Page 1 SERVICE STATION MANUAL 854214 SPORTCITY CUBE 250 - 300...
Page 2 The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this booklet 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.
Page 3 - This manual provides the main information to carry out regular maintenance operations on your vehicle. - This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing vehicles.
Page 5: Index Of Topics
INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Safety Rules
SPORTCITY CUBE 250 - 300 Characteristics Rules Safety rules GENERAL PRECAUTIONS AND INFORMATION When repairing, dismantling and reassembling the vehicle, follow the recommendations given below carefully. CAUTION USE OF NAKED FLAMES IS FORBIDDEN DURING ALL TYPES OF OPERATION. BEFORE START- ING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THE ENGINE AND REMOVE THE KEY.
Page 8 SPORTCITY CUBE 250 - 300 Characteristics The engine and the components of the exhaust system can get very hot and remain hot for some time even after the engine has been switched off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.
Page 9: Maintenance Rules
SPORTCITY CUBE 250 - 300 Characteristics RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIAL- IST AS SOON AS POSSIBLE. IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOL- LOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATE- THE BATTERY RELEASES EXPLOSIVE GASES.
Page 10 DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS. NOTE BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Use only ORIGINAL Aprilia SPARE PARTS. • Comply with lubricant and consumables usage guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 11 SPORTCITY CUBE 250 - 300 Characteristics • In presence of dirt, rust, humidity etc., clean the connector's internal parts carefully, using a pressurised air jet. • Ensure that the cables are correctly fastened to the internal connector terminals. NOTE THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAY ROUND.
Page 12: Vehicle Identification
For the best functioning of the engine the temperature of the coolant fluid should register in the central zone of the appropriate gauge. If the needle enters the red zone, stop the engine, allow it to cool, and check the level of the fluid; if it is normal, contact an Official aprilia Dealer. CAUTION DO NOT USE YOUR MOTORCYCLE IF THE COOLANT LEVEL IS BELOW THE MINIMUM LEVEL MARKED "MIN".
Page 13: Dimensions And Mass
SPORTCITY CUBE 250 - 300 Characteristics Engine number The engine number is stamped near the rear shock absorber lower support. CAUTION ALTERING IDENTIFICATION NUMBERS CAN BE SERI- OUSLY PUNISHED BY LAW, PARTICULARLY MODIFYING THE CHASSIS NUMBER WILL IMMEDIATELY INVALIDATE THE WARRANTY. Dimensions and mass SIZES Specification...
Page 14 SPORTCITY CUBE 250 - 300 Characteristics Specification Desc./Quantity Spark plug electrode gap 0.7 - 0.8 mm Transmission TRANSMISSION Specification Desc./Quantity Gearbox automatic continuous variator Primary drive V-belt Secondary transmission Gear reduction unit Engine/wheel total ratio - minimum: 1:2.3 - maximum: 1:0.815 Capacities CAPACITY Specification...
Page 15: Wheels And Tyres
SPORTCITY CUBE 250 - 300 Characteristics Frame and suspensions CHASSIS AND SUSPENSIONS Specification Desc./Quantity Size "A" 423.5 mm Size "B" 479 mm Trail 86.2 mm Chassis type High-strength steel tubular chassis, single spar at the front, su- perimposed double cradle at the rear. Steering inclination angle 26.5°...
Page 16: Tightening Torques
SPORTCITY CUBE 250 - 300 Characteristics Tightening Torques HANDLEBAR Name Torque in Nm Handlebar to fork retainer 48±20% Safety screw 20±20% Steering set nut 15±20% Steering series fixing lock nut 110±20% Instrument panel support to handlebar retainer 6±20% Mirror supports to handlebar retainer 52±20% Mirrors retainer 25±20%...
Page 17: Front And Rear Brake
SPORTCITY CUBE 250 - 300 Characteristics Name Torque in Nm Rear light cover on helmet compartment retainer Rear light cover on tail sections retainer 1±20% License plate holder on right and left half-tail sections retainer 3±20% License plate holder on rear mudguard chassis retainer 5±20% Luggage carrier cover on luggage carrier retainer 1±20%...
Page 18: Front Wheel
SPORTCITY CUBE 250 - 300 Characteristics Name Torque in Nm Electric fan on radiator retainer 1±20% Expansion tank on air deflector retainer 4±20% FRONT WHEEL Name Torque in Nm Pin retainer 50±20% Safety screw retainer 10±20% LINK ROD Name Torque in Nm Connecting rod to chassis retainer 60±20% Connecting rod to engine retainer...
Page 19: Assembly Clearances
SPORTCITY CUBE 250 - 300 Characteristics Name Torque in Nm Shock absorber on muffler plate retainer 40±20% Shock absorber bracket on engine retainer 25±20% FUEL SUPPLY SYSTEM Name Torque in Nm Probe to tank retainer 1.5±20% Fuel coupling clamp retainer 1±20% Tank to helmet compartment retainer 2±20%...
Page 20 SPORTCITY CUBE 250 - 300 Characteristics THE PISTON MUST BE FITTED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE FITTED WITH THE REFERENCE «TOP» OR THE STAMPED MARK FACING UPWARDS. - Check the pin outside diameter - Calculate the rod small end - gudgeon pin cou- pling clearance.
Page 21 SPORTCITY CUBE 250 - 300 Characteristics clearance 2nd compression ring - 0.015 ÷ 0.06 mm maximum clearance allowed after use 0.07 mm oil scraper - standard coupling clearance 0.015 oil scraper - maximum clearance al- ÷ 0.06 mm lowed after use 0.07 mm - Check that the coupling surface with the head is not worn or misshapen.
Page 22 SPORTCITY CUBE 250 - 300 Characteristics CYLINDER - PISTON Specification Desc./Quantity Piston diameter 74.967 +0.014 -0.014 mm Cylinder diameter 75 +0.038 +0.01 mm COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting cylinder - piston 75.01 ÷ 75.017 74.953 ÷ 74.960 0.050 ÷...
Page 23 SPORTCITY CUBE 250 - 300 Characteristics - Measure the diameter of the bearings on the pis- ton. Characteristic Standard diameter 16 +0.006 +0.001 mm - Calculate the pin - piston coupling clearance. NOTE THE PIN HOUSINGS HAVE TWO LUBRICATION CHANNELS FOR THIS REASON MEASURE THE DIAMETER ACCORDING TO THE PISTON AXIS Characteristic Standard clearance:...
Page 24 SPORTCITY CUBE 250 - 300 Characteristics - Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified according to their diameter. The coupling is carried out in pairs (M-M, N-N, O-O, P-P). Characteristic Maximum run-out allowed: 0.05 mm...
Page 25 SPORTCITY CUBE 250 - 300 Characteristics CRANKSHAFT Specification Desc./Quantity Camshaft bearings: Standard diameter: Cat. 1 28.998 ÷ 29.004 mm Crankshaft bearings: Standard diameter: Cat. 2 29.004 ÷ 29.010 mm CHAR - 25...
Page 26 SPORTCITY CUBE 250 - 300 Characteristics MAXIMUM OFF-LINE ALLOWED Specification Desc./Quantity 0.15 mm 0.010 mm 0.010 mm 0.10 mm CHAR - 26...
Page 27 SPORTCITY CUBE 250 - 300 Characteristics Characteristic Crankshaft-crankcase axial clearance (H) 0.15 ÷ 0.40 mm - Measure the inside diameter of the rod small end using a bore meter. NOTE IF THE CONNECTING ROD SMALL END DIAMETER EX- CEEDS THE STANDARD DIAMETER, SHOWS SIGNS OF WEAR OR OVERHEATING, REPLACE THE CRANKSHAFT AS DESCRIBED IN THE «CRANKCASE AND CRANK- SHAFT»...
Page 28: Cylinder Head
SPORTCITY CUBE 250 - 300 Characteristics COMBINATIONS BUSHING CATEGORY CRANKCASE BUSHING INSIDE DIAMETER AFTER FITTING HALVES CATEGORY 29.024 ÷ 29.054 29.024 ÷ 29.054 29.018 ÷ 29.048 29.018 ÷ 29.048 Combine the crankshaft with two crankwebs category 1 with a crankcase category 1 (or cat. 2 with cat. 2) A spare crankcase cannot be combined with a crankshaft with mixed categories.
Page 29 SPORTCITY CUBE 250 - 300 Characteristics - Check the sealing surfaces for the inlet and exhaust manifold. - Check that the camshaft and the rocker pin bearings show no signs of wear. - Check that the head cover show no signs of wear. - Check that the coolant sealing buffer is not rusted.
Page 30 SPORTCITY CUBE 250 - 300 Characteristics TANDARD LENGTH OF VALVE Specification Desc./Quantity Valve check: standard length Inlet: 94.6 mm Valve check: standard length Outlet: 94.4 mm - Measure the diameter of the valve stem at the three positions indicated in the diagram. STANDARD DIAMETER Specification Desc./Quantity...
Page 31 SPORTCITY CUBE 250 - 300 Characteristics - Check the concentricity of the valve head by placing a dial gauge at right angles to the valve head and rotating it on the «V» shaped support. Characteristic Limit allowed: 0.03 mm Measure the valve guides. Characteristic Valve guide: 5+0.012 mm...
