APRILIA SPORTCITY ONE 125 Service Station Manual
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APRILIA SPORTCITY ONE 125 Service Station Manual

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SERVICE STATION MANUAL
854184
SPORTCITY ONE 125

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  • Page 1 SERVICE STATION MANUAL 854184 SPORTCITY ONE 125...
  • Page 2 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.
  • 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 scooters.
  • Page 4 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS PRE DE DELIVERY...
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 6: Safety Rules

    SPORTCITY ONE 125 Characteristics 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.
  • Page 7 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.
  • Page 8 SPORTCITY ONE 125 Characteristics 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 SPECIAL- IST AS SOON AS POSSIBLE.
  • Page 9 NOTE BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH- ERWISE THEY NEED REPLACING. • Use only ORIGINAL aprilia SPARE PARTS. • Comply with lubricant and consumables usage guidelines. • Lubricate parts (whenever possible) before reassembling them.

  • Page 10: Vehicle Identification

    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.

  • Page 11: Specifications

    SPORTCITY ONE 125 Characteristics Specification Desc./Quantity Max. width (to brake levers) 740 mm Max. height (to the rear-view mirrors) 1.270 mm Saddle height 775 mm Wheelbase 1.358 mm Minimum ground clearance 125 mm Kerb weight in running order 126 kg...

  • Page 12: Electrical System

    SPORTCITY ONE 125 Characteristics Specification Desc./Quantity Depth of fork oil level from the rim - without spring - fork included 85 mm Seats Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Battery 12V - 9 Ah Fuse 20 - 7.5 - 15 Ah...

  • Page 13: Wheels And Tyres

    SPORTCITY ONE 125 Characteristics Brakes BRAKES Specification Desc./Quantity Front brake Ø 220-mm disc brake with hydraulic transmission Rear brake Ø 140-mm drum brake with mechanic transmission Wheels and tyres WHEEL RIM Specification Desc./Quantity Rims alloy Front wheel 3.00 x 14"...
  • Page 14 SPORTCITY ONE 125 Characteristics ENGINE UNIT Name Torque in Nm 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 55 ÷...
  • Page 15 SPORTCITY ONE 125 Characteristics HANDLEBAR UNIT Name Torque in Nm Handlebar to headstock fixing nut 52.5 Throttle control fixing screw Opening throttle control transmission fixing nut Mirror fixing screw ELECTRICAL SYSTEM UNIT Name Torque in Nm Horn fixing screw Voltage regulator fixing screw...

  • Page 16: Assembly Clearances

    SPORTCITY ONE 125 Characteristics Name Torque in Nm Bag hook fixing screw Rear mudguard fixing screw LABELS / TRANSFER UNIT Name Torque in Nm License plate fixing nut Overhaul data Assembly clearances Cylinder - piston assy. COUPLING BETWEEN PISTON AND CAST IRON CYLINDER (125)
  • Page 17 SPORTCITY ONE 125 Characteristics Name Description Dimensions Initials Quantity Oil scraper ring 1st 57.2x1 0.10 ÷ 0.30 oversize Oil scraper ring 1st 57.2x2.5 0.10 ÷ 0.35 oversize Compression ring 2nd 57.4x1 0.15 ÷ 0.30 oversize Oil scraper ring 2nd 57.4x1 0.10 ÷...
  • Page 18 SPORTCITY ONE 125 Characteristics Characteristic Crankshaft/crankcase axial clearance «A»: 0.15 ÷ 0.40 Slot packing system SHIMMING SYSTEM Measure taken Gasket thickness 0 ÷ 0.1 0.8 ± 0.05 0.1 ÷ 0.3 0.6 ± 0.05 0.3 ÷ 0.4 0.4 ± 0.05 Characteristic Compression ratio 10.6 ±...
  • Page 19 SPORTCITY ONE 125 Characteristics Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP CITY HI TEC 4T Engine oil SAE 5W/40, API SL, ACEA A3, JASO MA AGIP GEAR SYNTH SAE 75W-90 Gearbox oil API GL4, GL5 AGIP FORK 7.5W Fork oil...
  • Page 20 INDEX OF TOPICS TOOL OOLING...
  • Page 21 SPORTCITY ONE 125 Tooling OOLS Stores code Description 020423Y Driven pulley lock wrench 001467Y009 Bell for OD 42-mm bearings 001467Y013 Calliper to extract 15-mm diameter bear- ings 008564Y Flywheel extractor 020074Y Support base for checking crankshaft alignment 020150Y Air heater support...
  • Page 22 SPORTCITY ONE 125 Tooling Stores code Description 020151Y 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 TOOL - 22...
  • Page 23 SPORTCITY ONE 125 Tooling Stores code Description 020357Y 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...
  • Page 24 SPORTCITY ONE 125 Tooling Stores code Description 020375Y 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...
  • Page 25 SPORTCITY ONE 125 Tooling Stores code Description 020425Y 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...
  • Page 26 SPORTCITY ONE 125 Tooling Stores code Description 020565Y Flywheel lock calliper spanner TOOL - 26...
  • Page 27 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 28: Maintenance Chart

