter, disconnect the electrical connexion of the minimum oil pressure
switch and then remove the switch.
- With the engine idling at 1650 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 0.5 ÷ 1.2 atm.
- With the engine idling at 6000 rpm and the oil
temperature at ~90°C, check that the oil pressure
is between 3.2 ÷ 4.2 atm.
- Remove the appropriate tools once the measurement is complete, refit the oil pressure switch
and washer, tightening it to the prescribed torque
and fit the fan cover.
- If the oil pressure is outside the specified limits,
in the following order, check: the oil filter, the oil
by-pass valve, the oil pump and the crankshaft
seals.
NOTE
THE CHECK MUST BE CARRIED OUT WITH OIL AT THE
CORRECT LEVEL AND WITH AN OIL FILTER IN GOOD
CONDITION.
Characteristic
Minimum pressure admitted
3.2 atm.
Locking torques (N*m)
Locking torque 12 ÷ 14 (also valid for the control connector).
Crankshaft oil seals
ENG - 111
Engine
Removal
- First remove the transmission cover and the complete driving pulley
- Install the base of the appropriate tool on the oil
guard using the screws provided.
- Screw the threaded bar onto the base of the tool
and extract the oil guard.
Specific tooling
020622Y Transmission-side oil guard punch
Refitting
- Prepare the new oil guard, lubricating the sealing
lip. Warning: do not lubricate the surface for keying
onto the engine crankcase.
CAUTION
DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO
THE ENGINE CRANKCASE.
ENG - 112
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
- Preassemble the oil seal with the appropriate
tool, positioning the screws
- Place the sheath over the crankshaft
- Insert the tool with the oil seal on the crankshaft
until it comes into contact with the crankcase
CAUTION
ORIENT THE OIL GUARD BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. WHEN THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
GUARD. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL GUARD
SHEATH.
- Orientate the oil guard by inserting the bracket
which is part of the specific tool.
- Tighten the threaded bar onto the crankshaft as
far as it will go.
ENG - 113
Engine
SPORTCITY ONE 125
- Use the nut to move the base of the tool until you
can see end of the oil seal driving stroke
- Remove all of the tool components following the procedure in reverse order
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE
ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN.
Oil pump
Removal
- Remove the chain cover acting on the 3 retaining
screws as shown in the figure and the relevant
copper washer.
- Extract the cover using the appropriate appendages.
NOTE
WITH THE AIM OF AVOIDING DAMAGING THE APPENDAGES PRACTICE A RUN PARALLEL TO CRANKSHAFT.
- Remove the cover of the pump control pulley using the two retainers, as shown in the figure.
- Block the rotation of the oil pump control pulley
using a screwdriver inserted through one of its two
holes.
ENG - 114
SPORTCITY ONE 125
Engine
- Remove the central screw with Belleville washer,
as shown in the diagram.
- Remove the chain with the pulley.
- Remove the crankshaft control pinion.
- Remove the oil pump acting on the 2 retainers as
shown in the figure.
- Remove the oil pump seal.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover.
- Remove the clip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with petrol and compressed air.
- Reassemble the rotors in the pump body, keeping the two reference marks visible Replace the
clip.
- Using a thickness gauge, check the distance between the rotors in the position shown in the figure.
Characteristic
Maximum clearance admitted
0.12 mm
ENG - 115
Engine
Measure the distance between the outer rotor and
the pump body; see figure.
Characteristic
Admissible limit clearance:
0.20 mm
Check the axial clearance of the rotors with a trued
bar as reference, as shown in the figure.
Characteristic
Limit values admitted:
0.09 mm
Refitting
- Check there are no signs of wear on the oil pump
shaft or body.
- Check there are no signs of scoring or wear on
the oil pump cover.
- If you detect non-conforming measurements or
scoring, replace the faulty parts or the assembly.
- Fit the pulley to the pump, the central screw to
the specified torque and the belleville washer.
-Fit the oil pump cover, by tightening the two
screws to the prescribed torque.
NOTE
FIT THE BELLEVILLE WASHER SO THAT ITS OUTER
(CURVED) RIM TOUCHES THE PULLEY.
Locking torques (N*m)
Central screw 12 ÷ 14 Nm Cover screws 0.7 ÷ 0.9 Nm
ENG - 116
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
Removing the oil sump
- Remove the oil filler plug, the transmission cover,
the complete drive pulley assembly with belt and
the sprocket wheel, as described in the Transmission chapter.
- Drain the oil from the sump as described above.
- Remove the 7 screws indicated in the figure and
the 2 rear brake transmission fixing brackets.
- Remove the spring, the by-pass piston and the
gasket shown in the second image.
Inspecting the by-pass valve
- Check the unloaded spring length.
- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and
that it guarantees a good seal.
- If not, eliminate any impurities or replace defective parts.
Characteristic
By-pass check up: Standard length
54.2 mm
ENG - 117
Engine
Refitting the oil sump
- Refit the by-pass valve plunger in its housing.
- Insert the pressure-regulating spring.
- Fit a new sump seal.
- Refit the sump, taking care to locate the spring in
the appropriate recess machined into the inside of
the sump.
- Refit the rear brake transmission support brackets and the screws in the reverse order from which
they were removed.
- Tighten the screws to the prescribed torque.
- Refit the drive pulley assembly, the drive belt, the
sprocket wheel and the transmission cover, as described in the "Transmissions" chapter.