Page 32 SPORTCITY CUBE 250 - 300 Characteristics - If no faults are found during the above checks, the same valves can be reused. For better sealing results, we recommend grinding the valve seats. Grind the valves gently with fine-grained lapping compound. Upon grinding, keep the cylinder head in horizontal position.
Page 33 SPORTCITY CUBE 250 - 300 Characteristics - Using a gauge, measure the height of the cams. TANDARD HEIGHT Specification Desc./Quantity Camshaft check: Standard height Inlet: 30.285 mm Camshaft check: Standard height Outlet: 29.209 mm - Check camshaft axial clearance AMSHAFT AXIAL CLEARANCE Specification Desc./Quantity Camshaft check: Standard axial clearance:...
Page 34 SPORTCITY CUBE 250 - 300 Characteristics Slot packing system 250 cm³ - 300 cm³ Versions Characteristic Compression ratio 10.5 ÷ 11.5 : 1 Distance "A" to be measured is a value of piston recess, it indicates by how much the piston crown descends below the plane formed by the cylinder crown.
Page 35 SPORTCITY CUBE 250 - 300 Characteristics SHIMMING FOR 300 ENGINES Name Measure A Thickness Shimming 3.70 - 3.60 0.4 ± 0.05 Shimming 3.60 - 3.40 0.6 ± 0.05 Shimming 3.40 - 3.30 0.8 ± 0.05 Products ECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP TEC 4T, SAE 10W-40...
Page 36: Index Of Topics
INDEX OF TOPICS TOOL OOLING...
Page 37 SPORTCITY CUBE 250 - 300 Tooling PECIAL TOOLS Stores code Description AP8140259 Universal tool for clutch assemblies AP8140665 Adapter for clutch assembly removal AP8140535 Front pulley fitting/removal AP8140181 Fuel pressure checking tool AP8140266 Comparator door AP8140729 Chain cover fitting/removal TOOL - 37...
Page 38 SPORTCITY CUBE 250 - 300 Tooling Stores code Description AP8140301 Flywheel extractor AP8140659 Valve oil seal punch AP8140662 Punch for roller casing 020425Y Shaft oil seal punch 020376Y Adapter handle 020455Y 10-mm guide for oil seal on water pump shaft 020412Y Clutch oil seal punch D 15 mm TOOL - 38...
Page 39 SPORTCITY CUBE 250 - 300 Tooling Stores code Description 020439Y Shaft 2 oil seal punch 17 mm 020359Y 42 x 47 mm punch 020363Y Crankshaft oil seal punch D 20 mm 020456Y Ø 24 mm punch 020364Y 25 mm Adaptor 020414Y 28 mm punch 020357Y...
Page 40 SPORTCITY CUBE 250 - 300 Tooling Stores code Description 020375Y 28x30 mm punch 020360Y 52x55 mm punch AP8140917 Tool for valve pressure plate AP8140661 Lock wrench for clutch bell AP8140300 55 mm wrench 020627Y Flywheel lock wrench AP8140179 Support for valve fitting/removal TOOL - 40...
Page 41 SPORTCITY CUBE 250 - 300 Tooling Stores code Description AP8140660 Piston fitting ring AP8140664 Guide to mount the movable driven pulley 020483Y 30 mm guide 020477Y 37-mm Adaptor 002095Y Engine support AP8140919 Valve oil seal extractor TOOL - 41...
Page 42 SPORTCITY CUBE 250 - 300 Tooling Stores code Description AP8140920 Tool for pin rings AP8140922 Crankcase splitting strip AP8140921 Oil seal punch 001467Y035 Bell for OD 47-mm bearings 020481Y Adaptor cable harness AP8140915 Crankcase check TOOL - 42...
Page 43 SPORTCITY CUBE 250 - 300 Tooling Stores code Description AP8140916 Hub cover support AP8140252 Multipurpose wrench AP8140595 Axone + battery charger (230V 50Hz) AP8202311 Axone + battery charger (110V 60Hz) TOOL - 43...
Page 44: Maintenance
INDEX OF TOPICS MAIN AINTENANCE...
Page 45: Maintenance Chart
SPORTCITY CUBE 250 - 300 Maintenance Maintenance chart OUTINE MAINTENANCE TABLE I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Replace every 2 years km x 1,000 Safety fasteners Spark plug Drive belt Throttle control Air filter...
Page 46 SPORTCITY CUBE 250 - 300 Maintenance Hub oil Ride a few kilometres until the regular working temperature is reached, then shut off the engine. NOTE USE RECOMMENDED OIL ONLY. REFER TO THE RECOMMENDED PRODUCTS TABLE. Check • Park the vehicle on firm and level ground.
Page 47: Air Filter
SPORTCITY CUBE 250 - 300 Maintenance • Rest the vehicle on its centre stand. • Stop the engine and let it cool down. This will allow the oil to settle into the crankcase and cool down. CAUTION WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD. •...
Page 48: Engine Oil
SPORTCITY CUBE 250 - 300 Maintenance • Remove the filter. • Wash the filtering element with clean, non-flammable or high-volatility sol- vents, and let it dry properly. • Apply a specific filter oil over all the surface. CAUTION PARTIAL AIR FILTER CLEANING DOES NOT EXCLUDE NOR POSTPONE AIR FILTER REPLACEMENT.
Page 49 SPORTCITY CUBE 250 - 300 Maintenance • Unscrew and remove the cartridge en- gine oil filter «4». • Unscrew and remove the oil drainage plug «3» and then drain all the engine oil into the collecting container. • Fit a new oil cartridge filter «4» and take special care to lubricate the filter sealing O-rings with oil.
Page 50: Engine Oil Top-Up
SPORTCITY CUBE 250 - 300 Maintenance • Unscrew and take out the measuring cap-dipstick «1». • Clean the area in contact with oil with a clean cloth. • Screw the cap-dipstick «1» fully down into its tube «2». • Pull out the cap-dipstick again «1» and read the level the oil reaches on the dipstick: MAX = maximum level.
Page 51: Braking System
SPORTCITY CUBE 250 - 300 Maintenance PARK THE MOTORCYCLE ON SAFE AND LEVEL GROUND. • Shut off the engine and wait until it cools off. • Undo the indicated screw on both sides and remove the front case. • Make sure that the liquid level in the expansion tank is between "MIN"...
Page 52 SPORTCITY CUBE 250 - 300 Maintenance PAY UTMOST ATTENTION THAT NO WATER OR DUST INADVERTENTLY GETS INTO THE CIR- CUIT. Level check • Park the vehicle on its centre stand. • Turn the handlebar so that the fluid in the brake fluid reservoir is parallel to the «MIN»...
Page 53: Headlight Adjustment
SPORTCITY CUBE 250 - 300 Maintenance CAUTION DO NOT FILL UP THE TANK TO THE MAXIMUM, BUT JUST OVER THE ''MIN'' LEVEL. TOP-UP TO MAXIMUM LEVEL MARK ONLY WHEN BRAKE PADS ARE NEW. BRAKE LEV- EL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN.
Page 54: Electrical System
INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 55 SPORTCITY CUBE 250 - 300 Electrical system 1. Multiple connectors 2. fall sensor 3. ECU diagnosis 4. Fan 5. Instrument panel 6. MODE button 7. Speed sensor 8. Turn indicators 9.Left light switch 10. Horn 11. Key switch 12. Front stop switch 13.
Page 56: Engine Temperature Sensor
SPORTCITY CUBE 250 - 300 Electrical system 20. Stop light relay 21.Start-up relay 22. Starter motor 23. Battery 24. Plug socket 25. Main fuses 26. Auxiliary fuses 27.Voltage regulator 28.Generator 29. Pick-up 30. Oil sensor 31.Injection relay 32. Lambda Probe 33.
Page 57 SPORTCITY CUBE 250 - 300 Electrical system M brown N black R red V green Vi purple Ro pink Components arrangement 1. CDI control unit To reach it, remove the inspection cover in the helmet compartment. ELE SYS - 57...
Page 58 SPORTCITY CUBE 250 - 300 Electrical system 2. Horn 3. Start-up relay To reach them, remove the front wheel compart- ment. 4. Solenoids To reach them, remove the front wheel compart- ment. A. Fan relay B. Injection relay C. Stop lights relay 5.
Page 59: Electrical System Installation
SPORTCITY CUBE 250 - 300 Electrical system 9. HV coil Remove the helmet compartment to reach it. 10. Fuel probe Open the saddle to reach it. Electrical system installation Front side HANDLEBAR AREA ELE SYS - 59...
Page 60 SPORTCITY CUBE 250 - 300 Electrical system 1.Through the hole 2.(98x2.5) Clamp 3.(290x4.5) Clamp 4.Through the hole ELE SYS - 60...
Page 61 SPORTCITY CUBE 250 - 300 Electrical system STEERING AREA 1.(180x4.5) Clamp ELE SYS - 61...
Page 62 SPORTCITY CUBE 250 - 300 Electrical system 1.Clamp too long FOOTREST AREA 1. (290x4.5) Clamp ELE SYS - 62...
Page 63 SPORTCITY CUBE 250 - 300 Electrical system 1. (290x4.5) Clamp 1. Through the hole ELE SYS - 63...
Page 64 SPORTCITY CUBE 250 - 300 Electrical system ELE SYS - 64...
