Aprilia Sportcity 250 Service Manual

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Aprilia Sportcity 250 Service Manual 2017
2009 Aprilia Sportcity 250 Service Manual

The SportCity 250 was Aprilia’s first SportCity scooter to be sold in North America. Aprilia launched it into the USA market as part of their 2007 scooter line up. For 2009 Aprilia tweaked the styling and added grab handles and pegs for a passenger. The SportCity Cube 250 remained on sale in the USA until 2013, while the Aprilia withdrew the SportCity Cube from the Canadian market after 2012.

The updated 250cc model was joined for 2009 by the addition of the smaller SportCity One 50 & 125. The SportCity One models shared the same inspiration as the 250, but the design was entirely different so Aprilia added ‘Cube’ to the original SportCity 250 name to differentiate it from the smaller models.
The other news for 2009 was the introduction of both the SportCity Cube 250 and SportCity One scooters into the Canadian market. Despite Canadians getting the SportCity Cube 250 a few years after their American counterparts, Aprilia Canada went one step beyond Aprilia USA a year later and introduced the larger SportCity Cube 300 for 2010. In some Canadian Aprilia literature, the ‘Cube’ name is not used and the smaller SportCity models lose the ‘One’ moniker, so the 50, 125 and 300 sizes are all simply called the SportCity. Often on the actual scooters, Aprilia uses a badge that says Cu3e.
Engine
With Aprilia being wholly owned by the Piaggio Group as of 2004, it’s no surprise to see Piaggio engines powering the SportCity scooters. The SportCity Cube 250 and 300 use 244cc and 278cc versions respectively of Piaggio’s QUASAR engine. This popular motor has been powering mid-size scooters for a number of years now, starting with the Vespa GTS250. This motor can also be found in Piaggio’s BV/Beverly 250 and 300 scooters and smaller MP3 models.
This motor is a nice design that utilizes 4-valves, liquid cooling and fuel injection to deliver solid power and milage for its size. The 244cc version found in the SportCity Cube 250 offers 22.5 HP, which is double what the smaller SportCity One 125 puts out. Unlike the simpler engines found in the SportCity One scooters, the Cube models enjoy high tech engines that also contribute to the much higher MSRPs (just under $5 grand). Maximum velocity for the 250 falls between 75-80mph.
Styling
The original version of the SportCity 250 (left) filled a niche in Aprilia’s line up for a midsized sporty scooter. The Scarabeo series had been selling well for Aprilia, but a large portion of North American scooters buyers aren’t interested in the large 16” wheels that are more popular in Europe. The SportCity takes the wheel size down to 15”, which doesn’t sound like a big change but the SportCity Cube hides the wheel size much better than the gangly Scarabeo. The SportCity Cube is physically a large scooter (78” long) which makes the 15” wheels more aesthetically proportioned.

The mild 2009 updates to the SportCity 250’s style (compare top and bottom photos) were intended to make this scooter more recognizable as an Aprilia. The tail light was intentionally designed to look more like the rear lamps found on Aprilia’s bigger bikes. The wind deflector and vents above the front headlights were also tweaked for a more modern look. Most of the design remained unchanged, including the rims, fenders and main body work pieces. Aprilia did update the gauges for 2009, which was a welcome change as the original gauges were showing their age.

Storage & Convenience
Storage is about what you’d expect for a scooter of this size. There’s good space under the seat and larger glovebox than the SportCity One models, while still not offering huge storage for touring like some mid sized scooters (Ie. Yamaha Morphous, Kymco Downtown 300i). Despite the size of the glovebox, it is quite a shallow shape so it’s not quite as useful as it initially appears.
There are some nice convenience features on the Cube, such as a clock, trip odometer and coolant gauge. The passenger pegs are also a neat folding design that gets out of the way for most trips when you won’t be needing them.

Comparison
The SportCity Cube 250 / 300 competed in a fairly popular market segment of 200 - 300cc sporty scooters. The Japanese brands (Honda, Yamaha and Suzuki) have been sticking with a bit larger scooters in recent years, but Honda has introduced a competing 300cc Forza model to Canada and Yamaha did sell a nice 250 sporty scooter called the Morphous back in 2006 - 2008 which is worth a look for buyers in the used market and who are looking to log highway miles.