- When testing the lubrication system, refer to
the "Crankcase and Crankshaft" chapter, regarding lubrication of the crankshaft and connecting rod
Locking torques (N*m)
Locking torque 11 ÷ 13
Fuel supply
With the multimeter, check if the potentiometer is
working correctly by placing the probes on both
contactors indicated in the photograph .
With throttle valve completely closed, the resistance value should be approx. 1.3 kOhm.
With throttle valve completely open, the resistance
value should be approx. 4.05 kOhm.
ENG - 118
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
Removing the carburettor
- To detach the carburettor from the engine, it is
necessary to move the air filter and remove the
throttle control transmission, the automatic starter
connection, the clamps anchoring the carburettor
to the filter housing and to the inlet manifold, the
air delivery pipe to the diaphragm, the heater, the
intake fitting and the TPS cable.
- Remove the heater
- Remove the protection, the bracket and the starter acting on the screw shown in the figure.
- Remove the 2 screws and the starter support with
the gasket.
ENG - 119
Engine
- Remove the 4 fixing screws shown in the figure
and the vacuum chamber cover.
WARNING
DURING THE REMOVAL OF THE CARBURETTOR COVER
TAKE SPECIAL CARE NOT TO RELEASE THE SPRING
ACCIDENTALLY.
- Remove the vacuum valve together with the diaphragm.
- Unscrew the bayonet joint 1/8 of a turn and remove, take out the spring and vacuum valve needle
ENG - 120
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
- Remove the 4 screws indicated in the figure.
- Remove the chamber with the accelerating
pump, its control and gasket.
- Remove the oil pump seal.
- Remove the intake and outlet valves of the intake
pump from the tank
NOTE
CAUTION, THE ACCELERATION PUMP VALVES ARE
MADE UP OF NOZZLES, SPRING AND BALL.
NOTE
AVOID REMOVING THE PISTON OF THE PUMP AND ITS
CONTROL.
Adequately support the carburettor and using a
rod and hammer remove the float pin acting from
the throttle control side.
- Remove the float and the plunger.
- Remove the maximum nozzle
ENG - 121
Engine
-Remove the maximum nozzle.
-Remove diffuser.
ENG - 122
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
- Remove the sprayer.
NOTE
WHEN CLEANING THE CARBURETTOR BODY REMOVE
THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO
REMOVE IT AS THIS WILL ONLY DAMAGE IT.
-Remove the minimum nozzle.
- Remove the minimum flow set screw and the
spring.
CAUTION
DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE
CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE,
PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR
PROGRESSIONS AND INLET NOZZLE, MINIMUM AND
MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL
SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNECTION SCREWS. THE FIXING SCREWS ARE CAULKED AFTER ASSEMBLY AND THEIR REMOVAL DAMAGES THE
SHAFT.
ENG - 123
Engine
SPORTCITY ONE 125
Refitting the carburettor
- Before refitting, wash the carburettor body accurately with petrol and compressed air.
- Pay special attention to the fuel supply pipe and
the plunger seat.
- For maximum circuit, check the air adjustment is
correct as shown in the figure.
- For the minimum circuit, make sure the following
points are properly cleaned: air gauging, outlet
section controlled by flow screw, progression
holes near the throttle valve.
- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the
nozzle support hides other inaccessible internal calibrations.
- Blow the intake nozzle properly.
NOTE
THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE
THROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAYING.
- Check that there are 5 closing ball joints for the operating pipes on the carburettor body.
ENG - 124
SPORTCITY ONE 125
Engine
- Check that the coupling surfaces, the tank and the diaphragm are not dented.
-Check that the depression valve housing pipe is not scratched.
- Check that the throttle valve and the shaft do not show abnormal wear.
- Check that the plunger seat does not show abnormal wear.
- Replace the carburettor in case of irregularities.
- Check that the return spring of the accelerating pump rocking lever is not deformed by over-stretching.
NOTE
TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.
- Wash and blow the minimum nozzle properly and
reassemble it.
- Properly wash and blow the components of the
sprayer maximum circuit, the diffuser and the nozzle.
- Introduce the sprayer in the carburettor body with
the shortest cylindrical part directed to the diffuser.
- Assemble the diffuser making sure the sprayer is
being adequately inserted and lock it.
-Assemble the maximum nozzle.
- Check that the tapered pin does not show signs
of wear on the sealing surfaces of the shock absorber pin and the return clamp.
- Replace the rod if worn out.
- Check that the float is not worn on the pin housing or on the contact plate with the plunger and that
there are no fuel infiltration.
- Replace it in case of anomalies.
ENG - 125
SPORTCITY ONE 125
Engine
- Introduce the float with the rod on the fuel feeding tube side.
NOTE
INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY
- Remove the drainage screw from the tank, wash
and blow it properly and make sure the acceleration pump pipes are clean.
- Operate the acceleration pump piston repeatedly
and blow with compressed air.
- Reassemble the acceleration pump valves following this order:
INTAKE VALVE (A)
•
Spring
•
Ball
•
Nozzle
IN VALVE (M)
•
Ball
•
Spring
•
Nozzle
NOTE
THE IN VALVE NOZZLE, CORRESPONDING TO THE ACCELERATION PUMP, IS MILLED.
-Check the screw tightness introducing a small
amount of fuel in the tank.
- Assemble a new gasket on the tank.
- Assemble the tank on the carburettor body fastening the 4 screws.
- Check that the control roller is free to rotate in its
own seat.
NOTE
MAKE SURE THE TANK GASKET IS CORRECTLY INTRODUCED
NOTE
AVOID DEFORMING THE ACCELERATION PUMP CONTROL ROCKING LEVER.