    SPORTCITY ONE 125 Maintenance Maintenance chart OUTINE 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...

  • Page 29: Spark Plug

    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.
  • Page 30 SPORTCITY ONE 125 Maintenance • 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.

  • Page 31: Air Filter

    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».

  • Page 32: Engine Oil

    SPORTCITY ONE 125 Maintenance 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.
  • Page 33 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.

  • Page 34: Fuel Filter

    SPORTCITY ONE 125 Maintenance IN ORDER TO AVOID DAMAGING THE ENGINE, OIL LEVEL MUST NEVER EXCEED THE «MAX» MARK OR FALL BE- LOW THE «MIN» MARK. • Top-up if required. TOP-UP Do not exceed the «MAX» mark level when topping-up engine oil.
  • Page 35 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 CON- TROL.

  • Page 36: Braking System

    SPORTCITY ONE 125 Maintenance 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.
  • Page 37 SPORTCITY ONE 125 Maintenance Top-up • Remove the mirror and the pump cov- CAUTION TO REMOVE THE TWO SCREWS «1» THAT FIX THE RES- ERVOIR COVER «2», TURN THE HANDLEBAR SO THAT THE FLUID INSIDE THE BRAKE FLUID RESERVOIR IS PARALLEL TO «MIN»...

  • Page 38: Headlight Adjustment

    SPORTCITY ONE 125 Maintenance • Top-up the reservoir with brake fluid up to the ''MAX'' level. • Refit gasket «5» correctly in its posi- tion. • Refit cover guide «4» correctly in its position. • Refit cover «2». • Insert and tighten the two screws «1».
  • Page 39 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.
  • Page 40 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 41 SPORTCITY ONE 125 Electrical system 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.
  • Page 42 SPORTCITY ONE 125 Electrical system 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.
  • Page 43 SPORTCITY ONE 125 Electrical system Components arrangement ELE SYS - 43...
  • Page 44 SPORTCITY ONE 125 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.
  • Page 45 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 Characteristic Battery recharging voltage: 13 ÷ 14.5 V at 4000 rpm 7. Auxiliary fuses •...
  • Page 46 SPORTCITY ONE 125 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.
  • Page 47 SPORTCITY ONE 125 Electrical system 13. Coil • Remove the rear central cover to reach 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 ve- hicle right fairing.
  • Page 48 SPORTCITY ONE 125 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.
  • Page 49 SPORTCITY ONE 125 Electrical system Ignition circuit CAUTION THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS- CONNECTED. 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.
  • Page 50 SPORTCITY ONE 125 Electrical system Coil primary check: • Disconnect the connector of the control unit. • Measure the resistance present be- tween terminals No. 4 (White-Purple cable) and No. 12 (Blue cable). • If the measured value is incorrect, re- peat the check between the positive and negative terminals of the coil.
  • Page 51 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 insu- lated from the ground connection.
  • Page 52 SPORTCITY ONE 125 Electrical system THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS- CONNECTED. • 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 Green- Yellow cables.
  • Page 53 SPORTCITY ONE 125 Electrical system level indicators CAUTION THE CONTINUITY TEST SHOULD BE PERFORMED WITH THE RELATIVE CONNECTORS DIS- CONNECTED. • Check continuity of the Green cable which connects the instrument panel to the 15A fuse • Check continuity of the Grey-Green cable which connects the instrument panel to the probe checking fuel level.

  • Page 54: Fuses

    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.