Page 65: Back Side
SPORTCITY CUBE 250 - 300 Electrical system 1. (290x4.5) Clamp Back side ENGINE AREA ELE SYS - 65...
Page 66 SPORTCITY CUBE 250 - 300 Electrical system 1. (290x4.5) Clamp 2. Main cable harness ELE SYS - 66...
Page 67 SPORTCITY CUBE 250 - 300 Electrical system 1. Strap 2. Cable guide 3. (180x4.5) Clamp ELE SYS - 67...
Page 68 SPORTCITY CUBE 250 - 300 Electrical system 1. Lambda probe cable inside the metal cable guide ELE SYS - 68...
Page 69: Speed Sensor
SPORTCITY CUBE 250 - 300 Electrical system 1. Corrugated hose covering the starter motor cable. SPEED SENSOR ELE SYS - 69...
Page 70 SPORTCITY CUBE 250 - 300 Electrical system 1. (98x2.5) Clamp ELE SYS - 70...
Page 71 SPORTCITY CUBE 250 - 300 Electrical system 1. (98x2.5) Clamp 2. Plastic cable guide ELE SYS - 71...
Page 72 SPORTCITY CUBE 250 - 300 Electrical system 1. (290x4.5) Clamp MAIN CABLE HARNESS 1. (290x4.5) Clamp ELE SYS - 72...
Page 73 SPORTCITY CUBE 250 - 300 Electrical system 1. (290x4.5) Clamp REAR LIGHT AND LICENSE PLATE LIGHT ELE SYS - 73...
Page 74 SPORTCITY CUBE 250 - 300 Electrical system 1. (98x2.5) Clamp 1. (180x4.5) Clamp ELE SYS - 74...
Page 75 SPORTCITY CUBE 250 - 300 Electrical system Conceptual diagrams Ignition 11.Key switch 23.Battery 25. Main fuses 26.Auxiliary fuses 29. Pick-up 31.Injection relay 36. Spark plug 37.HV coil 40. CDI control unit ELE SYS - 75...
Page 76 SPORTCITY CUBE 250 - 300 Electrical system Battery recharge and starting 11. Key switch 12.Front stop switch 13. Rear stop switch 21. Start-up relay 22.Starter motor 23.Battery 25. Main fuses 26. Auxiliary fuses 27. Voltage regulator 28.Generator 40. CDI control unit 47.
Page 77 SPORTCITY CUBE 250 - 300 Electrical system Level indicators and enable signals section 2.fall sensor 5. Instrument panel 7.Speed sensor 11.Key switch 23.Battery 25. Main fuses 26.Auxiliary fuses 30.Oil sensor 31.Injection relay 32.Lambda Probe 34.Fuel probe 35.Fuel injector 39. ENGINE TEMPERATURE SENSOR 40.
Page 78: Devices And Accessories
SPORTCITY CUBE 250 - 300 Electrical system Devices and accessories 4.Fan 5.Instrument panel 6.MODE button 10.Horn 11.Key switch 23.Battery 24.Plug socket 25.Main fuses 26. Auxiliary fuses 31. Injection relay 33.Fuel pump 38.Fan relay 40. CDI control unit 49.Horn button ELE SYS - 78...
Page 79 SPORTCITY CUBE 250 - 300 Electrical system Lights and turn indicators 5.Instrument panel 8.Turn indicators 11.Key switch 12. Front stop switch 13. Rear stop switch 14. Turn indicator switch 15.Rear light 16.Rear left turn indicator 17.Tail light/stop light twin bulbs 18.Rear right turn indicator 19.
Page 80 SPORTCITY CUBE 250 - 300 Electrical system 43. High-beam bulb 44. Front headlamp tail light 45. Low-beam bulb 46. Front left turn indicator 50. Light switch Checks and inspections Ignition circuit No spark plug CAUTION THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS- CONNECTED.
Page 81: Stator Check
SPORTCITY CUBE 250 - 300 Electrical system Coil secondary check • Disconnect the spark plug cap from the coil cable and measure the resistance between the cable end and the coil negative terminal (Orange-White ca- ble). Electric characteristic Secondary resistance 2900±10% Ohm at 20 °C (68 °F) Battery recharge circuit With engine running at high revs, measure the voltage present at the battery poles.
Page 82 SPORTCITY CUBE 250 - 300 Electrical system Recharge system voltage check • Connect the ammeter induction clamp to the voltage regulator positive termi- nals (Red-Orange). • Measure the battery voltage and turn- ing on the vehicle lights, with engine off, wait for the voltage to set at about 12 V.
Page 83 SPORTCITY CUBE 250 - 300 Electrical system 5.Rear stop switch 6. Starter button 7. Start-up relay 8. Starter motor 9.Battery 10. Main fuses 11. Auxiliary fuses CAUTION THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS- CONNECTED. 1) Check fuses No. 1 and 4. 2) Check the contacts of the key switch and the engine stop switch.
Page 84: Horn Control
SPORTCITY CUBE 250 - 300 Electrical system Horn control KEY: 1. Horn button 2. Key switch 3. Horn 4.Battery 5.Main fuses 6.Auxiliary fuses CAUTION THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS- CONNECTED. 1) Check fuses No. 1 and 3. 2) Check key switch and horn button contacts.
Page 85 SPORTCITY CUBE 250 - 300 Electrical system Turn signals system check KEY: 1. Instrument panel 2. Blinker 3.Turn indicator switch 4.Key switch 5. Rear left turn indicator 6.Rear right turn indicator 7.Battery 8.Main fuses 9.Auxiliary fuses 10.Front right turn indicator 11.Front left turn indicator CAUTION THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS-...
Page 86 SPORTCITY CUBE 250 - 300 Electrical system 4) With the key switch set to «ON», check whether there is intermittent voltage between the Blue-Black cable of the turn indicator switch and the ground connection. 5) If no voltage is detected, check cable harness continuity. 6) Check the contacts of the turn indicator switch.
Page 87 SPORTCITY CUBE 250 - 300 Electrical system 1) Measure the resistance in the fuel level sensor ends in the different conditions. 2) If the resistance values are correct, but the in- dication on the instrument panel is incorrect, check the integrity and the connections of the cable har- nesses (Brown cable with pin 7 of the instrument panel connector and Grey-Green cable with pin 12 of the instrument panel connector.)
Page 88 SPORTCITY CUBE 250 - 300 Electrical system 6. Battery 7. Main fuses 8.Auxiliary fuses 9. High-beam bulb 10. Front headlamp tail lights 11.Low-beam bulb BULBS/WARNING LIGHTS Specification Desc./Quantity High/low beam bulb 12 V - 55 W - H7 Tail light bulb 12V - 5W Front turn indicator bulbs 12 V - 10 W (Amber)
Page 89 SPORTCITY CUBE 250 - 300 Electrical system Fuses CAUTION DO NOT REPAIR FAULTY FUSES. NEVER USE A FUSE THAT IS DIFFERENT THAN WHAT IS SPECIFIED TO PREVENT DAMAGES TO THE ELECTRI- CAL SYSTEM OR SHORT CIRCUITS, WITH THE RISK OF FIRE.
Page 90 SPORTCITY CUBE 250 - 300 Electrical system 4. Low fuel warning light, orange 5. Speedometer 6. High coolant temperature warning light 7. Coolant temperature indicator 8. Engine oil pressure warning light/Red electronic injection check warning light 9. ABS warning light (Active only for models with ABS) 10.
Page 91: Battery Installation
SPORTCITY CUBE 250 - 300 Electrical system Turn the key to ''ON'' and wait 10 seconds. During this operation the service icon flashes at a 1 Hz frequency. Sealed battery Commissioning sealed batteries If the motorcycle is provided with a sealed battery, the only maintenance required is to check if it is charged and to recharge it, if necessary.
Page 92 SPORTCITY CUBE 250 - 300 Electrical system 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 1) Battery preparation Position the battery on a flat surface.
Page 93 SPORTCITY CUBE 250 - 300 Electrical system Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery. Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect your hands and do not bring your face close to the battery.
Page 94 SPORTCITY CUBE 250 - 300 Electrical system e - Press the "MF" black button to activate the bat- tery recharge Maintenance Free as shown in fig- ure. f - Check the ignition of the green LED indicated with a red arrow in figure. g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place...
Page 95 SPORTCITY CUBE 250 - 300 Electrical system Connectors 1.Injection telltale light (Sky blue-Green) 2.Not connected 3. Not connected 4.Lambda probe negative (Green-White) 5. Permanent power supply (Green-Red) 6. Battery-powered (Red-Orange) 7.Not connected 8. Fan relay (Purple-Black) 9.Engine temperature sensor (Orange) 10.
Page 96 SPORTCITY CUBE 250 - 300 Electrical system Dashboard 1.Oil pressure sensor (Purple) 2. MODE Button (Pink) 3. Left turn indicator warning light (Sky Blue) 4. Right turn indicator warning light (Red) 5.High-beam warning light (White) 6. Not connected 7. Fuel level sensor (Brown) 8.
Page 97: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 98 SPORTCITY CUBE 250 - 300 Engine from vehicle Exhaust assy. Removal CAUTION ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF COMPLETELY. Silencer removal • Rest the vehicle on its centre stand. • Loosen the clamp (1) fixing the exhaust silencer to the manifold. •...