- Wash and blow the flow screw properly.
- Check that screw is not deformed and/or rusty.
- Assemble the spring on the screw.
- Screw the flow screw on the carburettor body.
ENG - 126
SPORTCITY ONE 125
Engine
- The screw final position should be determined by an exhaust fume analysis.
- Adjust the carburettor by turning the screw twice from the close position.
Level check
- Place the carburettor inclined as shown in the figure.
- Check that the float reference is parallel to the tank coupling surface
- If different positions are detected, change the plunger control metal plate direction to obtain the position
described above.
Inspecting the valve and needle
- Check that the tapered pin of the vacuum valve does not show wear.
- Check that the depression valve does not show threads on the external surfaces.
- Check that the vacuum intake hole is not clogged.
- Check that the diaphragm is not damaged or has hardened, otherwise replacement the whole valve.
- Insert the tapered pin into the vacuum valve housing.
- Reassemble the vacuum valve on the carburettor body taking care that the tapered pin is inserted into
the sprayer.
NOTE
THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE POSITION.
ENG - 127
Engine
SPORTCITY ONE 125
- Reassemble the spring with the pin lock.
- Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on
the cover.
- Tighten the screws.
ENG - 128
SPORTCITY ONE 125
Engine
- Wash and blow dry the filter sponge of the ambient pressure intake.
- Reassemble the filter with its clamp.
ENG - 129
Engine
SPORTCITY ONE 125
- Wash and blow dry the starter support.
Assemble a new gasket on the carburettor body and tighten the 2 fixing screws.
Inspecting the automatic choke device
- Check that the automatic starter piston is not deformed or rusty.
- Check that the piston slides freely from the seat to the support.
- Check that the piston sealing gasket is not deformed.
- The starter must be more or less functional depending on the ambient temperature.
- Measure the protrusion of the piston as shown in the figure and check its corresponding value.
- Make sure that the starter is adjusted for the ambient temperature.
- The starter should disconnect progressively by means of electric heating.
- Check the starter resistance when adjusted to the ambient temperature.
With a 12V battery power the automatic starter and check that the piston protrudes as much as possible.
ENG - 130
SPORTCITY ONE 125
Engine
- The correct warm up time depends on the ambient temperature.
- If protrusion, resistance or timing values are different from the ones prescribed, replace the starter.
- Assemble the starter to the carburettor being careful to position the O-Ring correctly, insert the plate
with the machined side contacting the starter, tighten the fixing screws.
- Position the starter as shown in the figure.
- Assemble the protection casing.
NOTE
TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION NOT TO GENERATE SHORT CIRCUITS
USE A CABLE SECTION WITH A TERMINAL SUITABLE TO BE CONNECTED TO THE STARTER.
Characteristic
Starter pin travel
10 mm (at 24°)
Starter resistance
20 Ohm (at 24°)
Check the automatic starter: Keihin maximum time
5 min
ENG - 131
Engine
ENG - 132
SPORTCITY ONE 125
SPORTCITY ONE 125
Engine
Adjusting the idle
- The engine does not require frequent idle speed
adjustments, but it is essential to strictly follow certain rules when adjusting the idle speed.
- Before adjusting the carburettor make sure that
the lubrication requirements and valve clearance
are met, timing is respected, the spark plug is in
optimum conditions, the air filter is clean and
sealed, and the exhaust system is sealed.
- Warm up the engine letting it run at 50 Km/h for
at least 5 minutes.
- Connect the multimeter thermometer (020331y)
to the sump, using a cap with oil expressly prepared for probes.
- Start the engine and before adjusting idle speed,
make sure that the oil temperature is between
70÷80 °C
- Using the rpm indicator or any other instrument
(020332y), adjust the idle screw to obtain 1600
rpm ÷ 1700 rpm.
NOTE
THE WASTED SPARK IGNITION SYSTEM OFFERS REMARKABLE POWER. READINGS MAY NOT BE ACCURATE IF INADEQUATE RPM INDICATORS ARE USED.
CORRECT COUPLING OF THE RPM INDICATOR WILL BE
INDICATED WHEN IT CAN ALSO READ RPM OVER 6000 ÷
8000
ENG - 133
INDEX OF TOPICS
SUSPENSIONS
SUSP
SPORTCITY ONE 125
Suspensions
Front
Removing the front wheel
CAUTION
WHEN REMOVING OR REFITTING THE WHEEL, PAY SPECIAL ATTENTION NOT TO DAMAGE
THE BRAKE CABLE, THE DISCS AND THE PADS. BEFORE CARRYING OUT THE FOLLOWING
OPERATIONS, COOL DOWN THE ENGINE AND THE MUFFLER TO AMBIENT TEMPERATURE
TO AVOID POSSIBLE BURNS.
•
Rest the vehicle on its centre stand.
•
Place a support under the vehicle so that the wheel can move freely and the vehicle does
not fall.
CAUTION
MAKE SURE THE SCOOTER IS STABLE AND FIRM. IF IT FALLS, IT MAY INJURY YOU OR OTHER
PEOPLE, DAMAGE THE VEHICLE ITSELF OR ANY ADJACENT OBJECTS.
•
Loosen the two locking screws of the
wheel axle «1».
•
Loosen the wheel axle fixing screw
«2».
•
Slide off the axle and remove the
wheel.
CAUTION
NEVER TOUCH THE FRONT BRAKE LEVER ONCE THE
FRONT WHEEL IS REMOVED. DOING SO MAY CAUSE THE
CALLIPER PLUNGERS TO COME OUT AND THE BRAKE
FLUID TO SEEP THROUGH.
