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Table of Contents
Troubleshooting
Related Manuals for APRILIA Enjoy City
Summary of Contents for APRILIA Enjoy City
- Page 1 Workshop manual Enjoy Racing Enjoy City 1037Y...
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Page 2: Introduction
As the repairing and checking procedures are not described in full detail, special care should be taken in avoiding damage to property and personal injury. With a view to providing its customers with the best possible riding experience, aprilia is committed to continually improving its products and the accompanying documentation. -
Page 3: Table Of Contents
Enjoy CONTENTS Introduction ............................... 1 SAFETY SIGNS ............................4 PRECAUTIONS AND GENERAL INFORMATION ..................5 GENERAL SPECIFICATIONS FOR TIGHTENING TORQUES ..............7 SPECIFICATIONS ............................ 9 TIGHTENING OF BOLTS AND NUTS ....................10 FASTENINGS ............................11 TROUBLESHOOTING ..........................12 LED AND BUZZER ALARMS ........................12 TROUBLESHOOTING .......................... - Page 4 Enjoy CHECKING THE TORQUE SENSOR ..................... 34 REMOVING THE SPEED SENSOR ....................... 34 CHECKING THE SPEED SENSOR ......................35 DISASSEMBLING THE STEERING SET (Racing Version) ..............35 DISASSEMBLING THE STEERING SET (City Version) ................. 36 ADJUSTING THE STEERING PLAY (Racing Version) ................37 ADJUSTING THE STEERING PLAY (City Version) ................
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Page 5: Safety Signs
Enjoy SAFETY SIGNS The following signs are used throughout the manual to denote the following: Safety warning sign. Whenever this symbol is shown on the vehicle or in the manual, there is a risk of personal injury. Failure to observe the prescriptions that follow this sign may expose you and other people to danger and cause damage to the vehicle. -
Page 6: Precautions And General Information
Enjoy PRECAUTIONS AND GENERAL INFORMATION When repairing, disassembling and reassembling the vehicle, scrupulously observe the following recommenda- tions. CAUTION The use of open flames is forbidden under all circumstances. Before performing any servicing or checks, switch off the motor, remove the key, allow the motor to cool down, and if possible lift the vehicle on a solid level floor using specific equipment. - Page 7 Enjoy Only use GENUINE aprilia spares. Always use the recommended lubricants and consumables. If possible, lubricate parts before refitting them. When tightening screws and nuts, start with the larger or the inner ones and proceed diagonally. Carry out the tightening in successive steps before applying the full tightening torque.
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Page 8: General Specifications For Tightening Torques
Enjoy GENERAL SPECIFICATIONS FOR TIGHT- ENING TORQUES The table below shows standard tightening torques for screws and bolts with ISO metric threads. Tightening torques Spanners Screw/bolt Nm (Ft-lb) 3 (2.2) 6 (4.4) 15 (11.1) 30 (22.1) 55 (40.5) 85 (62.7) 130 (95.9) 13.0 For information on specific joints and connections of... - Page 9 Enjoy Pedal crank shaft Chain tool fixing ring nut fastening tool Free wheel Spoke spanner removing tool Free wheel Pedal crank extractor fitting and removing tool Hub bearing adjusting Shears sole spanner Front sprocket Steering set adjusting removing tool sole spanner pair (City Version) Release 00 2000-11...
