APRILIA Caponord 1200 2016 User manual

MANUALE STAZIONE DI SERVIZIO
2Q000020
Caponord 1200 - Caponord 1200 Rally

MANUALE
STAZIONE DI
SERVIZIO
Caponord 1200 - Caponord 1200 Rally
THE VALUE OF SERVICE
Due to continuous updates and technical training programmes specific to aprilia products, only Aprilia
Official Network mechanics know this vehicle fully and have the specific tools necessary to carry out
maintenance and repair operations correctly.
Thereliabilityofthevehiclealsodependsonitsmechanicalconditions.Checkingthevehiclebeforeriding
it, performing maintenance correctly and using only original Aprilia spare parts are essential factors
for the reliability of your vehicle!
For information on the nearest Official Dealer and/or Service Centre consult our website:
www.aprilia.com
Only by requesting original aprilia spare parts can you be of purchasing products that were developed
andtested duringthe designand developmentof thevehicle itself.All Apriliaoriginal spareparts undergo
quality control procedures to guarantee reliability and durability.
The descriptions and images in this publication are given for illustrative purposes only.
While the basic features as described and illustrated in this manual remain unchanged, Piaggio & C.
S.p.A. reserves the right, at any time and without being required to update this publication beforehand,
to make any changes to components, parts or accessory supplies which it deems necessary to improve
the product, or which are required for manufacturing or commercial reasons.
Notallversions/modelsshowninthispublicationareavailableinallcountries.Theavailabilityofindividual
versions/models should be confirmed with the official Aprilia sales network.
The Aprilia trademark is the property of Piaggio & C. S.p.A.
© Copyright 2016 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com

MANUALE STAZIONE DI
SERVIZIO
Caponord 1200 - Caponord
1200 Rally
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. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, aprilia s.p.a. commits itself to
continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all aprilia Sales Outlets and its International
Subsidiaries.These changes willbe introducedin the subsequenteditions ofthe manual. Incase ofneed
or further queries on repair and check procedures, consult aprilia CUSTOMER DEPARTMENT, which
will be prepared to provide any information on the subject and any further communications on updates
and technical changes related to the vehicle.
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sectionsmarked with this symbol indicate the correctuse of thevehicle
to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee

INDEX OF TOPICS
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BRAKING SYSTEM BRAK SYS
CLUTCH SYSTEM CLU SYS
COOLING SYSTEM COOL SYS
BODYWORK BODYW
PRE-DELIVERY PRE DE

INDEX OF TOPICS
CHARACTERISTICS CHAR

Rules
OPTION 01
Caponord 1200 - Caponord 1200 Travel Pack
OPTION 02
Caponord 1200 Rally
Safety rules
Carbon monoxide
If you need to keep the engine running while working on the vehicle, please ensure that you do so in
an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an
enclosed area, make sure to use a fume extraction system.
CAUTION
EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCANCAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
FUEL USED TO DRIVE EXPLOSION ENGINES IS HIGHLY INFLAMMABLE AND CAN BECOME
EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY
OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE EN-
GINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR. AVOID
ANY CONTACT WITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES WHICH MAY
CAUSE IGNITION OR EXPLOSION.
DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN.
Hot parts
The engine and the exhaust system components get very hot and remain in this condition for a certain
time interval 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.
Coolant
The coolant contains ethylene glycol which, under certain conditions, can become flammable.
When it burns, ethylene glycol produces an invisible flame which however can cause burns.
CAUTION
Characteristics Caponord 1200 - Caponord 1200 Rally
CHAR - 8

TAKE PARTICULAR CARE NOT TO SPILL COOLANT ONTO HOT PARTS OR THE ENGINE AND
EXHAUST SYSTEM; THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES. WHEN
CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES.
WHILE POISONOUS, COOLANT HAS A SWEET TASTE WHICH MAKES IT EXTREMELY AP-
PEALING TO ANIMALS. NEVER LEAVE COOLANT IN OPEN CONTAINERS WHERE IT MAY BE
REACHED AND DRUNK BY AN ANIMAL.
KEEP OUT OF THE REACH OF CHILDREN.
NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER
PRESSURE AND MAY CAUSE BURNS.
Used engine oil and transmission oil
CAUTION
WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC-
TIVE IMPERMEABLE GLOVES.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN.
Brake and clutch fluid
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.
WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS
WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE
SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN
THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH
PLENTY OF COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN.
Battery electrolyte and hydrogen gas
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,
IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY
ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT
OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY
AMOUNTSOFBATTERY ACID MAYCAUSEBLINDNESS.IFTHEFLUID GETS IN CONTACTWITH
YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE
SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY
FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADE-
QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN
PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY
BEING ACTIVATED.
Caponord 1200 - Caponord 1200 Rally Characteristics
CHAR - 9

Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairs, disassembly and reassembly of the vehicle is carried out, follow the following recom-
mendations strictly.
BEFORE DISASSEMBLING COMPONENTS
•Remove the dirt, mud, dust and foreign objects from the vehicle before disassembling com-
ponents. Wherever required, use the special tools designed for this vehicle.
DISASSEMBLING COMPONENTS
•Do not loosen and/or tighten the screws and nuts using pliers or other tools, but always use
the specific wrench.
•Mark the positions on all the connection joints (hoses, cables, etc.) before separating them
and identify them with different distinctive marks.
•Each piece should be clearly marked in order to be identified during the installation phase.
•Carefully clean and wash the disassembled components with detergents with a low flam-
mability grade.
•Keep the coupled parts together because they have "adapted" to one another following
normal wear.
•Some components must be used together or replaced entirely.
•Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.
•Only use ORIGINAL Aprilia SPARE PARTS.
•Comply with lubricant and consumables use guidelines.
•Lubricate parts (whenever possible) before reassembling them.
•Whentighteningnuts andscrews, start eitherfrom the componentswith thelargestdiameter
or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-
cessive steps before applying the tightening torque.
•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins
and screws with new parts if the thread is damaged.
•When assembling the bearings, make sure to lubricate them well.
•Check that each component is assembled correctly.
•After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on
private grounds or in an area with low traffic.
Characteristics Caponord 1200 - Caponord 1200 Rally
CHAR - 10