SUSP - 135
Suspensions
SPORTCITY ONE 125
Front wheel hub overhaul
WHEEL BEARINGS
•
Remove the front wheel.
•
Keep the wheel level by means of two
wooden wedges.
•
With the appropriate pliers and tool remove the wheel bearing on the side the
odometer detects movement.
•
Slide off the internal spacer.
•
Use appropriate handle, adaptor and
guide to extract the bearing and the
spacer bushing on the brake disc side;
insert handle on the side the odometer
detects movement.
•
Check that the bearings do not show
flaws or jamming. Otherwise, replace
them.
•
Check that the internal spacer does not
show abnormal wear. Otherwise, replace it.
•
With a hot air gun heat the seat of the
bearing on the brake calliper side.
•
With an appropriate tool refit the bearing on the brake disc side.
•
Insert the spacer bushing on the brake
disc side.
•
With a hot air gun heat the seat of the bearing on the side the odometer detects movement.
•
Insert the internal spacer with the centring ring facing the brake disc side.
•
Use an appropriate tool to insert the bearing on the odometer movement detector side.
Specific tooling
SUSP - 136
SPORTCITY ONE 125
Suspensions
001467Y009 Bell for 42 mm outside diameter bearings
001467Y014 Pliers to extract Ø15 mm bearings
020357Y 32 x 35 mm adaptor
020376Y Adapter handle
020412Y 15 mm guide
020456Y Ø24 mm adaptor
WHEEL RIM INSPECTION
•
Make sure that the rim is not deformed
or cracked. Replace it if necessary.
•
Check wheel eccentricity. If tolerance
limits are exceeded, check the rim and
the bearings. If necessary, replace the
wheel.
Characteristic
Eccentricity limits:
Vertical: 2 mm (0.07874 in)
Horizontal: 2 mm (0.07874 in)
•
Check the wheel balance.
•
Check wheel on the wheel balancer and turn it several times, paying attention to its position
when it stops. If the wheel is steadily balanced, it will not always stop at the same point. If
it always stops at the same point, the wheel is not balanced and must be balanced. Place
weights on the lightest part of the wheel so that it does not stop any more at a particular
point after being turned several times.
Refitting the front wheel
CAUTION
WHEN REMOVING OR REFITTING THE WHEEL, PAY SPECIAL ATTENTION NOT TO DAMAGE
THE BRAKE CABLE, THE DISCS AND THE PADS. BEFORE CARRYING OUT THE FOLLOWING
OPERATIONS, COOL DOWN THE ENGINE AND THE MUFFLER TO AMBIENT TEMPERATURE
TO AVOID POSSIBLE BURNS.
SUSP - 137
Suspensions
•
Apply a thin layer of lubricating grease
inside the speedometer transmission,
in the external seats of the wheel hub
and on the wheel axle.
•
Place the speedometer transmission
on the front wheel
•
Place the wheel between the fork rods
by inserting correctly the odometer
transmission in the housing on the fork
rod.
•
Insert the fork shaft and screw the nut
«1» to the prescribed torque.
Locking torques (N*m)
Wheel pin to fork fixing nut 46.5
•
Tighten the two locking «2» screws of
the wheel axle.
Locking torques (N*m)
Wheel pin hub fixing screw 10
Handlebar
Removal
NOTE
SUSP - 138
SPORTCITY ONE 125
SPORTCITY ONE 125
Suspensions
IF THE HANDLEBAR IS REMOVED TO TAKE OUT THE FORK, IT IS NOT NECESSARY TO REMOVE THE BRAKE TRANSMISSION AND THE SUPPLY CABLES OF THE STOP BUTTONS.
•
Remove the front and rear handlebar
covers.
•
Disconnect the brakes transmission
and the supply cables of the stop buttons.
•
Unscrew the nut «1» and collect the
washer.
•
To refit, carry out the removal operations but in reverse order and tighten the screw «1» to
the prescribed torque.
Locking torques (N*m)
Handlebar to headstock fixing nut 52.5
Front fork
SUSP - 139
Suspensions
SPORTCITY ONE 125
REMOVAL
•
Remove circlip «7», and the two
screws «8» and slide off the stem.
•
Undo screw «6».
•
Remove the components including the
spring.
•
Drain the oil into a collecting container.
•
Undo screw «3», remove the stem and
the pumping member.
SERVICE
Stem
•
Check the sliding surface for scorings and/or scratches.
•
If the scorings are deep, replace the stem.
Sleeve
•
Check that it is not damaged and/or cracked.
•
If there are signs of excessive wear or damage, replace the affected component.
•
Replace oil seal «4» and the dust guard «5» and fit it once you have lubricated its seat.
•
Replace the O-ring on cap «1»
•
Replace sealing washer «2»
FITTING
•
Refit the stem and the pumping member and tighten screw «3» with its washer «2».
•
Pour the recommended quantity of specific oil into the stem unit.
•
Insert the spring and components.
•
Undo screw «6».
Characteristic
Depth of fork oil level from the rim - without spring - fork included
85 mm
Steering column
SUSP - 140
SPORTCITY ONE 125
Suspensions
Removal
•
Rest the vehicle on its centre stand.
•
Place a support under the vehicle so that the wheel can move freely and the vehicle does
not fall.
CAUTION
MAKE SURE THE SCOOTER IS STABLE AND FIRM.
•
Remove the handlebar.
•
Remove the front brake calliper.