  • Page 55: Sealed/Dry-Charge Battery

    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.
  • Page 56 SPORTCITY ONE 125 Electrical system 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;...
  • Page 57 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..
  • Page 58 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 59 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 OPERA- TIONS, LET THE ENGINE AND THE MUFFLER TO COOL OFF AT AMBIENT TEMPERATURE TO AVOID POTENTIAL BURNS.
  • Page 60 SPORTCITY ONE 125 Engine from vehicle • Disconnect the connector of the auto- matic starter «4» and the connector of the temperature sensor «5» and re- lease the wiring. • Remove the low-pressure pipe «6» from the cylinder head. •...
  • Page 61 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 transmis- sion. Locking torques (N*m) Rear brake adjustment nut CAUTION SUPPORT THE SCOOTER FIRMLY.
  • Page 62 SPORTCITY ONE 125 Engine from vehicle • Undo and remove the engine-rod ful- crum nut «13». • Operating on the chassis, lift the vehi- cle rear part. • Completely slide off the engine-rod ful- crum pin. • Slide off the engine towards the back.
  • Page 63 INDEX OF TOPICS NGINE...

  • Page 64: Automatic Transmission

    SPORTCITY ONE 125 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 driv- en pulley axle locking nut and recover the washer.
  • Page 65 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.

  • Page 66: Inspecting The Clutch Drum

    SPORTCITY ONE 125 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.
  • Page 67 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.
  • Page 68 SPORTCITY ONE 125 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 CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.

  • Page 69: Removing The Clutch

    SPORTCITY ONE 125 Engine Removing the clutch - By means of a calliper spanner, block the clutch assembly rotation. - With a 46 mm spanner re- move the clutch lock nut. - Remove the clutch and the spring. CAUTION UPON REMOVING THE CLUTCH ASSEMBLY LOCK NUT,...
  • Page 70 SPORTCITY ONE 125 Engine Inspecting the driven fixed half-pulley - Measure the external diameter of the pulley bush- ing. 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 O- rings.

  • Page 71: Refitting The Driven Pulley

    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 half- pulley. NOTE...
  • Page 72 SPORTCITY ONE 125 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 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the unloaded length of the spring of the movable driven half-pulley.
  • Page 73 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;...

  • Page 74: Removing The Driving Pulley

    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.
  • Page 75 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.
  • Page 76 SPORTCITY ONE 125 Engine - 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.
  • Page 77 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.
  • Page 78 SPORTCITY ONE 125 Engine Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, 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).
  • Page 79 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.
  • Page 80 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...
  • Page 81 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.
  • Page 82 SPORTCITY ONE 125 Engine 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.

  • Page 83: Removing The Stator

    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.
  • Page 84 SPORTCITY ONE 125 Engine 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...
  • Page 85 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...
  • Page 86 SPORTCITY ONE 125 Engine - Remove the internal hex screw and the counter- weight 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.

  • Page 87: Removing The Cylinder Head

    SPORTCITY ONE 125 Engine - Remove the pin of the rocking levers from the flywheel side holes. - Remove the rocking levers and the elastic wash- NOTE MARK THE ROCKING LEVERS ASSEMBLE POSITION, SO AS TO AVOID THE INVERSION OF INLET WITH THE OUT- LET.

  • Page 88: Inspecting The Small End

    SPORTCITY ONE 125 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.
  • Page 89 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.

  • Page 90: Inspecting The Piston

    SPORTCITY ONE 125 Engine Maximum allowable run-out: 0.05 mm - The cylinder rectifying operation should be car- ried 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 consump- tion and guarantees optimum performance.

  • Page 91: Removing The Piston

    SPORTCITY ONE 125 Engine Inspecting the piston rings NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Interventions rules Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust.
  • Page 92 SPORTCITY ONE 125 Engine - Calculate the difference between the two meas- urements. - By means of the table, see the SPECIFICA- TIONS chapter, identify the cylinder base gasket thickness to be used upon refitting. Correctly iden- tify the cylinder base gasket thickness to keep the correct compression ratio.