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Page 10: Specifications
Enjoy SPECIFICATIONS DIMENSIONS mm (in) RACING CITY 1760 (69.291) 1760 (69.291) Maximum length 430 (16.929) 430 (16.929) Maximum width 1030 (40.551) 1130 (44.488) Maximum handlebar height 1020 (40.157) 1020 (40.157) Saddle height (fully extracted) 1100 (43.307) 1100 (43.307) Wheelbase 29.5 (1.161) 31(1.220) Dry weight kg (lbs) ELECTRIC MOTOR... -
Page 11: Tightening Of Bolts And Nuts
Enjoy FRAME Type Extruded tubular aluminium 7005 T6 Steering angle 70° SUSPENSIONS spring and elastometer shock absorber Front fork BRAKES Front mechanical “V-brake” mechanical “V-brake” Rear WHEELS RACING CITY 26” x 1.90” 26” x 1.75” Front 26” x 1.90” 26” x 1.75” Rear TYRE INFLATING PRESSURES 3.0 to max 4.5 bar... -
Page 12: Fastenings
Enjoy FASTENINGS Check and if necessary tighten the fastenings after the first 500 km (312 mi), and then every 500 km (312 mi) or 6 months. WARNING The fastenings shown in the table below must be tightened using a torque spanner and, where appropriate, LOCTITE ®. -
Page 13: Troubleshooting
Enjoy TROUBLESHOOTING LED AND BUZZER ALARMS BUZZER ALARM SOLUTION Intermittent buzzer alarm: The battery voltage bassa Charge the battery. indicator is 0.8" on / 0.2" off is too low. always ON. Intermittent buzzer alarm: The battery middle is too Charge the battery. indicator is 0.3"... -
Page 14: Troubleshooting
Enjoy TROUBLESHOOTING TROUBLE CAUSE REMEDY Pedalling difficult - Main switch not set to ON. - Set the main switch to ON. - Battery voltage low. - Ensure that the battery is secure. - Battery improperly installed. - Fully recharge the battery. - Position the battery properly. -
Page 15: Scheduled Maintenance
Enjoy SCHEDULED MAINTENANCE Each Time You Ride Wipe off your bicycle with a damp rag. Check tyre pressure. Check brakes. Weekly Oil cable,chain and pivot points (brake levers and V-brakes, shift levers, derailleurs) with a light bicycle lubricant. Avoid heavy oils that evaporate and leave a gummy residue. -
Page 16: Lubricating Points
Enjoy LUBRICATING POINTS KEY TO LUBRICATING POINTS 1) Steering bearings Proper lubrication is a key factor in ensuring smooth 2) Drive chain operation and long life of the vehicle. 3) Derailleur 4) Central stand pin IMPORTANT Before lubricating any parts, thor- 5) Brake cables oughly clean them of any rust, grease, dirt or dust. -
Page 17: Location Of Serial Numbers
Enjoy LOCATION OF SERIAL NUMBERS These numbers are required to register the vehicle. IMPORTANT Tampering with vehicle serial num- bers is subject to severe penalties. In particular, tampering with the frame number immediately voids the warranty. FRAME NUMBER The frame number is stamped on the frame central section. -
Page 18: Bike Components
Enjoy BIKE COMPONENTS KEY TO COMPONENTS 19) FRAME 1) FRONT WHEEL 20) REAR BRAKE 2) FRONT SUSPENSION FORK 21) REAR WHEEL 3) FRONT MUDGUARD 22) REAR MUDGUARD 4) FRONT BRAKE 23) CARRIER 5) FRONT LAMP 24) REAR LAMP 6) BRAKE LEVER 25) REAR DERAILLEUR 7) GRIP SHIFT 26) CHAIN... -
Page 19: Power Plant
Enjoy POWER PLANT More unique features aprilia cycle is its Power Plant design, such as Dual-Sense module (torque sensor+speed sensor), enhanced computerized controller, spiral bevel gearing drivetrain system, etc. Spiral bevel gearing drive-train system (Dualsense Module = Torque sensor + Speed sensor) -
Page 20: Function Switch
Enjoy FUNCTION SWITCH Information on the function switch 1. As illustrated above,it is a 3-mode switch, which has left,middle,and right positions. 2. The function and definition of the switch An economic mode in lower power assisting, the assistance will be automatically off when the speed reaches about 24 km/hr (15 mi/hr). -
Page 21: Led Indicator Functions
Enjoy LED INDICATOR FUNCTIONS The LED indicator shows the battery voltage. The voltage can be high (LED 4 lit) or low (LED 1 lit) according to both the remaining battery capacity and to the operating conditions. Battery Indicator The longest range in kilometres is obtained by using the derailleur so that LEDs 3 and 4 stay lit as long as possible (use light gear ratios and avoid, for example, starting in 6th gear). -
Page 22: Safety Specifications