•
Release the fork from the odometer cable and from the front brake calliper
pipe.
•
Loosen the tightening ring nut «1» and
collect the shim washer «2».
Locking torques (N*m)
Upper ring nut 37.5
SUSP - 141
Suspensions
•
SPORTCITY ONE 125
Remove the upper ring «3» of the upper bearing.
•
Slide the fork and collect the cage with
the balls of the upper bearing.
Locking torques (N*m)
Lower ring nut 13
•
Remove the balls retainer «7» of the
lower bearing from the steering tube .
•
Insert a punch inside the steering tube housing on the chassis and take out the bearing seats
on the chassis «5» e «6» by tapping with a hammer.
•
Carefully wash the bearings components.
•
Check wear status of the upper rings «2» and «6» and of the lower rings «5» and «8» of the
bearings.
•
To refit, carry out the removal operations but in reverse order:
•
Appropriately lubricate the bearings with recommended products.
Steering bearing
Checking bearing clearance
To check the steering, it is necessary to:
•
Park the vehicle on its centre stand.
•
Place the support under the scooter with a soft cloth between them so that the front wheel
can move freely and the scooter does not fall.
SUSP - 142
SPORTCITY ONE 125
Suspensions
CAUTION
MAKE SURE THE SCOOTER IS STABLE AND FIRM.
NOTE
WHEN CARRYING OUT THIS OPERATION, PAY ATTENTION NOT TO MISTAKE THE CENTRE STAND CLEARANCE WITH THAT OF THE FORK. REPEAT THIS TEST
SEVERAL TIMES BEFORE DECIDING IF THE FORK HAS
TO BE ADJUSTED.
•
Hold the fork sleeves and pull the fork forwards and backwards, with the steering in forward
position.
•
There should be no clearance, neither forwards nor backwards. If there is some clearance,
the fork bearings must be adjusted.
Adjusting bearing clearance
•
Remove the shield and the shield back plate.
•
Loosen the tightening nut «1» using an adequate open wrench.
CAUTION
DO NOT TIGHTEN THE ADJUSTMENT NUT «2» TOO MUCH BECAUSE IT MAY DAMAGE THE
STEERING BEARINGS.
•
Tighten the adjustment nut «2» until
the the bearing clearance is completely
eliminated.
•
Check clearance as described above.
Make sure the front fork can move all
long its stroke, from left to right or vice
versa, rotating freely and smoothly.
•
Keep the adjustment nut «2» into position using an adequate wrench and
tighten the tightening nut «1». Check
bearing clearance again after tightening the nut to make sure the adjustment
is still correct.
Locking torques (N*m)
Lower ring nut 13 Upper ring nut 37.5
Rear
SUSP - 143
Suspensions
SPORTCITY ONE 125
Removing the rear wheel
•
Rest the vehicle on its centre stand.
•
Remove the muffler.
•
Use a screwdriver to remove the plastic cap.
•
Remove the split pin «1» and the cap
«2».
•
Pull the rear brake and keep it pulled
with a clamp.
•
Unscrew the wheel fixing nut and collect the washer.
•
Take out the wheel from its housing.
•
To refit, carry out the removal operations but in reverse order, be careful to use a new split
pin.
Locking torques (N*m)
Rear wheel to hub fixing nut 115
Swing-arm
SUSP - 144
SPORTCITY ONE 125
Suspensions
Removal
1. Nut
2. Screw
3. Spring
4. Rod engine attachment
5. Bushing
6. Buffer
7. Bracket
8. Seeger ring
9. Hexagonal screw
10. Needle bearing
11. Spacer
12. Nut
13. Spacer
14. Rod chassis attachment
15. Screw
SUSP - 145
Suspensions
SPORTCITY ONE 125
Overhaul
Periodically check the pin, fulcrum, engine and
bearings clearance. To carry out these operations,
proceed as follows:
•
Park the vehicle on its centre stand.
•
Hold the wheel firmly and try to move it
perpendicularly into the stroke direction.
•
If there is any clearance, check all the
retainers that connect the support.
Shock absorbers
Removal
CAUTION
HOLD THE REAR PART OF THE FRAME.
CAUTION
PLACE A SUPPORT OF SUITABLE THICKNESS UNDER THE REAR WHEEL TO PREVENT THE
ENGINE FROM FALLING.
•
Rest the vehicle on its centre stand.
•
Remove the tail section and unscrew
nut «1» fixing the shock absorber to the
chassis.
SUSP - 146
SPORTCITY ONE 125
•
Suspensions
Unscrew nut «2» fixing the shock absorber to the engine.
•
Follow the removal operations in reverse order for the fitting, screwing the nuts to the prescribed torque.
Locking torques (N*m)
Upper part of the shock absorber retaining nut 22.5 Lower part of the shock absorber retaining
nut 42.5
Centre-stand
•
Rest the vehicle on its centre stand.
•
Place a support under the vehicle so that it does not fall after the centre stand is removed.
CAUTION
MAKE SURE THE SCOOTER IS STABLE AND FIRM. IF IT FALLS, IT MAY INJURY YOU OR OTHER
PEOPLE, DAMAGE THE VEHICLE ITSELF OR ANY ADJACENT OBJECTS.
•
Remove the two springs «1».
SUSP - 147
Suspensions
•
SPORTCITY ONE 125
Unscrew the nut «2» and slide off the
pin.
•
To refit, carry out the removal operations but in reverse order and tighten the nut to the
prescribed torque.