The biggest competition to the SportCity Cube came from Kymco, who has fielded a whole slate of competitors: Kymco Grandvista 250, Downtown 200i / 300i and People S 250. Most of these Kymco scooters don’t feature the same level of technology found in the SportCity Cube, but they also come with a lower price tag. The exception is the newer Kymco Downtown 200i / 300i, which does use an advanced fuel injected motor and accordingly comes at a higher MSRP about $500 higher than the SportCity Cube. For its displacement, the SportCity Cube is an affordable scooter.

Also worth a look is Piaggio’s BV 250 and BV 300 scooters, which use the same motors as the SportCity Cube. These scooters have a nice design that is a bit more classic than the SportCity Cube.
Overall, the SportCity Cube scooters offer a high level of refinement and solid motors in an affordable package. If you’re looking for the cheapest scooter buy a used Kymco Grandvista 250, but if you’re looking for a newer and very well rounded scooter, the SportCity Cube competes very well with Kymco’s Downtown 200i / 300i scooters and Piaggio’s more classic styled BV 250 / 300.
OWNER REVIEWS (1) - Browse SportCity Cube ReviewsREVIEW - Add Your Review

Pros:
- High tech motors
- Excellent brakes
- Low MSRP

Cons:
- Could use a bit more storage

Links:
Sportcity Cube Service Manual - These manuals extremely helpful for the DIY’er mechanic.
MotorscooterGuide Forums - Visit the forums on this site to chat about this scoot.
ApriliaForums - Lots of knowledgable Aprilia folks here.

Key Specs - SportCity Cube 250 / 300:
* Engine: 244cc or 278cc single cylinder, 4-stroke, SOHC 4-valve, fuel injected
* Cooling: Liquid cooled
* Bore & Stroke: 72mm x 60mm (244cc), 75mm x 63mm (278cc)
* Power: 22.5 HP @ 8000 RPM (244cc)
* Top Speed: 76 mph (244cc), 80mph (278cc)
* Fuel Capacity: 2.4 gallons (9 litres)
* Milage: 65 mpg
* Ignition: Electronic (with inductive discharge, variable spark advance and three-dimensional mapping)
* Chassis: Load-bearing sheet steel chassis with welded structural supports
* Front Suspension: Single-sided trailing arm with dual chamber hydraulic shock absorber with coaxial spring
* Rear Suspension: Helical spring with adjustable four-position pre-load and dual effect hydraulic shock absorbers
* Brakes: Dual 260 mm disc (Front), single 220mm Disc (Rear)
* Wheels: 120/70-15 / 130/80-15 (Front and Rear)
* Length: 78.15”
* Width: 35”
* Wheelbase: 53.5”
* Seat Height: 32.1”
* Dry Weight: 327 lbs (250)
* Colors: Planet Blue, Aprilia Black, Silver Crowd
* MSRP: $4699 (2011 USA), $5995 (2011 Canada)