Page 99 SPORTCITY CUBE 250 - 300 Engine from vehicle • Undo and remove the three fixing screws of the exhaust silencer. • Remove the exhaust system. Removal of the engine from the vehicle Preventively remove: • Helmet compartment. • Rear central cover. •...
Page 100 SPORTCITY CUBE 250 - 300 Engine from vehicle • Disconnect the lambda probe connec- tor. • Remove the injector connector. • Remove the fast-release fitting from the injector support. • Remove the water temperature sensor connector. ENG VE - 100...
Page 101 SPORTCITY CUBE 250 - 300 Engine from vehicle • Remove the throttle body transmis- sions and release them from the en- gine. • Disconnect the connector of the ECU and release the cable harness. • Unscrew and remove the starter motor supply and ground nuts.
Page 102 SPORTCITY CUBE 250 - 300 Engine from vehicle • Remove the fuel breather pipe. • Hold the vehicle chassis by means of a hoister. • Working from the left side, unscrew and remove the nut and slide off the fixing pin of the shock absorber. •...
Page 103 SPORTCITY CUBE 250 - 300 Engine from vehicle • From the left side, slide off the pin and collect the washer and the spacer. • Remove the engine by pulling it back- wards. ENG VE - 103...
Page 104 INDEX OF TOPICS NGINE...
Page 105: Automatic Transmission
SPORTCITY CUBE 250 - 300 Engine This section describes the operations to be carried out on the engine and the tools required. Automatic transmission Transmission cover - To remove the transmission cover, it is necessary to remove the plastic cover first by inserting a screwdriver in the slotted holes.
Page 106: Removing The Driven Pulley Shaft Bearing
SPORTCITY CUBE 250 - 300 Engine - Remove the 5 screws on the two different levels, as well as the small casing. Removing the driven pulley shaft bearing - Remove the seeger ring from the inside of the cover. - Remove the bearing from the crankcase. Specific tooling 020376Y Adapter handle 020375Y 28x30 mm punch...
Page 107: Removing The Driven Pulley
SPORTCITY CUBE 250 - 300 Engine Baffle roller Plastic roller - Check that the roller shows no signs of abnormal wear and that it rotates freely. - Remove the special fixing screws as indicated in the photograph - Check the roller outside diameter does not have defects that could jeopardise belt functioning - For refitting, place the roller with the belt contain- ment edge on the engine crankcase side...
Page 108: Inspecting The Clutch Drum
SPORTCITY CUBE 250 - 300 Engine Inspecting the clutch drum - Make sure that the clutch bell is not worn or dam- aged. - Measure the clutch bell inside diameter. Characteristic Clutch bell max. value (250 cm³) Ø 135 mm Max clutch bell value (300 cm³) Ø...
Page 109: Removing The Clutch
SPORTCITY CUBE 250 - 300 Engine 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 CEN- TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.
Page 110 SPORTCITY CUBE 250 - 300 Engine Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. NOTE USE 2 SCREWDRIVERS IN CASE OF ANY DIFFICULTY. NOTE BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGING THE O-RING SEAL. - Remove the 4 torque server pins and pull the half- pulleys apart.
Page 111 SPORTCITY CUBE 250 - 300 Engine - Remove the roller bearing using the specific punch. Specific tooling 020376Y Adapter handle 020456Y Ø 24 mm punch 020363Y Crankshaft oil seal punch D 20 mm Inspecting the driven fixed half-pulley • Measure the outside diameter of the pulley bushing.
Page 112 SPORTCITY CUBE 250 - 300 Engine Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the 2 O- rings; - Measure the inside diameter of the movable half- pulley bushing. - Check the contact surface with the belt to make sure there are no signs of abnormal wear.
Page 113: Refitting The Driven Pulley
SPORTCITY CUBE 250 - 300 Engine Specific tooling 020376Y Adapter handle 020375Y 28x30 mm punch AP8140662 Punch for roller casing Refitting the driven pulley - Insert the new oil seals and O-rings on the mov- able half-pulley. - Lightly grease the O-rings (A) shown in the figure. - Fit the half-pulley on the bushing.
Page 114 SPORTCITY CUBE 250 - 300 Engine Specific tooling AP8140664 Guide to mount the movable driven pulley Inspecting the clutch spring - Measure the length of the movable driven half- pulley spring, when unloaded. Characteristic Standard length 123 mm limit after use 118 mm Refitting the clutch - Assemble the spring, clutch and driven pulley.
Page 115 SPORTCITY CUBE 250 - 300 Engine Refitting the driven pulley - Refit the clutch bell. Drive-belt • Make sure that the driving belt is not damaged. • Check belt for correct width. Characteristic Driving belt - standard width 21.3 ± 0.2 mm Driving belt - minimum width 19.5 mm During the wear checks foreseen in the scheduled...
Page 116: Removing The Driving Pulley
SPORTCITY CUBE 250 - 300 Engine Removing the driving pulley - Turn the crankshaft until the slots of the pulley are on a horizontal axis - With the specific tool remove the fixing nut, the Belleville spring and its washer - Remove the stationary driving half-pulley and the steel washer in contact with it Specific tooling AP8140535 Front pulley fitting/removal...
Page 117 SPORTCITY CUBE 250 - 300 Engine movable driving half-pulley bushing: Max. di- ameter admitted Ø 26.12 mm sliding bushing: Standard Diameter Ø 25.959 ÷ 25.98 mm sliding bushing: Minimum diameter admitted Ø 25.95 mm roller: Standard Diameter Ø 20.5 ÷ 20.7 mm roller: Minimum diameter admitted Ø...
Page 118 SPORTCITY CUBE 250 - 300 Engine - Fit the steel shim contacting the bushing and the stationary driving half-pulley. - Install the appropriate tool as described in the removal phase. - Tighten the nut and washer to the prescribed torque. Specific tooling AP8140535 Front pulley fitting/removal Locking torques (N*m)
Page 119 SPORTCITY CUBE 250 - 300 Engine Removing the hub cover - Empty the rear hub through the oil drainage plug. - Remove the 7 flanged screws indicated in the figure. - Remove the hub cover and the relevant gasket. Removing the wheel axle - Remove the wheel axle with gear.
Page 120 SPORTCITY CUBE 250 - 300 Engine Removing the wheel axle bearings - Remove the seeger ring from the outside of the hub cover. - Support the hub cover and expel the bearing. - Remove the oil seal as shown in the figure using the specific tool.
Page 121 SPORTCITY CUBE 250 - 300 Engine - Remove the driven pulley shaft bearing. Specific tooling 020376Y Adapter handle 020375Y 28x30 mm punch 020363Y Crankshaft oil seal punch D 20 mm Inspecting the hub shaft - Check the three shafts for wear or distortions on the toothed surfaces, on the bearing housings and the oil seal positions.
Page 122 SPORTCITY CUBE 250 - 300 Engine Refitting the wheel axle bearing - Support the hub cover on a wooden surface. - warm the cover crankcase with the specific heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure.
Page 123 SPORTCITY CUBE 250 - 300 Engine Refitting the hub cover bearings To fit the hub box bearings, the engine crankcase and the cover should be heated with the specific heat gun. - The three 15-mm bearings must be fitted using the appropriate tools: The 42-mm side of the adaptor should face the bearing.
Page 124 SPORTCITY CUBE 250 - 300 Engine Refit the driven pulley shaft bearing with a modular punch as shown in the figure. NOTE IF A BEARING WITH AN ASYMMETRICAL BALL RETEN- TION CAGE IS USED, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INTERNAL SIDE.
Page 125: Flywheel Cover
SPORTCITY CUBE 250 - 300 Engine Refitting the ub cover - Fit a new gasket together with the centring dow- els. - Seal the gasket of the bleeding pipe using black silicone sealant. - Fit the cover making sure the bleeding pipe is in the correct position.
Page 126: Removing The Stator
SPORTCITY CUBE 250 - 300 Engine Removing the stator - Remove the 2 Pick-Up screws and the one for the wiring bracket as well as the 3 stator fixing screws shown in the figure. - Remove the stator and its cable harness. Locking torques (N*m) Screws fixing freewheel to flywheel 13÷15 (9.6÷11.1 ftlb) Refitting the stator...
Page 127: Removing The Starter Motor
SPORTCITY CUBE 250 - 300 Engine Refitting the flywheel cover - Position the keying clip on the crankshaft and orient the end as shown in the figure. - Orient the water pump shaft taking as reference the transmission gear seat as shown in the pho- tograph.
Page 128 SPORTCITY CUBE 250 - 300 Engine Removing the flywheel magneto - Remove the keying clip of the water pump shaft and crankshaft - Refit the driving half-pulley (if removed) - Lock the crankshaft rotation with a multipurpose wrench - Unscrew and remove the flywheel nut and its spacer - Do up the flywheel fixing nut by 3 or 4 threads so that the flywheel does not fall accidentally upon...
Page 129 SPORTCITY CUBE 250 - 300 Engine Inspecting the flywheel components - Check that the internal plastic parts of the flywheel and the Pick-Up control plate are in good conditions. Refitting the free wheel - Make sure the freewheel faying surfaces are in good condition. - Thoroughly clean the freewheel to remove any LOCTITE left.