Locking torques (N*m)
Central stand to chassis fixing screw 42.5
SUSP - 148
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Braking system
SPORTCITY ONE 125
Interventions rules
When pads are worn, the brake fluid level in the
reservoir decreases to automatically compensate
pad wear.
The front brake fluid reservoir «1» is located on the
end section to the right of the handlebar next to the
front brake lever.
CAUTION
NEVER USE THE SCOOTER IF THERE IS A FLUID LEAK
ON ANY SYSTEM PART.
CAUTION
WHEN PADS ARE WORN, THE BRAKE FLUID LEVEL DECREASES PROGRESSIVELY TO COMPENSATE PAD WEAR.
If the fluid does not reach the 'MIN' reference
mark:
•
Check brake pads for wear.
If there is no need to replace any pads/discs,
check the braking system to determine the cause
of the problem, by checking:
•
the brake pipe condition. Mainly check
if there are broken or cracked areas;
•
the connections are properly tightened;
•
the connections may exhibit leaks;
•
the calliper and the reservoir may exhibit leaks;
BRAK SYS - 150
SPORTCITY ONE 125
•
Braking system
the bleed screw may exhibit leaks. If
dripping is detected, tighten to the appropriate tightening torque;
•
the fuel tank caps for possible leaks
and the gaskets conditions.
After repairing the brake:
•
Check and bleed the system.
•
Top up the reservoir with an appropriate brake fluid.
Front brake calliper
Removal
CAUTION
THE OPERATIONS REFER TO ONLY ONE BRAKE CALLIPER, BUT APPLY TO BOTH CALLIPERS.
•
Undo the two screws indicated and remove the brake calliper.
NOTE
SHOULD IT BE NECESSARY TO REPLACE THE CALLIPER, FIRST LOOSEN THE JOINT CONNECTING THE PIPE
TO THE BRAKE CALLIPER.
Refitting
•
To fit, follow the removal steps but in reverse order, and tighten the locking screws to the
prescribed torque using the recommended product.
Recommended products
Loctite 243 Medium strength threadlock
-
Locking torques (N*m)
Front brake calliper fixing screw 25
•
If the calliper is disconnected from the brake pipe:
CAUTION
BRAK SYS - 151
Braking system
SPORTCITY ONE 125
ALWAYS USE NEW GASKET WASHERS FOR THE BRAKE PIPE JOINT.
CAUTION
ONCE REFITTING IS FINISHED, BLEED THE SYSTEM.
Locking torques (N*m)
Brake fluid pipe-calliper fitting 20 ÷ 25
Front brake pads
Removal
•
Remove the brake calliper.
•
Undo the two screws indicated.
•
Remove the brake pads.
CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE
BRAKE CONTROL LEVER; OTHERWISE, THE CALLIPER
PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN
BRAKE FLUID LEAKAGE.
•
Check friction material for appropriate
thickness. If thinner than the minimum
value, replace it.
Characteristic
Friction material minimum thickness
1.5
BRAK SYS - 152
SPORTCITY ONE 125
•
Braking system
In case of uneven wear, replace the
brake pads when the friction material
thickness difference is 0.5 mm.
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY
ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
Refitting
•
To refit, carry out the removal operations but in reverse order and tighten the locking screws
to the prescribed torque.
Locking torques (N*m)
Brake pad locking screws 15 ÷ 20
Fill - Bleeding the braking system
NOTE
IF THERE IS AIR IN THE HYDRAULIC SYSTEM, THE WATER WILL ABSORB MOST OF THE
POWER OF THE BRAKE MAIN CYLINDER AND THEREFORE, IT WILL REDUCE THE CALLIPER
PERFORMANCE WHEN BRAKING. THE PRESENCE OF AIR IS SIGNALLED BY THE 'SPONGINESS' OF THE BRAKE CONTROL AND POOR BRAKING EFFICIENCY.
CAUTION
CONSIDERING THE DANGER POSED FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY
TO BLEED THE HYDRAULIC SYSTEM AFTER REFITTING BRAKES AND CARRYING OUT REGULAR MAINTENANCE OPERATIONS.
•
Remove the protection cap «1» from
the bleeder spout «2».
BRAK SYS - 153
Braking system
•
SPORTCITY ONE 125
Connect a transparent pipe to the
bleeder «2».
CAUTION
DO NOT DIRT THE PADS OR THE DISC WITH BRAKE FLUID.
•
Keep the free part of the glass tube in
a clean container.
•
Pull the brake lever slowly «5» all along
its stroke two or three times, then keep
it pulled to the fullest.
CAUTION
LOOSEN THE BLEED PLUG SPOUT «2» AND CHECK THE
RESERVOIR BRAKE FLUID LEVEL «6». DO NOT EMPTY
THE RESERVOIR COMPLETELY SINCE THIS MAY FURTHER CAUSE AIR TO ENTER THE BRAKING SYSTEM.
•
Loosen the bleed plug spout «2» and check if there are bubbles in the glass tube.
CAUTION
BEFORE RELEASING THE BRAKE LEVER «5», CLOSE THE BLEED PLUG «2» TO PREVENT
WATER FROM ENTERING THE BRAKE SYSTEM.
•
When the brake fluid that comes out is homogeneous, without bubbles, it means air has
successfully been eliminated from the system. Close the bleed plug «2» accurately, and
tighten it correctly.
NOTE
REPEAT THE LAST TWO OPERATIONS UNTIL THE BUBBLES ARE TOTALLY ELIMINATED.
•
Refit the protection cap «1» on the bleed plug spout «2».
•
Check the brake fluid level.