  • Page 93: Inspecting The Cylinder Head

    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 retain- ing 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.
  • Page 94 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.
  • Page 95 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 speci- fied limits, replace the cylinder head.
  • Page 96 SPORTCITY ONE 125 Engine - Check that there are no signs of wear on the contact surface with the articulated register termi- nal. - 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.
  • Page 97 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.
  • Page 98 SPORTCITY ONE 125 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.
  • Page 99 SPORTCITY ONE 125 Engine In case of anomalies, replace the damaged com- ponents. 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.
  • Page 100 SPORTCITY ONE 125 Engine - Insert the retention plate and tighten the two screws shown in the figure to the prescribed tor- que. 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.
  • Page 101 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 tor- que. Locking torques (N*m) Locking torque 12 - 14 - Set the tensioner cursor in the rest position.
  • Page 102 SPORTCITY ONE 125 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.
  • Page 103 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.
  • Page 104 SPORTCITY ONE 125 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.
  • Page 105 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.
  • Page 106 SPORTCITY ONE 125 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.
  • Page 107 SPORTCITY ONE 125 Engine - Inspect the mating surfaces on the crankcase halves for scratches or deformation, taking partic- ular with the surfaces that mate with the cylinder and the mating surfaces between the crankcase halves. - Defects in the crankcase coupling gasket or the...
  • Page 108 SPORTCITY ONE 125 Engine TO KEEP THIS POSITION OF THE BUSHINGS ON THE CRANKCASE, FITTING IS FORCED ON STEEL RINGS IN- SERTED 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.
  • Page 109 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, to- gether with the locating dowels. Locking torques (N*m) Locking torque 27 ÷...
  • Page 110 SPORTCITY ONE 125 Engine Conceptual diagrams ENG - 110...

  • Page 111: Oil Pressure Check

    SPORTCITY ONE 125 Engine Oil pressure check - After removing the cover protections as descri- bed in the "Flywheel" chapter, disconnect the elec- trical 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...
  • Page 112 SPORTCITY ONE 125 Engine Removal - First remove the transmission cover and the com- plete 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.
  • Page 113 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...

  • Page 114: Oil Pump

    SPORTCITY ONE 125 Engine - 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.
  • Page 115 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.
  • Page 116 SPORTCITY ONE 125 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.
  • Page 117 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 Transmis- sion chapter. - Drain the oil from the sump as described above.

  • Page 118: Fuel Supply

    SPORTCITY ONE 125 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.

  • Page 119: Removing The Carburettor

    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.
  • Page 120 SPORTCITY ONE 125 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 di- aphragm.
  • Page 121 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...
  • Page 122 SPORTCITY ONE 125 Engine -Remove the maximum nozzle. -Remove diffuser. ENG - 122...
  • Page 123 SPORTCITY ONE 125 Engine - Remove the sprayer. NOTE WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY- ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
  • Page 124 SPORTCITY ONE 125 Engine Refitting the carburettor - Before refitting, wash the carburettor body accu- rately 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.
  • Page 125 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.
  • Page 126 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 accelera- tion pump pipes are clean.
  • Page 127 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.
  • Page 128 SPORTCITY ONE 125 Engine - 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...
  • Page 129 SPORTCITY ONE 125 Engine - Wash and blow dry the filter sponge of the ambient pressure intake. - Reassemble the filter with its clamp. ENG - 129...
  • Page 130 SPORTCITY ONE 125 Engine - 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.
  • Page 131 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.
  • Page 132 SPORTCITY ONE 125 Engine ENG - 132...
  • Page 133 SPORTCITY ONE 125 Engine Adjusting the idle - The engine does not require frequent idle speed adjustments, but it is essential to strictly follow cer- tain rules when adjusting the idle speed. - Before adjusting the carburettor make sure that...
  • Page 134 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 135: Removing The Front Wheel

    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.
  • Page 136 SPORTCITY ONE 125 Suspensions 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 re- move the wheel bearing on the side the odometer detects movement.
  • Page 137 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 •...
  • Page 138 SPORTCITY ONE 125 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...

  • Page 139: Front Fork

    SPORTCITY ONE 125 Suspensions IF THE HANDLEBAR IS REMOVED TO TAKE OUT THE FORK, IT IS NOT NECESSARY TO RE- MOVE THE BRAKE TRANSMISSION AND THE SUPPLY CABLES OF THE STOP BUTTONS. • Remove the front and rear handlebar covers.

  • Page 140: Steering Column

    SPORTCITY ONE 125 Suspensions 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.
  • Page 141 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.
  • Page 142 SPORTCITY ONE 125 Suspensions • Remove the upper ring «3» of the up- per bearing. • Slide the fork and collect the cage with the balls of the upper bearing. Locking torques (N*m) Lower ring nut • Remove the balls retainer «7» of the lower bearing from the steering tube .
  • Page 143 SPORTCITY ONE 125 Suspensions CAUTION MAKE SURE THE SCOOTER IS STABLE AND FIRM. NOTE WHEN CARRYING OUT THIS OPERATION, PAY ATTEN- TION NOT TO MISTAKE THE CENTRE STAND CLEAR- ANCE WITH THAT OF THE FORK. REPEAT THIS TEST SEVERAL TIMES BEFORE DECIDING IF THE FORK HAS TO BE ADJUSTED.