Page 130 SPORTCITY CUBE 250 - 300 Engine Refitting the flywheel magneto - Remove the freewheel retention plate indicated in the photograph - Remove the transmission gear and the freewheel - Insert the freewheel on the flywheel as shown in the photo - Then refit the flywheel together with the free- wheel and transmission gear - Tighten the flywheel fixing nut to the prescribed torque with a multipurpose wrench...
Page 131: Removing The Intake Manifold
SPORTCITY CUBE 250 - 300 Engine Cylinder assy. and timing system Removing the intake manifold Loosen the 3 screws and remove the air intake manifold. When refitting, tighten the screws to the prescribed torque. Removing the rocker-arms cover Remove the 5 screws indicated in the figure Removing the timing system drive - First remove the parts listed below: transmission cover, driving pulley with belt, oil sump with spring...
Page 132 SPORTCITY CUBE 250 - 300 Engine - Remove the return spring of the automatic valve- lifter assembly, the automatic valve-lifter assembly and its end of stroke washer. - Loosen the central screw on the tensioner first. - Remove the 2 clamps indicated in the figure. - Remove the tensioner and its gasket.
Page 133: Removing The Cam Shaft
SPORTCITY CUBE 250 - 300 Engine - Remove the command sprocket wheel and the timing chain. - Remove the screw indicated in the figure, the spacer and the tensioner pad. The tensioner pad must be removed operating from the transmission side. The lower chain guide pad can only be removed after the head has been removed.
Page 134: Removing The Cylinder Head
SPORTCITY CUBE 250 - 300 Engine Removing the cylinder head - Remove the spark plug. - Remove the 2 side retainers indicated in the fig- ure. - Loosen the 4 head-cylinder fixing nuts in two or three stages and in a criss-cross sequence. - Remove the head, the 2 centring dowels and the gasket.
Page 135: Inspecting The Small End
SPORTCITY CUBE 250 - 300 Engine Removing the cylinder - piston assy. Cylinder and piston removal - Remove the chain guide pad. - Remove the 4 sealing O-rings on the stud bolts - Slide off the cylinder. - Remove the gasket on the cylinder base. - Remove the 2 seeger rings, the pin and the pis- ton.
Page 136: Removing The Piston
SPORTCITY CUBE 250 - 300 Engine Cylinder - piston assy. Cylinder - piston assy. Inspecting the cylinder NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder - piston assy. Cylinder - piston assy. Inspecting the piston rings NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-...
Page 137 SPORTCITY CUBE 250 - 300 Engine S = left D = right - Set the snap ring into its position with the punch. - Fit the pin stop ring using the plug as shown in the figure. NOTE THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY.
Page 138 SPORTCITY CUBE 250 - 300 Engine Refitting the piston rings • Place the oil scraper spring on the pis- ton. • Fit the oil scraper ring keeping the port opposite to the spring union and the word "top" facing the piston crown. In any case, the chamfered side of the must be facing the piston crown.
Page 139: Inspecting The Cylinder Head
SPORTCITY CUBE 250 - 300 Engine AP8140921 Oil seal punch AP8140660 Piston fitting ring Inspecting the cylinder head NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder head Inspecting the timing system components - Check that the guide slider and the tensioner pad are not excessively worn.
Page 140 SPORTCITY CUBE 250 - 300 Engine Inspecting the valve housings NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder head Inspecting the valves NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
Page 141: Inspecting The Cam Shaft
SPORTCITY CUBE 250 - 300 Engine Specific tooling AP8140179 Support for valve fitting/removal AP8140659 Valve oil seal punch AP8140917 Tool for valve pressure plate Inspecting the cam shaft NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
Page 142 SPORTCITY CUBE 250 - 300 Engine - Insert the retention plate and tighten the two screws shown in the picture to the prescribed tor- que. - Refit the spacer on the camshaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase.
Page 143 SPORTCITY CUBE 250 - 300 Engine Locking torques (N*m) Timing chain tensioner support screw 11÷13 (8.1÷9.6 ftlb) Spark plug 12÷14 (8.9÷10.3 ftlb) Starter ground screw 7÷8.5 (5.2÷6.3 ftlb) Timing chain tensioner pad screw 10÷14 (7.4÷10.3 ftlb) Starter ground bell screw 11÷15 (8.1÷11.1 ftlb) Timing chain tensioner central screw 5÷6 (3.7÷4.4 ftlb) Camshaft retention plate screw 4÷6 (3÷4.4 ftlb) - Fit the timing chain guide pad.
Page 144 SPORTCITY CUBE 250 - 300 Engine - Rotate by an angle of 270° - To carry out the operations described above, fol- low the tightening sequence indicated in the figure. - Fit the two screws on the timing chain side and tighten them to the prescribed torque.
Page 145: Crankcase - Crankshaft
SPORTCITY CUBE 250 - 300 Engine Refitting the intake manifold - Assemble the inlet manifold and tighten the 3 screws. Locking torques (N*m) Inlet manifold screws 11÷13 (8.1÷9.6 ftlb) Crankcase - crankshaft Splitting the crankcase halves - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft.
Page 146 SPORTCITY CUBE 250 - 300 Engine - If the crankshaft-crankcase axial clearance ex- ceeds what specified and the crankshaft does not show any defect, the problem must be due to ei- ther excessive wear or wrong machining on the crankcase. - Check the diameters of both crankshaft bearings according to the axes and surfaces shown in the figure.
Page 147 SPORTCITY CUBE 250 - 300 Engine Inspecting the crankcase halves - Before checking the crankcase halves, thorough- ly clean all the surfaces and oil pipes. - For the crankcase half on the transmission side, take particular care cleaning the housing and oil pipes of the oil pump, the duct and the by-pass valve, the main bushings and the cooling nozzle on the transmission side (see figure).
Page 148 SPORTCITY CUBE 250 - 300 Engine DUCE OIL TEMPERATURE. JET CLOGGING IMPAIRS HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET FAILURE CAUSES A DROP IN LUBRICATION PRES- SURE FOR THE MAIN BUSHINGS AND CONNECTING ROD. Inspecting the crankshaft plain bearings - In order to obtain proper bushing lubrication, it is necessary to have both an outstanding lubricating pressure (3.2 bar) and a good oil flow rate.
Page 149 SPORTCITY CUBE 250 - 300 Engine A spare crankcase cannot be combined with a crankshaft with mixed categories. Spare shafts have half-shafts of the same category. NOTE SPARE CRANKCASES ARE CHOSEN WITH HALF-SHAFTS OF THE SAME CATEGORY. - Fit the internal bulkhead by locking the 2 screws to the prescribed torque.
Page 150 SPORTCITY CUBE 250 - 300 Engine Locking torques (N*m) Screws for engine crankcase internal bulkhead (transmission-side half shaft) 4÷6 (3÷4.4 ftlb) Engine crankcase coupling screws 11÷13 (8.1÷9.6 ftlb) engine oil drainage plug/mesh filter 24÷30 (17.7÷22.1 ftlb) Oil filter fitting on crankcase 27÷33 (19.9÷24.4 ftlb) Studs Check that the stud bolts have not worked loose from their seats in the crankcase.
Page 151: Lubrication Circuit
SPORTCITY CUBE 250 - 300 Engine Lubrication Conceptual diagrams LUBRICATION CIRCUIT ENG - 151...
Page 152 SPORTCITY CUBE 250 - 300 Engine ENG - 152...
Page 153: Oil Pressure Check
SPORTCITY CUBE 250 - 300 Engine Oil pressure check - Disconnect the electrical connection of the mini- mum oil pressure switch and then remove the switch. - Check that the oil pressure reading is between 0.5 ÷ 1.2 atm with engine idling at 1650 rpm and oil at the required temperature (wait for at least one electric ventilation).
Page 154 SPORTCITY CUBE 250 - 300 Engine Removal - First remove the transmission cover and the en- tire driving pulley - Install the base of the appropriate tool on the oil guard using the screws supplied Specific tooling AP8140729 Chain cover fitting/removal - Screw the threaded bar onto the base of the tool and extract the oil guard Specific tooling...
Page 155 SPORTCITY CUBE 250 - 300 Engine Refitting - Always use a new oil guard when refitting - Prepare the new oil guard by lubricating its seal- ing lip. - Preassemble the oil guard 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...
Page 156: Oil Pump
SPORTCITY CUBE 250 - 300 Engine Specific tooling AP8140729 Chain cover fitting/removal Oil pump Removal - Undo the 2 clamping screws in the figure and re- move the cover over the pump control crown gear. - Block the rotation of the oil pump driving pulley by inserting a screwdriver through one of its holes.
Page 157 SPORTCITY CUBE 250 - 300 Engine Inspection - Remove the two screws and the oil pump cover. - Remove the circlip fixing the inner rotor. - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Reassemble the rotors in the pump body, keep- ing the 2 reference marks visible.
Page 158 SPORTCITY CUBE 250 - 300 Engine Refitting - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of wear or scoring on the oil pump cover. - If non-conforming values or signs of wear are found, replace the faulty parts or the assembly.
Page 159 SPORTCITY CUBE 250 - 300 Engine FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP TURNS FREELY. Locking torques (N*m) Screws fixing oil pump to crankcase 5÷6 (3.7÷4.4 ftlb) oil pump driving crown gear screw 10÷14 (7.4÷10.3 ftlb) Oil pump cover screws 7÷9 (5.2÷6.6 ftlb) Removing the oil sump - Remove the oil filler plug, the transmission cover,...