Aprilia Sportcity 250 Service Manual 2017

4
Vehicle View
5
Index of Topics
8
Characteristics
8
Safety Rules/General Precautions
11
Maintenance Rules/General Precautions and Information
15
Vehicle Identification
15
Chassis Number/Engine Number
16
Dimensions and Mass
16
Engine Techinical Data
17
Transmisson Technical Data
17
Capacities
17
Eletrical System Technical Data
18
Frame and Suspensions Technical Data
19
Tightening Torques/Lubrication
19
Cylinder Head
20
Transmission Data
20
Flywheel Data
20
Crankcase and Crankshaft Data
20
Handlebar Data
21
Chassis Data
21
Electrical System Data
21
Saddle/Locks Data
21
Instrument Panel Data
22
Rear Bodywork Data
22
Central Bodysork Data
23
Front and Rear Brake Data
23
Front Bodywork Data
23
Filter Housing Data
24
Cooling Unit/Front Wheel Data
24
Link Rod/Exhaust Data
24
Rear Wheel Data
24
Stand/Engine Data
25
Overhaul Data/Assembly Clearances
25
Rear Suspension Data
25
Cylinder - Piston Assy
26
Cylider-piston Coupling Category
26
Crankcase-crankshaft-connecting Rod
26
Crankshaft/crankcase Axial Clearance
27
Slot Packing System
27
Compression Ratio
27
Shimming for 250 Engines
28
Products: Recommended Products Table
30
Tooling
30
Special Tools
36
Maintenance
36
Maintenance Chart: Every 2 Years
39
Spark Plug Maintenance
40
Locking Torques
41
Hub Oil
43
Air Filter Maintenance
45
Engine Oil
46
Engine Oil Check
47
Engine Oil Top-up
48
Engine Oil Filter
48
Oil Pressure Warning Light
48
Transmissions/Throttle Grip Removal
49
Throttle Grip Refitting
50
Checking the Ignition Timing
50
Cooling System
50
Radiator Cleaning
50
Level Check
51
Topping-up the Coolant Level
52
Braking Systems
53
Brake Fluid Topping-up
54
Rear Brake Calliper
58
Troubleshooting
58
Engine: Excessive Oil Consumption/Exhaust Smoke/Excessive Wear
58
Poor Lubrication Pressure
58
Clutch Grabbing or Performing Inadequately
59
Suspension Oil Leakage
62
Electrical System
62
Schematic Diagram
65
Parts of the Electrical System
71
Cable Colours
72
Conceptual Diagrams
74
Ignition Diagram
75
Battery Recharge and Starting Diagram
76
Level Indicators and Enable Signals Section Diagram
77
Devices and Accessories Diagram
78
Lights and Turn Indicators Diagram
79
Checks and Inspections
79
Battery Recharge Circuit
80
Dashboard
80
Multifunctional Indicator Functions
80
Total Odometer (ODO) Function
81
Data Check Function
81
Battery Voltage
81
Unit of Measurement - Km/MI Conversion
81
Clock Adjustment
82
Oil Pressure Sensor
83
Battery Failure
83
Fuel Level Sensor
84
Connectors
84
Dashboard Pinout
85
Connector Pinout
88
Engine From Vehicle
88
Exhaust Assy. Removal
88
Silencer Removal
89
Removal of the Engine From the Vehicle
96
Engine
96
Automatic Transmission
96
Transmission Cover
96
Air Duct
97
Removing the Driven Pulley Shaft Bearing
97
Refitting the Driven Pulley Shaft Bearing
98
Baffle Roller/Plastic Roller
99
Removing the Driven Pulley
99
Inspecting the Clutch Drum
100
Removing/inspecting the Clutch
101
Pin Retaining Collar
102
Removing the Driven Half-pulley Bearing
102
Inspecting the Driven Fixed Half-pulley
103
Inspecting the Driven Sliding Half-pulley
103
Movable Driven Half-pulley Dimensions
104
Refittinng the Driven Half-pulley Bearing
104
Refitting the Driven Pulley
105
Inspecting the Clutch Spring
106
Refitting the Clutch/Refitting the Driven Pulley
106
Drive Belt
107
Removing the Driving Pulley
107
Inspecting the Rollers Case
109
Refitting the Driving Pulley
110
Refitting the Transmission Cover
110
End Gear
110
Removing the Hub Cover
111
Removing the Hub Bearings
111
Removing the Wheel Axle Bearings
112
Remove the Driven Pulley Shaft Bearing
113
Inspecting the Hub Shaft/hub Cover
113
Refitting the Wheel Axle Bearing
114
Refitting the Hub Cover Bearings
116
Refitting the Hub Bearings and Hub Cover
116
Flywheel Cover
117
Remove the Hub Cover
117
Removing/refitting the Stator
118
Refitting the Flywheel Cover
119
Flywheel and Starting
119
Removing the Starter Motor
119
Removing the Flywheel Magneto
120
Inspecting the Flywheel Components
120
Refitting the Free Wheel
121
Refitting the Flywheel Magneto
122
Refitting the Starter Motor
122
Removing the Intake Manifold
123