CAUTION
AFTER REFITTING, PULL THE BRAKE LEVER REPEATEDLY AND CHECK THAT THE BRAKING
SYSTEM OPERATES CORRECTLY.
CAUTION
PAY ATTENTION TO THE DISC AND THE FRICTION MATERIAL MAKING SURE THEY ARE NOT
DIRTY OR GREASED, SPECIALLY AFTER MAINTENANCE OPERATIONS OR INSPECTION.
BRAK SYS - 154
SPORTCITY ONE 125
Braking system
Front brake pump
Removal
•
Remove the front and rear handlebar covers.
•
Remove the brake pipes and the contacts of the stop light switch.
•
Undo the two screws «1».
To refit, carry out the removal operations but in reverse order and tighten the screws to the prescribed
torque.
ONCE REFITTING IS FINISHED, BLEED THE SYSTEM.
Locking torques (N*m)
Brake pump to handlebar fixing screw 8.05 Brake pipe to brake pump fixing screw 18
Rear drum brake
•
Remove the rear wheel.
•
Hold the lower shoe and slide it with the
upper one.
For fitting:
•
First assembly two shoes and the
springs then place them on the pin and
on the cam.
To replace the transmission:
•
Remove the front handlebar cover.
•
Loosen the brake set screw
•
Release the transmission from its
clamps to the engine and from its
clamps to the chassis.
•
Adjust the drum brake activation point.
Locking torques (N*m)
BRAK SYS - 155
Braking system
Rear brake adjustment nut 5
To adjust the drum brake:
•
Unscrew the lock nut.
•
Adjust the activation point of the rear
drum brake by acting on the set screw.
1
•
With the brake lever released, the
wheel should rotate freely.
BRAK SYS - 156
SPORTCITY ONE 125
INDEX OF TOPICS
CHASSIS
CHAS
SPORTCITY ONE 125
Chassis
Seat
•
Remove the four screws «1» shown in
figure and collect the washers.
Locking torques (N*m)
Saddle plate fixing nut 10
Rear rack
•
Remove the three screws «1» shown
in figure and collect the washers.
Locking torques (N*m)
Passenger handgrip fixing screw 20.5
Driving mirrors
•
Undo the screw «1» and remove the
rear view mirror.
•
Collect the cover and spacer.
Locking torques (N*m)
Mirror fixing screw 25
CHAS - 158
SPORTCITY ONE 125
Chassis
Rear handlebar cover
•
Remove the mirrors.
•
Remove the front handlebar cover.
•
Undo the four screws «1» and release
it from the connector and from the odometer cable.
Instrument panel
•
Remove the front handlebar cover.
•
Undo the four screws «1».
Front handlebar cover
•
Remove the rear-view mirrors.
•
Undo the two screws «1».
CHAS - 159
SPORTCITY ONE 125
Chassis
•
Undo the screw «2».
Headlight assy.
•
Remove the legshield.
•
Undo the five screws «1».
Front turn indicators:
•
Remove the legshield.
•
Undo the indicated screw.
To replace the bulb:
•
Slide off the rubber bulb holder.
•
Hold the bulb, press it and turn it anticlockwise.
Legshield
•
Remove the shield back plate.
•
Working from the front wheel well internal side, undo the three screws «1»
from both sides of the vehicle.
CHAS - 160
SPORTCITY ONE 125
•
Chassis
Working from the front wheel well internal side, undo the screw «2».
Knee-guard
•
Undo the twelve screws indicated and
remove the shield back plate.
•
Before fitting the shield back plate, remove the footrest fixing screws in order
to insert the two plastic parts.
NOTE
UPON FITTING, REMEMBER TO CONNECT THE FRONT
TOP BOX OPENING TRANSMISSION.
Front wheel housing
•
Remove the legshield.
•
Remove the front mudguard.
•
Remove the front wheel.
•
Undo the five screws «1».
CHAS - 161
SPORTCITY ONE 125
Chassis
•
Undo the screw «2».
Taillight assy.
•
Remove the luggage rack.
•
Remove the side fairings.
•
Undo the two screws «1» and remove
the rear light unit from the side fairings.
•
Undo the screw «2» and remove the
taillight fairing.
Inside the rear light unit there are:
•
One position light/stop light bulb «3».
•
Two turn indicator bulbs «4».
To replace the tail/stop bulb:
•
Hold the bulb holder, turn it anticlockwise and slide it off.
CHAS - 162
SPORTCITY ONE 125
•
Chassis
Hold the bulb, press it and turn it anticlockwise.
To replace the turn indicator bulbs:
•
Hold the rubber bulb holder, turn it anticlockwise and slide it off.
•
Hold the bulb and slide it off.
Footrest
•
Undo the screw «2» and remove the
protection.
•
Undo the four screws «3».
•
Remove the front knee-guard panel.
•
Remove the rear central cover.
•
Remove the two screws «1».
CHAS - 163
SPORTCITY ONE 125
Chassis
Side fairings
•
Remove the luggage rack.
•
Remove the rear central cover.
•
Undo the two screws «1».
•
Undo the side screw «2» from both
sides of the vehicle.
•
Undo the two screws «3».
•
Release the helmet compartment from
the cable harnesses.
•
From both sides of the vehicle undo the
screw «4» placed under the footrest.
•
Remove the two fairings together with
the rear light unit.
•
Release it from the rear light unit cable
harnesses.
CHAS - 164
SPORTCITY ONE 125
Chassis
License plate holder
•
Undo the two screws «1».
