Engine Mechanical:
Complete disassembly, inspection, and reassembly of 125cc and 200cc engines, including cylinder head, piston, crankshaft, connecting rod, and valve train.
Fuel System:
Carburetor tuning, cleaning, and rebuilding; fuel pump operation; fuel tank inspection and cleaning; fuel line routing and maintenance.
Cooling System:
Radiator maintenance, coolant flow, thermostat operation, water pump inspection and replacement.
Ignition System:
Spark plug selection and gap, ignition coil testing, CDI unit troubleshooting, stator and rotor inspection.
Exhaust System:
Muffler and exhaust pipe inspection, gasket replacement, catalytic converter (if applicable) information.
Transmission Drivetrain:
Automatic transmission (CVT) operation, belt inspection and replacement, clutch and variator maintenance, final drive unit lubrication and inspection.
Brakes:
Front and rear brake caliper maintenance, hydraulic system bleeding, brake pad replacement, brake disc inspection, brake lever and pedal adjustments.
Suspension:
Front telescopic forks (oil change, seal replacement), rear shock absorber inspection and adjustment, linkage maintenance.
Steering:
Handlebar removal and installation, steering bearing inspection and lubrication, steering column adjustments.
Electrical System:
Battery testing and charging, starter motor operation, lighting system (headlight, taillight, turn signals), wiring diagrams, fuse box layout and identification, instrument panel diagnostics.
Bodywork:
Fairing removal and installation, seat removal, storage compartment access, fender maintenance, cosmetic component repair.
Chassis Frame:
Frame integrity inspection, general chassis component checks.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug replacement, coolant checks, brake fluid checks, chain/belt lubrication and adjustment (if applicable).
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common issues (e.g., no start, poor performance, electrical faults) with symptom-based troubleshooting guides.
Component Overhaul:
Detailed instructions for engine, transmission, brake caliper, and suspension component rebuilds.
Adjustment Procedures:
Carburetor idle and mixture adjustments, brake lever and pedal free play, suspension preload settings.
Assembly Disassembly:
Comprehensive guides for removing and reinstalling major components and sub-assemblies.
Diagnostic Tools:
Information on required tools for diagnostics, including multimeters, feeler gauges, torque wrenches, and specialized Aprilia tools.
Torque Specifications:
Precise torque values for all critical fasteners, bolts, and nuts throughout the vehicle.
Clearances Tolerances:
Specific measurement ranges for engine components (e.g., valve clearances, piston-to-cylinder wall clearance) and other mechanical parts.
Wiring Diagrams:
Detailed, legible electrical schematics showing all circuits, components, and wire colors.
Special Tools:
Identification and usage instructions for any Aprilia-specific tools required for complex procedures.
Engine Type 125:
Four-stroke, liquid-cooled, single-cylinder
Bore Stroke 125:
57.0 mm x 48.6 mm
Engine Type 200:
Four-stroke, liquid-cooled, single-cylinder
Bore Stroke 200:
64.0 mm x 61.0 mm
Horsepower 125:
Approx. 14.5 HP @ 9,000 RPM
Torque 125:
Approx. 11.5 Nm @ 8,000 RPM
Horsepower 200:
Approx. 18 HP @ 8,500 RPM
Torque 200:
Approx. 16.5 Nm @ 7,000 RPM
Carburetor Type:
Mikuni VM26 (typical for 125cc), Keihin CVK (typical for 200cc) or similar, depending on specific market.
Fuel Capacity:
Approx. 10-12 Liters
Engine Oil Change:
Every 3,000-5,000 km or annually, whichever comes first.
Air Filter Cleaning:
Every 4,000-6,000 km or as needed based on operating conditions.
Spark Plug Replacement:
Every 8,000-10,000 km, or as recommended by Aprilia.
Transmission Oil Change:
Every 6,000-10,000 km (final drive oil).
Engine Oil Type:
SAE 10W-40 or 15W-50 API SG or higher, JASO MA compliant synthetic or semi-synthetic motorcycle oil.
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
CVT belt, variator rollers, brake pads, fork seals, and rear shock absorbers can be common wear items.
Electrical Connectors:
Corrosion or looseness in electrical connectors, especially on older models, can lead to intermittent electrical faults.
Carburetor Settings:
Carburetors may require periodic adjustment or cleaning due to modern fuel formulations or aging components.