Page 160 SPORTCITY CUBE 250 - 300 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 two centring dowels. - Refit the sump, taking care to locate the spring in the appropriate piece found in the sump.
Page 161: Index Of Topics
INDEX OF TOPICS INJEC NJECTION...
Page 162 SPORTCITY CUBE 250 - 300 Injection 1. CDI control unit 2. Engine temperature sensor 3. Fuel injector 4. Instrument panel 5. Fan 6. Fan relay 7. Injection relay 8. Battery 9. Lambda probe 10. Pick-up 11. Fuel pump 12. HV coil MIU injection system This is an integrated ignition and injection system.
Page 163 SPORTCITY CUBE 250 - 300 Injection - Intake air temperature - Lambda probe value The system implements an idle supply correction with cold engine through a Stepper motor on a by- pass circuit of the throttle valve. The electronic control unit manages the Stepper motor and the injector opening time, thereby ensuring idle steadiness and proper carburetion.
Page 164 SPORTCITY CUBE 250 - 300 Injection The control unit is fitted with a self-diagnosis sys- tem connected to the EFI icon in the instrument panel display. Failures are detected and restored by the diag- nostic tester. In any case, when the fault is no longer present, data storage is automatically wiped clean after 16 cycles of use (cold starting, running at regular en- gine temperature, stop).
Page 165 SPORTCITY CUBE 250 - 300 Injection b. Blown fuse c. Solenoids d. Connectors B: Chassis ground connection C: Fuel system a. Broken fuel pump b. Dirty fuel filter D: Ignition system a. Faulty spark plug b. Broken coil c. Broken shielded cap E: Intake circuit a.
Page 166 SPORTCITY CUBE 250 - 300 Injection 4. When checking functions, make sure that the battery voltage is over 12V. 5. Before attempting to start-up, check to make sure there is at least 2 litres of fuel in the tank. Failure to observe this procedure can damage the fuel pump.
Page 167 SPORTCITY CUBE 250 - 300 Injection Terminals setup ERMINAL LAYOUT Specification Desc./Quantity Injection warning light lambda probe (-) permanent battery power supply (+) Battery (+) Electric fan remote control Water Temperature Sensor lambda probe (+) Engine stop switch Engine revolution sensor (+) Fuel injector Engine revolution sensor (-) Diagnosis output...
Page 168 SPORTCITY CUBE 250 - 300 Injection EMS circuit diagram SYSTEM DIAGRAM Specification Desc./Quantity fall sensor Connector for diagnosis Electric fan Instrument panel Key switch contacts Rear stop button Front stop button Starter button Engine stop switch Start-up remote control Starter motor Battery Main fuses Auxiliary fuses...
Page 169 6. Adjustable parameters/Fixed parameters Specification Desc./Quantity Aprilia hardware (XXXXXX000) This is the mapping code with the numbers inverted. If there are only zeros, this means that the central unit is blank (no mapping): the suitable mapping should be remotely reloaded...
Page 170: Device Status
SPORTCITY CUBE 250 - 300 Injection DEVICE STATUS Specification Desc./Quantity Engine status (Off/running) Engine off or running Rpm sensor (Synchronised/Not synchron.) Synchronised if the control unit detects a correct synchronisa- tion (by means of the crankshaft rpm detection sensor Idle/full load (on/off) ON if idle functioning Active lambda probe (on/off) ON if the control unit is using the lambda probe signal to keep...
Page 171: Troubleshooting Procedure
SPORTCITY CUBE 250 - 300 Injection The adjustable parameters screen page is used: • to align the throttle position sensor. Throttle position sensor alignment Align the throttle position sensor if the throttle body and/or the control unit should be replaced. •...
Page 172 SPORTCITY CUBE 250 - 300 Injection Possible Cause Operation Correctness of the parameters Coolant temperature Intake air temperature Stepper throttle valve position (steps and actual opening) Cleaning the auxiliary air pipe and air filter efficiency throttle valve Engine stops at idle ENGINE DOES NOT HOLD IDLING/ IDLING IS UNSTABLE/ IDLING TOO LOW Possible Cause Operation...
Page 173 SPORTCITY CUBE 250 - 300 Injection Exhaust backfires in deceleration EXHAUST BACKFIRING WHEN DECELERATING Possible Cause Operation Faults detected by self-diagnosis Pump relay HV coil Injector Engine speed timing sensor Air temperature Coolant temperature Lambda Probe Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor...
Page 174: Fuel Supply System
SPORTCITY CUBE 250 - 300 Injection Possible Cause Operation Lambda Probe Power to spark plug Spark plug Shielded cap HV Cable HV Coil Intake system Air filter Filter housing (seal) Intake sleeve (seal) Parameter reliability Throttle valve position signal Coolant temperature signal Intake air temperature signal Ignition advance Fuel system...
Page 175: Removing The Injector
SPORTCITY CUBE 250 - 300 Injection Removing the injector Preventively remove: • Helmet compartment. • Rear central cover. • Remove the footrest lower protection by sliding it upwards and turning it. • Remove the injector connector. INJEC - 175...
Page 176 SPORTCITY CUBE 250 - 300 Injection • Remove the fast-release fittings from the injector support. • Undo and remove the screw. Refitting the injector For refitting, follow the operations in reverse order observing the tightening torque. Removing the butterfly valve •...
Page 177 SPORTCITY CUBE 250 - 300 Injection • Remove the MIU control unit connector • Unscrew the throttle body / sleeve fas- tening clamp. • Remove the sleeve. • Remove throttle control retainer. Refitting the butterfly valve To refit, follow the removal steps but in reverse or- der, being careful to position the clip fixing the throttle body to the air filter bellows at 45°...
Page 178: Electrical Data
SPORTCITY CUBE 250 - 300 Injection Pump supply circuit COMPONENTS Specification Desc./Quantity Injection electronic control unit Ignition key contacts Main fuses Battery 12V - 12 Ah Auxiliary fuses Injection load remote control Fuel pump Fuel injector HV coil When switched to "ON", the fuel pump starts to rotate for 2 seconds and then stops. With engine on and when a revolution timing signal is displayed, the pump is continuously supplied.
Page 179 SPORTCITY CUBE 250 - 300 Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 80 ÷ 120 Ohm. Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Page 180 SPORTCITY CUBE 250 - 300 Injection Circuit leak test Fit the specific tool for fuel pressure control with the pipe fitted with the pressure gauge on the de- livery pipe. Checking under regular functioning by placing the specific tool between the pump and the injector. With >12V battery voltage, check that the fuel pressure is 2.5 BAR and that the input current is 1.4 ÷...
Page 181 SPORTCITY CUBE 250 - 300 Injection Fuel filter check Disconnect the terminals of the electrical pump Remove the screw indicated in the photograph Remove the clamp fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph.
Page 182 SPORTCITY CUBE 250 - 300 Injection Remove the filter from the pump support Inspecting the injector circuit COMPONENTS Specification Desc./Quantity Injection electronic control unit Ignition key contacts Main fuses Battery 12V - 12 Ah Auxiliary fuses Injection load remote control Fuel pump Fuel injector HV coil...
Page 183 SPORTCITY CUBE 250 - 300 Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 80 ÷ 120 Ohm. Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Page 184 SPORTCITY CUBE 250 - 300 Injection With injector disconnected and the injector load remote control disconnected, check the continuity of the Red-Brown cable between the injector con- nector and remote control base. Inspecting the injector hydraulics To check the injector, remove the intake manifold by removing the three fixing screws at the head and the clip connecting the control unit to the mani- fold...
Page 185: Components Location
SPORTCITY CUBE 250 - 300 Injection Carry out the injector sealing test Dry the injector outlet with a blast of compressed air. Activate the fuel pump. Wait for one minute and make sure there are no leaks coming from the injector.
Page 186 SPORTCITY CUBE 250 - 300 Injection 12. HV coil Tachometer With interface wiring disconnected from the control unit and connected to the system, check that the sensor resistance between pins 13 - 15 is between 100 and 150 Ohm at an engine temperature of about 20°...
Page 187 SPORTCITY CUBE 250 - 300 Injection With the interface cabling disconnected from the control unit, check the continuity of the rpm sensor connector red cable between pin 13 and pin 1 and the rpm sensor connector white cable between pin 15 and pin 2 With the interface wiring disconnected from the control unit and the rpm sensor connector also...
Page 188 SPORTCITY CUBE 250 - 300 Injection Specification Desc./Quantity Ignition key contacts Main fuses Battery 12V - 12 Ah Auxiliary fuses Injection load remote control Fuel pump Fuel injector HV coil The combined ignition/injection system is a high-efficiency induction system. The control unit manages two significant parameters: - Ignition advance This is optimised at once according to the engine revs, engine load, temperature and ambient pressure.
Page 189 SPORTCITY CUBE 250 - 300 Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 80 ÷ 120 Ohm. Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Page 190: Coolant Temperature Sensor
SPORTCITY CUBE 250 - 300 Injection Coolant temperature sensor TEMPERATURE SENSOR Specification Desc./Quantity Injection electronic control unit Water Temperature Sensor Instrument panel On the interface wiring with the control unit side connector disconnected and the coolant tempera- ture sensor connector connected, check the re- sistance values between pins 9 and 26 in relation to the engine temperature.