•
Undo the two screws indicated.
Air filter
•
Remove the rear central cover.
•
Undo the two screws «1».
•
Disconnect the vapour recovery pipe.
CHAS - 165
SPORTCITY ONE 125
Chassis
•
Remove the inspection latch from inside the helmet compartment.
•
Loosen the clamp «2».
Rear mudguard
•
Undo the two screws «1».
•
Undo the screw «2».
Helmet bay
•
Remove the saddle.
•
Remove the luggage rack.
•
Remove the rear central cover.
•
Remove the side fairings.
•
Undo the two screws «1» placed inside
the helmet compartment.
•
Remove the battery cover and the battery.
CHAS - 166
SPORTCITY ONE 125
•
Undo the two screws «3».
•
Release the helmet compartment from
Chassis
the cable harnesses.
spoiler
•
Remove the footrest.
•
Undo the three screws «1».
•
From both sides of the vehicle undo the
screw «4» placed under the footrest.
•
Remove the two fairings together with
the rear light unit.
•
Release it from the rear light unit cable
harnesses.
Fuel tank
•
Remove the saddle.
•
Remove the luggage rack.
•
Remove the rear central cover.
•
Remove the side fairings.
•
Remove the helmet compartment.
•
Operating from both sides of the vehicle, undo the two screws «1».
Locking torques (N*m)
CHAS - 167
SPORTCITY ONE 125
Chassis
Fuel tank to chassis lateral fixing screw 10
•
Undo the screw «2».
Locking torques (N*m)
Fuel tank to chassis rear fixing screw 10
•
Loosen the two screws «3» placed inside the rear wheel well.
•
Disconnect the connector of the fuel
probe «4» and release the tank from
the pipes.
Front mudguard
•
Operating from both sides of the vehicle, undo the three screws «1».
CHAS - 168
SPORTCITY ONE 125
Chassis
Rear central cover
•
Remove the saddle.
•
Undo the four screws «1» and remove
the cover by sliding it upwards so as to
detach the locking tabs.
Battery
•
Remove the three screws «1 and remove the battery cover.
•
Disconnect the negative and positive
cables «2»
•
Slide off the breather pipe «3»
CHAS - 169
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
SPORTCITY ONE 125
Pre-delivery
Carry out the listed checks before delivering the vehicle.
WARNING
BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL.
Aesthetic inspection
- Paintwork
- Fitting of Plastic Parts
- Scratches
- Dirt
Tightening torques inspection
- Safety locks:
front and rear suspension unit
front and rear brake calliper retainer unit
front and rear wheel unit
engine - chassis retainers
steering assembly
- Plastic parts fixing screws
Electrical system
- Main switch
- Headlamps: high-beam lights, low-beam lights, tail lights (front and rear) and relevant warning lights
- Headlight adjustment according to regulations in force
- Front and rear brake light buttons and relevant bulb
- Turn indicators and relevant warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator (if present)
- Instrument panel warning lights
- Horn
- Electric start-up
- Engine stop via emergency stop switch and side stand
- Saddle electric opening switch (if present)
PRE DE - 171
Pre-delivery
SPORTCITY ONE 125
- Through the diagnosis instrument, check that the last mapping version is present in the control unit/s
and, if necessary, program the control unit/s again: consult the technical service website to know about
available updates and operation details.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
CAUTION
UPON INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE
PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN.
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.
Levels check
- Hydraulic braking system fluid level
- Rear hub oil level
- Engine coolant level (if present)
- Engine oil level
- Mixer oil level (if present)
Road test
- Cold start
- Instrument panel operation
- Response to throttle control
- Stability when accelerating and braking
PRE DE - 172
SPORTCITY ONE 125
Pre-delivery
- Front and rear brake efficiency
- Front and rear suspension efficiency
- Abnormal noise
Static test
Static check after test drive:
- Restarting when warmed up
- Starter operation (if present)
- Minimum holding (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
- Radiator electric fan operation (if present)
Functional inspection
- Hydraulic braking system
- Brake levers stroke
- Clutch - Check for correct operation
- Engine - Check for correct general operation and absence of abnormal noise
- Other
- Documentation check:
- Chassis and engine numbers check
- Supplied tools check
- License plate fitting
- Lock checking
- Tyre pressure checking
- Installation of mirrors and possible accessories
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST.
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
Specific operations for the vehicle
License plate side extension fitting:
- Apply heat protection transfer to the license plate side extension.
CAUTION
PRE DE - 173
Pre-delivery
SPORTCITY ONE 125
FITTING THE HEAT PROTECTION TRANSFER IS ESSENTIAL TO PROTECT THE LICENSE
PLATE SIDE EXTENSION AGAINST MUFFLER WARM GASES.
A. License plate Italy
B. License plate side extension - Germany
C. Heat guard adhesive to be added to the side extension
PRE DE - 174
A
Air filter: 31, 165
B
Battery: 50, 55, 169
Brake: 151, 152, 155
Bulbs:
C
Carburettor: 28, 119, 124
Clutch: 66, 68, 69, 72
E
Engine oil: 32
F
Fork: 139
Fuel: 34, 118, 167
Fuses: 54
H
Headlight: 38, 160
Horn: 52
Hub oil: 29
I
Identification: 10
Instrument panel: 159
M
Maintenance: 28
Mirrors: 158
R
Recommended products:
S
Saddle:
Shock absorbers: 146
Spark plug: 29
Stand:
T
Tank: 167
Transmission: 11, 64, 76
Tyres: 13
W
Warning lights:
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