  • Page 144: Removing The Rear Wheel

    SPORTCITY ONE 125 Suspensions Removing the rear wheel • Rest the vehicle on its centre stand. • Remove the muffler. • Use a screwdriver to remove the plas- tic cap. • Remove the split pin «1» and the cap «2».

  • Page 145: Swing-Arm

    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.

  • Page 146: Shock Absorbers

    SPORTCITY ONE 125 Suspensions 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 direc- tion.
  • Page 147 SPORTCITY ONE 125 Suspensions • Unscrew nut «2» fixing the shock ab- sorber to the engine. • Follow the removal operations in reverse order for the fitting, screwing the nuts to the pre- scribed 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...
  • Page 148 SPORTCITY ONE 125 Suspensions • 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...
  • Page 149 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 150 SPORTCITY ONE 125 Braking system 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.
  • Page 151 SPORTCITY ONE 125 Braking system • the bleed screw may exhibit leaks. If dripping is detected, tighten to the ap- propriate tightening torque; • the fuel tank caps for possible leaks and the gaskets conditions. After repairing the brake: •...

  • Page 152: Front Brake Pads

    SPORTCITY ONE 125 Braking system 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.
  • Page 153 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 •...
  • Page 154 SPORTCITY ONE 125 Braking system • Connect a transparent pipe to the bleeder «2». CAUTION DO NOT DIRT THE PADS OR THE DISC WITH BRAKE FLU- • Keep the free part of the glass tube in a clean container. •...

  • Page 155: Rear Drum Brake

    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.
  • Page 156 SPORTCITY ONE 125 Braking system Rear brake adjustment nut To adjust the drum brake: • Unscrew the lock nut. • Adjust the activation point of the rear drum brake by acting on the set screw. • With the brake lever released, the wheel should rotate freely.
  • Page 157 INDEX OF TOPICS CHAS HASSIS...

  • Page 158: Rear Rack

    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 Rear rack • Remove the three screws «1» shown in figure and collect the washers.

  • Page 159: Instrument Panel

    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 od- ometer cable. Instrument panel • Remove the front handlebar cover.
  • Page 160 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.
  • Page 161 SPORTCITY ONE 125 Chassis • Working from the front wheel well in- ternal side, undo the screw «2». Knee-guard • Undo the twelve screws indicated and remove the shield back plate. • Before fitting the shield back plate, re- move the footrest fixing screws in order to insert the two plastic parts.
  • Page 162 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.
  • Page 163 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.
  • Page 164 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».
  • Page 165 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...

  • Page 166: Rear Mudguard

    SPORTCITY ONE 125 Chassis • Remove the inspection latch from in- side the helmet compartment. • Loosen the clamp «2». Rear mudguard • Undo the two screws «1». • Undo the screw «2». Helmet bay • Remove the saddle. •...

  • Page 167: Fuel Tank

    SPORTCITY ONE 125 Chassis • Undo the two screws «3». • Release the helmet compartment from 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.

  • Page 168: Front Mudguard

    SPORTCITY ONE 125 Chassis Fuel tank to chassis lateral fixing screw • Undo the screw «2». Locking torques (N*m) Fuel tank to chassis rear fixing screw • Loosen the two screws «3» placed in- side the rear wheel well. •...
  • Page 169 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 re- move the battery cover.
  • Page 170 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 171 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...
  • Page 172 SPORTCITY ONE 125 Pre-delivery - 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.
  • Page 173 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)
  • Page 174 SPORTCITY ONE 125 Pre-delivery 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...
  • Page 175 Air filter: 31, 165 Battery: 50, 55, 169 Brake: 151, 152, 155 Bulbs: Carburettor: 28, 119, 124 Clutch: 66, 68, 69, 72 Engine oil: 32 Fork: 139 Fuel: 34, 118, 167 Fuses: 54 Headlight: 38, 160 Horn: 52 Hub oil: 29 Identification: 10 Instrument panel: 159 Maintenance: 28...
  • Page 176 Warning lights:...

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