Removing the Rocker-arms Cover
123
Removing the Timing System Drive
125
Removing the Cam Shaft
126
Removing the Cylinder Head
126
Removing the Valves
127
Removing the Cylinder - Piston Assy
127
Inspecting the Small End
128
Inspecting the Wrist Pin
128
Inspecting the Piston
129
Inspecting the Cylinder
130
Inspecting the Piston Rings
130
Removing the Piston
131
Choosing the Gasket
132
Refitting the Piston Rings
133
Refitting the Cylinder
134
Inspecting the Cylinder Head
134
Inspecting the Timing System Components
135
Inspecting the Valve Sealings
135
Inspecting the Valve Housings
136
Inspecting the Valves
138
Inspecting the Springs and Half-cones
138
Refitting the Valves
139
Inspecting the Cam Shaft
140
Refitting the Head and Timing System Components
143
Refitting the Rocker-arms Cover
144
Refitting the Intake Manifold
144
Crankcase - Crankshaft
144
Splitting the Crankcase Halves
147
Inspecting the Crankshaft Alignment
147
Inspecting the Crankcase Halves
149
Inspecting the Crankshaft Plain Bearings
152
Refitting the Crankcase Halves
154
Studs
154
Lubrication
154
Conceptual Diagrams: Lubrication Circuit
156
Oil Pressure Check
156
Crankshaft Oil Seals: Removal
157
Crankshaft Oil Seals: Refitting
159
Oil Pump Removal
160
Oil Pump Inspection
161
Oil Pump Refitting
162
Removing the Oil Sump
162
Inspecting the By-pass Valve
166
Injection
166
MIU Injection System
168
Transparency
169
Injection: Troubleshooting Tips
171
Terminals Setup
172
EMS Circuit Diagram
173
Handheld Computer Menu Symbols
174
Engine Parameter Reading
175
Device Status
175
Adjustable Parameters
175
Devices Activation
176
Errors Display
177
Troubleshooting Procedure
177
Engine Does Not Start Even if Pulled
178
Engine Does Not Hold Idling/idling Is Unstable/idling Is Too Low
179
Engine Does Not Return to Idling/idling Too High
179
Exhaust Backfiring When Decelerating
180
Engine Revs Irregularly
180
Regular Engine Progress With Valve Slightly Open
180
Poor Performance at Full Throttle/Irregular Engine Progress On Acceleration
181
Engine Knocking (Combustion Shocks)
182
Fuel Supply System
182
Removing the Injector
183
Refitting the Injector
183
Removing the Butterfly Valve
185
Refitting the Butterfly Valve
185
Pump Supply Circuit
188
Circuit Leak Test
189
Fuel Filter Check
190
Inspecting the Injector Circuit
195
Inspecting the Injector Hydraulics
197
Components Layout
198
Tachometer Diagram
204
Coolant Temperature Sensor
205
Zeroing the Throttle
207
Lambda Probe
211
Signal Check
214
Suspensions
214
Removing the Front Wheel
216
Front Wheel Hub Overhaul
218
Refitting the Front Wheel
218
Handlebar Removal
220
Handlebar Refitting
220
Front Fork
222
Front Fork Removal/Stem Removal
222
Wheel Holder Stems Sleeves Removal
226
Overhaul/Components Check
227
Oil Filling
231
Steering Column
232
Steering Bearing
232
Removing the Rear Wheel
233
Refitting the Rear Wheel
233
Shock Absorbers Removal
234
Shock Absorbers Refitting
234
Centre-stand
238
Braking System - Exploded Diagram
238
Rear Brake Calliper Removal
239
Front Brake Calliper Removal
239
Rear Brake Disc Removal
240
Disc Inspection
240
Front Brake Disc Removal
241
Front Brake Disc Refitting/Disc Inspection
242
Front Brake Pads Removal
243
Front Brake Pads Refitting
243
Rear Brake Pads Removal
244
Rear Brake Pads Refitting
244
Fill - Bleeding the Braking System
245
Air Bleeding
250
Cooling System - Exploded Diagram
250
Electric Fan Check
251
Electric Fan Removal
252
Coolant Replacement
253
Coolant System Bleed
253
Thermostat
254
Thermostat Check
258
Chassis
258
Seat
258
Rear Rack
259
Driving Mirrors
260
Rear Handlebar Cover
260
Instrument Panel
261
Front Handlebar Cover
262
Legshield
265
Footrest
266
Left and Right Fairings Removal
267
Passenger Footrest Removal
267
Air Filter Removal
268
Filter Casing Removal
270
Tail Guard
272
Rear Mudguard
274
Helmet Bay
276
Front Mudguard
277
Fuel Tank Removal
277
Fuel Probe Removal
278
Rear Central Cover
278
Right Inspection Cover Removal
279
Radiator Fan
280
Expansion Tank
281
Flyscreen
282
Fairing Removal
282
Radiator Cover
283
Lower Cover

2009 Aprilia Sportcity 250 Service Manual

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