Page 191 SPORTCITY CUBE 250 - 300 Injection With the control unit side connector disconnected and the coolant temperature sensor connector dis- connected, check the continuity of the Orange cable between pin 9 of the interface wiring and the pin 3 of sensor connector, and the continuity be- tween pin 26 of the interface wiring and pin 1 of sensor connector Specific tooling...
Page 192 SPORTCITY CUBE 250 - 300 Injection Specific tooling AP8140595 Axone + battery charger (230V 50Hz) AP8202311 Axone + battery charger (110V 60Hz) Make sure that the throttle valve control is in con- tact with the stop screw. Guaranteeing that this position will be kept, give the confirmation for the TPS reset procedure. Reset should be performed in the following cases: - on first fitting.
Page 193: Lambda Probe
SPORTCITY CUBE 250 - 300 Injection Lambda probe The lambda probe or oxygen sensor is a sensor which provides information about the oxygen content in the exhaust fumes. The signal generated is not of the proportional but of the ON/OFF type, i.e. whether there is oxygen or not.
Page 194: Signal Check
SPORTCITY CUBE 250 - 300 Injection between the fuse box in the battery compartment and the remote control base and of the Red-Blue cable between pin 20 of the control unit and the remote control base. NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED. (BATTERY, REMOTE CONTROLS, CONTROL UNIT, FUSES, ETC.).
Page 195: Index Of Topics
INDEX OF TOPICS SUSP USPENSIONS...
Page 196: Removing The Front Wheel
SPORTCITY CUBE 250 - 300 Suspensions Front Removing the front wheel KEY: 1. Grey front wheel rim; 2. Bearing; 3. Spacer; 4. Front wheel left spacer; 5. Front wheel right spacer; 6. Front wheel pin; 7. Tubeless valve; 8. Front brake disc; 9.
Page 197: Front Wheel Hub Overhaul
SPORTCITY CUBE 250 - 300 Suspensions Rest the vehicle on its centre stand. • Place a support under the chassis. • Remove the brake calliper. • Loosen the pin locking screw. CAUTION UPON REMOVING/REFITTING, PAY ATTENTION NOT TO DAMAGE THE BRAKE HOSES, DISCS AND PADS. •...
Page 198: Wheel Axle
SPORTCITY CUBE 250 - 300 Suspensions • Wash all the parts with clean deter- gent. CAUTION UPON REFITTING, USE A BUFFER WITH A DIAMETER EQUAL TO THE EXTERNAL RING OF THE BEARINGS TO INSERT THE BEARINGS. DO NOT HIT THE BALLS AND/OR THE INTERNAL RING.
Page 199 SPORTCITY CUBE 250 - 300 Suspensions 2 mm Check the tyre conditions. CAUTION CHECK TYRE TREAD FOR WEAR. BADLY WORN TYRES COMPROMISE TRACTION AND VEHICLE HANDLING. REPLACE TYRES WHEN WORN OR IF THERE IS A PUNC- TURE BIGGER THAN 5 MM IN THE TREAD. SOME TYRE TYPES HOMOLOGATED FOR THIS VEHICLE FEATURE WEAR INDICATORS.
Page 200 SPORTCITY CUBE 250 - 300 Suspensions • Unscrew the two screws and remove the u-bolt fixing the brake pump. • Repeat the operations now for the left brake pump. • Undo the safety screw and handlebar fixing screw; collect the washer. •...
Page 201: Front Fork
SPORTCITY CUBE 250 - 300 Suspensions Front fork KEY: 1. Fork base 2. Fork clamp screws 3. Snap ring 4. Rubber cap 5. Sealing cap 6. O-ring 7. Spring 8. Pumping member 9. Counter spring 10. Bottom buffer 11. Left stem 12.
Page 202 SPORTCITY CUBE 250 - 300 Suspensions 20. Right stem 21. Right wheel holder 22. Locking screw Removal STEM REMOVAL • Remove the front wheel. • Remove the front mudguard. • Undo and remove the two screws «1». NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE WHEEL HOLDER STEM - SLEEVE, BUT THEY APPLY TO BOTH.
Page 203 SPORTCITY CUBE 250 - 300 Suspensions • Remove the upper closing cap. • Lower the pumping element until the Seeger ring «1» can be removed. • Remove the Seeger ring «1». • Remove the cap and the O-ring. • Remove the spring and wait some mi- nutes so that the oil deposited on it drips off.
Page 204 SPORTCITY CUBE 250 - 300 Suspensions • Drain off the oil into the collecting con- tainer by pumping it out with the stem. WHEEL HOLDER STEMS SLEEVES REMOVAL • Drain off the oil. • Place the stem in a vice fitted with pro- tection jaws (aluminium).
Page 205 SPORTCITY CUBE 250 - 300 Suspensions • Remove the pumping member «2» and the spring «3» from the stem. • Remove the dust guard from the sleeve. • Remove the Seeger ring. • Remove the oil seal. SUSP - 205...
Page 206 SPORTCITY CUBE 250 - 300 Suspensions • Remove the washer. • If necessary, remove the spacer «4». Overhaul Components check Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (fine grain). •...
Page 207 SPORTCITY CUBE 250 - 300 Suspensions • Check that there are no damages and/ or cracks; otherwise, replace it. • If there are signs of excessive wear or damage, replace the affected compo- nent. Replace the following components with new ones: •...
Page 208 SPORTCITY CUBE 250 - 300 Suspensions • Insert the oil seal. • Fit the Seeger ring. • Fit the dust guard. • Insert the pumping member and the spring in the stem. SUSP - 208...
Page 209: Oil Filling
SPORTCITY CUBE 250 - 300 Suspensions • Fit the components below on the sleeve in the following order: the cen- tring bushing «2» and the stem. • Tighten the lower screw «3». • Refill with oil. OIL FILLING • Place the wheel holder stem sleeve unit in a vice fitted with protection jaws (aluminium).
Page 210 SPORTCITY CUBE 250 - 300 Suspensions • Pour fork oil into the wheel holder stem sleeve unit. CAUTION NEVER REUSE OIL. • Remove the cap with the O-ring. • Fit the pumping member «1». • Lower the pumping element until the Seeger ring «2»...
Page 211: Steering Column
SPORTCITY CUBE 250 - 300 Suspensions • Fit the upper closing cap. Steering column KEY: 1. Cap; 2. Lock nut; 3. Adjusting nut; 4. Upper dust guard; 5. Upper bearing; 6. Separating ring; 7. Lower bearing; 8. Lower dust guard. SUSP - 211...
Page 212: Steering Bearing
SPORTCITY CUBE 250 - 300 Suspensions Steering bearing Check that the ball contact area «1» on the rotating seat «2» and on the fixed seat «3» is not damaged or too worn. Replace the whole bearing if neces- sary. CAUTION CHECK THAT THE COMPONENTS ARE IN GOOD CONDI- TIONS.
Page 213 SPORTCITY CUBE 250 - 300 Suspensions 8. Brake disc; *9. TE flanged screw; 10. SPEED SENSOR screw; 11. Tubeless valve. • Park the vehicle on its centre stand. • Remove the exhaust silencer. • Remove the right rare shock absorber. •...
Page 214 SPORTCITY CUBE 250 - 300 Suspensions Swing-arm KEY: 1. Engine coupling link rod 2. Chassis coupling link rod 3. Silent-block 4. Chassis hinge pin 5. Link rod hinge pin 6. Engine hinge pin 7. Spacer 8. Link rod bushing 9. Resin bushing 10.
Page 215 SPORTCITY CUBE 250 - 300 Suspensions - Rest the vehicle on its centre stand. - Remove the lower cover. - Remove the footrest. - Support the engine firmly. - Unscrew the pin connecting it to the engine and collect the spacer. - Operating from both sides of the vehicle, unscrew the nut from the inside and collect the washer.
Page 216 SPORTCITY CUBE 250 - 300 Suspensions - Slide off the pin connecting it to the chassis. - Remove swinging arm by sliding it off towards the front. Overhaul WARNING CHECK SWINGING ARM CLEARANCES WITH THE ARM FITTED IN RIDING CONDITIONS. - Remove the lower cover.
Page 217 SPORTCITY CUBE 250 - 300 Suspensions - Check clearances on the connection between the chassis-side arm and the chassis using a thick- ness gauge. - If values non-conforming with those specified are measured, remove the arm and replace the Teflon spacer bushings.
Page 218: Shock Absorbers
SPORTCITY CUBE 250 - 300 Suspensions Refitting - Follow the removal steps but in reverse order. - Tighten to the prescribed torque. LINK ROD Name Torque in Nm Connecting rod to chassis retainer 60±20% Connecting rod to engine retainer 40±20% Chassis connecting rod on engine connecting rod retainer 60±20% Silent-block on chassis retainer...
Page 219: Centre-Stand
SPORTCITY CUBE 250 - 300 Suspensions • Lower the shock absorber. • Unscrew and remove the nut «1». • Slide off the right shock absorber. • Unscrew and remove the nut «2» and collect the washer. • Remove the screw «3». •...
Page 220 SPORTCITY CUBE 250 - 300 Suspensions To refit, carry out removal operations but in reverse order SUSP - 220...