Enjoy SPECIFICATION Item Specification Model Cod. Apr. Output Current 4Adc ± 5% Output Voltage 32.0Vdc ± 2% Input Current 2.0A Input Voltage 100-120 Vac Or 200-240 Vac (Manual Select) Performance Switching Mode Charging Method Two Stage Constant Current Battery Application Ni-MH Batteries (1.2V a 20 Cells 13000mAh) Output Detection... -
Page 23: Recharging Safety
Enjoy RECHARGING SAFETY Avoid recharging the battery under the following circumstances: Immediately after using the bicycle, when the battery temperature has increased. When ambient temperature is higher than 30° C or lower than 0° C. BATTERY RECHARGING PROCEDURE The battery can be recharged by inserting the plug directly into the socket on the frame. -
Page 24: Led Indications
Enjoy LED INDICATIONS When the colour of the battery charger recharge LED changes from orange to green, recharging is com- plete. At that point, the charger current will decrease, and even if the power cord stays connected no dam- age will occur. If the battery charger recharge LED (orange LED) does not light up, the recharge system is not working properly. -
Page 25: Removing The Battery
Enjoy REMOVING THE BATTERY Read through the section PRECAUTIONS AND GENERAL INFORMATION. Put the bicycle on the stand. Press power switch (1) and rotate it anticlockwise to the OPEN position. Open recharge cover (2). Remove battery (3) by pulling handle (4). REMOVING THE SIDE FAIRINGS Read through the section PRECAUTIONS AND GENERAL INFORMATION. -
Page 26: Removing The Function Switch
Enjoy REMOVING THE FUNCTION SWITCH Read through the section PRECAUTIONS AND GENERAL INFORMATION. Put the vehicle on the stand. Remove the battery as described in the paragraph REMOVING THE BATTERY. Remove the side fairings as directed in the paragraph REMOVING THE SIDE FAIRINGS. Detach three-way electrical connector (1). -
Page 27: Checking The Brake Switches
Enjoy CHECKING THE BRAKE SWITCHES Read through the section PRECAUTIONS AND GENERAL INFORMATION. Put the vehicle on the stand. Remove the battery as described in the paragraph REMOVING THE BATTERY. Remove the side fairings as directed in the paragraph REMOVING THE SIDE FAIRINGS. Detach two-way electrical connector (2) (white). -
Page 28: Removing The Controller
Enjoy REMOVING THE CONTROLLER Read through the section PRECAUTIONS AND GENERAL INFORMATION. Put the vehicle on the stand. Remove the battery as described in the paragraph REMOVING THE BATTERY. Remove the side fairings as directed in the paragraph REMOVING THE SIDE FAIRINGS. Detach all controller connections. -
Page 29: Removing The Battery Condition Indicator
Enjoy REMOVING THE BATTERY CONDITION INDICATOR Read through the section PRECAUTIONS AND GENERAL INFORMATION. Put the vehicle on the stand. Remove the battery as described in the paragraph REMOVING THE BATTERY. Remove the side fairings as directed in the paragraph REMOVING THE SIDE FAIRINGS. -
Page 30: Removing The Power Plant
Enjoy REMOVING THE POWER PLANT Read through the section PRECAUTIONS AND GENERAL INFORMATION. Remove the side fairings as directed in the paragraph REMOVING THE SIDE FAIRINGS. Unscrew pedal crank (1), paying attention to the direction of the thread. Loosen and remove the two screws (2). Loosen screw (3) without removing it. - Page 31 Enjoy Loosen and remove the three screws (12). Detach the speed sensor and torque sensor electrical connectors, (14) and (15) respectively. While supporting the power plant, completely remove screw (13). Remove power plant (16), paying attention to the cables and electrical connectors. Release 00 2000-11...
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Page 32: Checking The Power Plant
Enjoy CHECKING THE POWER PLANT Follow these steps should any unspecified malfunc- tion occur: - Check the battery charge. - Disconnect the motor from the battery by detaching the connector and then measure the resistance between the wires, which should be 1 ± 0.5 Ohm at 25°... - Page 33 Enjoy Loosen and remove the two screws (5). Remove electric motor (6). Check the condition of the O-rings (7) fitted to studs (8) and if necessary replace them. Disconnect electric motor (6) from the drive unit. Remove drive gear (9). Check the condition of gasket (10) and if necessary replace it.
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Page 34: Removing The Torque Sensor
Enjoy Using a plastic mallet, strike a few blows on drive shaft (13) to remove drive unit cover (14) with the crown. Check the condition of the O-ring on the drive unit cover and if necessary replace it. From the drive unit, remove, in the following order, speed sensor mitre wheel (15), planetary gear system (16), and toothed wheel (17), interacting with the torque sensor. -
Page 35: Checking The Torque Sensor
Enjoy CHECKING THE TORQUE SENSOR CHECKING PROCEDURE WITH THE TORQUE SENSOR NOT INSTALLED Using a multimeter, perform the following check: - Check that the sensors are in perfect mechanical condition. - Connect the red wire to 12 V dc. - Earth the black wire. - The voltage between the white and black wires should be 1.15 ±... -
Page 36: Checking The Speed Sensor
Enjoy Unscrew and remove speed sensor (2) with the related O-ring. CHECKING THE SPEED SENSOR CHECKING PROCEDURE WITH THE SPEED SENSOR INSTALLED Read through the section PRECAUTIONS AND GENERAL INFORMATION. Remove the battery as described in the paragraph REMOVING THE BATTERY. Remove the side fairings as directed in the paragraph REMOVING THE SIDE FAIRINGS so as to gain access to the sensor connector. -
Page 37: Disassembling The Steering Set (City Version)
Enjoy Loosen the two screws (4) without removing them. Loosen screw (5). Remove the cable from the front brake so as to disengage the fork. While supporting the fork, remove handlebar support (6). Remove steering head tube (7) with fork assembly (8). Remove the following components in sequence: handlebar support (9) washer (10) -
Page 38: Adjusting The Steering Play (Racing Version)
Enjoy To remove the steering set, remove counternut (4) and completely unscrew adjusting ring nut (5). ADJUSTING THE STEERING PLAY (Racing Version) Loosen the two stop nuts (1) without removing them and then turn upper adjusting screw (2) clockwise until the desired play is obtained. -
Page 39: Removing The Front Wheel Assembly
Enjoy REMOVING THE FRONT WHEEL ASSEMBLY Read through the section PRECAUTIONS AND GENERAL INFORMATION. When removing and refitting the wheel, take care not to damage other parts of the vehicle. IMPORTANT Provide yourself with the specially designed bicycle stand before attempting to remove the front wheel. -
Page 40: Refitting The Front Wheel
Enjoy REFITTING THE FRONT WHEEL Read through the section PRECAUTIONS AND GENERAL INFORMATION. CAUTION Danger of personal injury! Do not insert the fin- gers to align the holes. Shift the wheel until the central spindle is aligned with the slotted holes on the fork. Tighten nut (1) until the play between the clamping system and fork sheaths (2) is such that quick clamp lever (3) can be closed with the proper tightening... -
Page 41: Removing The Front Brake Cable
Enjoy REMOVING THE FRONT BRAKE CABLE Read through the section PRECAUTIONS AND GENERAL INFORMATION. Put the vehicle on the stand. Turn the power switch to OFF. Detach cable guide tube (1), which is anchored to brake arm (2), after manually bringing the brake unit into braking position. -
Page 42: Removing The Rear Wheel Assembly
Enjoy Brake arm adjustment Turn adjusting screw (4) with a screwdriver. The following operation applies to both brake arms. Turn in the screw to move the brake arm away from the rim. Turn out the screw to move the brake arm towards the rim. -
Page 43: Checking The Rear Wheel
Enjoy CHECKING THE REAR WHEEL WARNING Check the condition of all components, and in particular of the following: BEARINGS Manually rotate race (1) making sure it turns smoothly and silently. There should be no axial plays. Any bearings showing the above defects must be replaced. -
Page 44: Removing The Rear Brake Cable
Enjoy Reattach cable guide tube (6) after manually closing the brakes on brake arm (7). CAUTION After replacing the wheel, repeatedly actuate the rear brake lever and check the operation of the brake system. Check the alignment of the wheel. REMOVING THE REAR BRAKE CABLE Read through the section PRECAUTIONS AND GENERAL INFORMATION. -
Page 45: Removing The Rear Brake Assembly
Enjoy REMOVING THE REAR BRAKE ASSEMBLY Read through the section PRECAUTIONS AND GENERAL INFORMATION. Put the vehicle on the stand. Turn the power switch to OFF. Remove the cable from the assembly as described in the paragraph REMOVING THE REAR BRAKE CABLE. -
Page 46: Wiring Diagram
Enjoy WIRING DIAGRAM function motor switch battery charger indicator buzzer NORM HILL connector connector main Bi v switch battery T OV SW1 e YSW2 LOCK CONTROLLER torque sensor TOQ IN brake speed switch sensor CABLE COLOURS 1 Recharge circuit thermistor (Delta-T control, T- orange max control). - Page 47 Enjoy NOTE Release 00 2000-11...
- Page 48 Enjoy NOTE Release 00 2000-11...
- Page 49 Enjoy NOTE Release 00 2000-11...
- Page 50 Via G. Galilei, 1 30033 Noale (VE) Tel. +39 (0) 41 - 5829111 Fax +39 (0) 41 - 441054 www.aprilia.com www.serviceaprilia.com Italy 8000086...