Page 221: Index Of Topics
INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 222: Rear Brake Calliper
SPORTCITY CUBE 250 - 300 Braking system Rear brake calliper Removal • Undo the two screws indicated and re- move the brake calliper. • If you would like to replace the calliper, undo the screw joining the pipe to the calliper.
Page 223: Rear Brake Disc
SPORTCITY CUBE 250 - 300 Braking system • Undo the two screws indicated and re- move the brake calliper. • If you would like to replace the calliper, undo the screw joining the pipe to the calliper. To refit, carry out the removal operations but in reverse order. Locking torques (N*m) Calliper on fork retainer 25±20% Rear brake disc...
Page 224: Front Brake Disc
SPORTCITY CUBE 250 - 300 Braking system • Check the brake disc for wear by measuring the minimum thickness with a micrometer at different points. Replace the disc if the minimum thickness, even at a single point of the disc, is less than the minimum value.
Page 225: Front Brake Pads
SPORTCITY CUBE 250 - 300 Braking system • Check the brake disc for wear by measuring the minimum thickness with a micrometer at different points. Replace the disc if the minimum thickness, even at a single point of the disc, is less than the minimum value.
Page 226: Rear Brake Pads
SPORTCITY CUBE 250 - 300 Braking system AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER; OTHERWISE, THE CAL- LIPER 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.
Page 227 SPORTCITY CUBE 250 - 300 Braking system • Slide off the pin. • Remove the spring. CAUTION THE ARROW STAMPED ON THE SPRING MUST ALWAYS BE TURNED IN THE RIDING DIRECTION. • Slide off the brake pads. • Check friction material for appropriate thickness.
Page 228: Rear Brake
SPORTCITY CUBE 250 - 300 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 CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED.
Page 229 SPORTCITY CUBE 250 - 300 Braking system BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. • Screw the bleeding valve and remove the pipe. • Top-up the reservoir until the correct brake fluid level is obtained. •...
Page 230 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 231: Circuit Diagram
SPORTCITY CUBE 250 - 300 Cooling system Circuit diagram KEY: 1. Expansion tank with cap; 2. Radiator / fitting pipe; 3. Radiator fitting / pump pipe; 4. Clamp; 5. Breather pipe; 6. White clic clamps; 7. White clic clamp; 8. Expansion tank cap; 9.
Page 232 SPORTCITY CUBE 250 - 300 Cooling system Electric fan check Key: 1.CDI control unit 2. Fan 3.Key switch 4. Main fuses 5. Battery 6. Auxiliary fuses 7.Fan relay ELECTRIC FAN OPERATION CHECK To check the electric fan operation: • Remove the front wheel housing. •...
Page 233: Coolant Replacement
SPORTCITY CUBE 250 - 300 Cooling system • Check the connection of the fan con- nector. • Rotate the fan manually and check that the blades do not touch the support. If the rotation is free of obstacles: • Check the battery charge system and the main fuse.
Page 234 INDEX OF TOPICS CHAS HASSIS...
Page 235: Rear Rack
SPORTCITY CUBE 250 - 300 Chassis Seat • Undo and remove the four screws. • Remove the saddle. Rear rack • Lift the saddle. • Undo and remove the four screws. • Slide off the screw cover cap. • Undo and remove the screw. •...
Page 236: Instrument Panel
SPORTCITY CUBE 250 - 300 Chassis Driving mirrors Loosen the nut indicated. CAUTION THE RIGHT MIRROR SHOULD BE UNSCREWED CLOCK- WISE. Rear handlebar cover • Remove the front handlebar cover. • Undo the two screws indicated. • Disconnect the connector powering the instrument panel.
Page 237 SPORTCITY CUBE 250 - 300 Chassis Front handlebar cover • Undo the two screws indicated. • Operating from both sides of the vehi- cle, undo the two screws indicated. • Operating on both sides of the vehicle, undo the screw indicated. Frame central cover •...
Page 238 SPORTCITY CUBE 250 - 300 Chassis • Undo and remove the two screws. • Remove the central inspection cover by sliding it off its hooks. Legshield • Operating on both sides, undo and re- move the screw. • Remove the front case by sliding it off its hooks, being careful with the tongues and the fitting slots.
Page 239 SPORTCITY CUBE 250 - 300 Chassis • Remove the front mudguard. • R emove the front wheel. • Working on both sides, undo and re- move the five screws. CAUTION PLACE A SUPPORT UNDER THE CHASSIS SO THAT THE FRONT WHEEL DOES NOT TOUCH THE GROUND. <span style="FONT-SIZE: 9pt;...
Page 240 SPORTCITY CUBE 250 - 300 Chassis • Working on both sides, undo the two screws and remove the front turn indi- cators from the back. • Slide the external front shield off the front fork. Knee-guard • Remove the front central cover. •...
Page 241 SPORTCITY CUBE 250 - 300 Chassis • Insert the key in the glove-box lock, turn it clockwise and open the com- partment. • Undo and remove the four screws. • Close the glove-box. • Operating from both sides, undo and remove the four side screws.
Page 242 SPORTCITY CUBE 250 - 300 Chassis • Operating on both sides, undo and re- move the two screws of the footrest. • Remove the battery. • Unscrew and remove the bolt inside the battery compartment. • Operating from both sides, undo and remove the lower screw fixing it to the internal legshield.
Page 243 SPORTCITY CUBE 250 - 300 Chassis Side fairings Left and right fairings removal • Remove the rear central cover. • Undo and remove the screw. • Undo the two screws and remove the passenger footrest rubber. • Undo and remove the screw. •...
Page 244 SPORTCITY CUBE 250 - 300 Chassis Air filter • Remove the left side fairing. • Remove the helmet compartment. • Loosen the intake manifold clamp. • Slide off the intake manifold. • Undo the two screws fixing the filter casing. •...
Page 245 SPORTCITY CUBE 250 - 300 Chassis • Undo and remove the two screws in- side the helmet compartment. • Operating on both sides, undo and re- move the screw. • Undo and remove the three fixing screws. CHAS - 245...
Page 246: Rear Mudguard
SPORTCITY CUBE 250 - 300 Chassis • Remove the tail section from it fittings with the side fairings. • Move the tail section backwards and disconnect the rear light connector. • Undo the two fixing screws and remove the seat lock. •...
Page 247 SPORTCITY CUBE 250 - 300 Chassis • Undo the three screws and remove li- cense plate. • Undo and remove the screw. • Undo and remove the screws indica- ted. • Undo the screw and slide off the li- cense plate light backwards. CHAS - 247...
Page 248 SPORTCITY CUBE 250 - 300 Chassis • Disconnect the license plate light con- nector. • Remove the rear mudguard. Should the rear mudguard holder frame be re- moved before taking out the rear mudguard pro- ceed as follows: • Undo and remove the two screws. Helmet bay •...
Page 249: Front Mudguard
SPORTCITY CUBE 250 - 300 Chassis • Working on both sides of the vehicle, undo the screw indicated and collect the washer. • Remove the helmet compartment. Front mudguard • Operating from both sides, undo and remove the two screws. •...
Page 250: Radiator Fan
SPORTCITY CUBE 250 - 300 Chassis • Undo the two screws indicated. Radiator fan • Drain off the system. • Remove the shield back plate. • Remove the legshield. • Disconnect the electric fan connector. • Disconnect the two thermal switch con- nectors.
Page 251: Expansion Tank
SPORTCITY CUBE 250 - 300 Chassis • Undo and remove the screw. • Slide off the radiator upwards. Expansion tank Drain off the cooling system: • Remove the front central cover. • Remove the shield back plate. • Loosen and remove the clamp. •...
Page 252: Lower Cover
SPORTCITY CUBE 250 - 300 Chassis • Operating from both sides, undo and remove the screw. • Remove the expansion tank. Lower cover • Undo and remove the rear screw. • Undo and remove the two side screws. • Undo and remove the two screws. CHAS - 252...
Page 253 SPORTCITY CUBE 250 - 300 Chassis • Undo and remove the screw fixing it to the legshield on the front wheel hous- ing. • Undo and remove the screw. • Lift the footrest and slide the lower shield off its hooks being careful with the tongues and related fitting slots.
Page 254 INDEX OF TOPICS PRE DE DELIVERY...
Page 255 SPORTCITY CUBE 250 - 300 Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...
Page 256 SPORTCITY CUBE 250 - 300 Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
Page 257: Static Test
SPORTCITY CUBE 250 - 300 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)
Page 258 Accessories: 78 Air filter: 47, 244 Battery: 76, 81, 91 Brake: 222–226 Brake calliper: 222 Brake disc: 223, 224 Brake pads: 225, 226 Bushings: Clutch: 108, 109, 114 Coil: 187 Connectors: 95 coolant: 190, 233 Coolant: 190, 233 Crankcase: 24, 135, 145–148 Crankshaft: 24, 135, 145, 146, 148, 153 Cylinder: 19, 28, 131, 134–136, 138–141 Display:...
Page 259 Lambda probe: 193 Maintenance: 9, 45 Maintenance Table: Mirrors: 236 Mudguard: 246, 249 Oil sump: 159, 160 Radiator: 250 Rear wheel: 212 Recommended products: Saddle: Shock absorbers: 218 Side fairings: 243 Spark plug: 45, 80 Stand: Start-up: Starter motor: 127, 130 Tank: 249, 251 Technical data: Transmission: 14, 105, 118...

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