APRILIA CAPONORD Manual
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APRILIA CAPONORD Manual

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APRILIA WOULD LIKE TO THANK YOU
for choosing one of its products. We have drawn up this booklet to provide a comprehensive overview of your vehicle's quality features. Please read it
carefully before riding the vehicle for the first time. It contains information, tips and precautions for using your vehicle It also describes features, details
and devices to assure you that you have made the right choice. We believe that if you follow our suggestions, you will soon get to know your new vehicle
well and will use it for a long time at full satisfaction. This booklet is an integral part of the vehicle, and should the vehicle be sold, it must be transferred
to the new owner.
CAPONORD
Ed. 01_03/2014

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  • Page 1 APRILIA WOULD LIKE TO THANK YOU for choosing one of its products. We have drawn up this booklet to provide a comprehensive overview of your vehicle's quality features. Please read it carefully before riding the vehicle for the first time. It contains information, tips and precautions for using your vehicle It also describes features, details and devices to assure you that you have made the right choice.
  • Page 2 The instructions given in this manual are intended to provide a clear, simple guide to using your vehicle; it also describes routine maintenance procedures and regular checks that should be carried out on the vehicle at an Aprilia Dealer or Authorised Workshop. The booklet also contains instructions for simple repairs.
  • Page 3 Personal safety Failure to completely observe these instructions will result in serious risk of personal injury. Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent dam- aging 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 The symbols illustrated above are very important.

  • Page 5: Table Of Contents

    INDEX GENERAL RULES............... System ABS................57 Foreword................System ATC (Aprilia Traction Control)........60 Motorcycle care..............ADD system (Aprilia Dynamic Damping)........63 Carbon monoxide..............11 Immobilizer system operation..........65 Fuel..................12 Opening the saddle............... 66 Hot components..............12 Glove/tool kit compartment............ 67 The braking................
  • Page 6 Tyres..................115 Spark plug dismantlement............116 Removing the air filter............... 117 Cooling fluid level..............117 Checking the brake oil level............119 Braking system fluid top up........... 120 Checking clutch fluid..............120 Topping up clutch fluid............121 Battery removal..............121 Checking the electrolyte level..........122 Charging the battery..............

  • Page 7: General Rules

    CAPONORD Chap. 01 General rules...

  • Page 8: Foreword

    TIONS, OFF ROAD OR FOR TRACK USE. Motorcycle care Aprilia recommends using quality products to clean the vehicle. The use of unsuitable products can damage vehicle components. For cleaning do not use solvents such as "nitro thinner", "cold cleaning agents", fuels or similar, or cleaning products that contain alcohol.
  • Page 9 USE OF HOT WATER INTENSIFIES THE EFFECT OF THE SALT. USE ONLY PLENTY OF COLD WATER TO WASH AND REMOVE ANTI-ICING SALT USE OF HIGH PRESSURE WASHING SYSTEMS (OR STEAM CLEANERS) CAN DAMAGE THE SEALS, OIL SEALS, BRAKING SYSTEM, ELECTRICAL SYSTEM AND THE SADDLE.
  • Page 10 OF PLASTIC PARTS. ROTARY BRUSHES OR SPONGES WITH HARD SURFA- CES CAN MAKE SCRATCHES CHROME PARTS AND POLISHED METAL TREAT THE PARTS MADE OF CHROME, ALUMINIUM OR POLISHED STEEL IN A SPECIAL MANNER. WASH THEM WITH PLENTY OF WATER AND CAR SHAM- POO, POLISH AND REGULARLY BRIGHTEN THEM WITH POLISH PASTE, PRO- TECT THEM WITH WAXES OR SUITABLE ACID-FREE PRODUCTS (E.G.

  • Page 11: Carbon Monoxide

    THE USE OF SILICONE SPRAY TO CLEAN THE RUBBER SEALS MAY CAUSE DAMAGE. DO NOT USE OTHER PRODUCTS CONTAINING SILICON FOR CLEANING THE MOTORCYCLE Carbon monoxide If you need to keep the engine running in order to perform a procedure, please ensure that you do so in an open or very well ventilated area.

  • Page 12: Fuel

    Fuel CAUTION THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTE- NANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF.

  • Page 13: The Braking

    CARRY OUT ENGINE OIL LEVEL CHECK. IF THE OIL PRESSURE LEVEL RE- MAINS LOW ALTHOUGH THE PROCEDURE DESCRIBED ABOVE HAS BEEN PROPERLY CARRIED OUT, CONTACT AN OFFICIAL Aprilia DEALER TO HAVE THE CIRCUIT CHECKED. IF THE WARNING LIGHT TURNS PERMANENTLY ON AND THE HELMET ICONS...

  • Page 14: Coolant

    HAS DETECTED A FAULT. IN MANY CASES THE ENGINE WILL CONTINUE TO OPERATE REGULARLY, WITH LIMITED PERFORMANCE OF THE SHOCK AB- SORBERS; FOR SAFETY REASONS, SLOW DOWN; IMMEDIATELY CONTACT AN Official Aprilia Dealer. Coolant The coolant contains ethylene glycol which, under certain conditions, can become flammable.

  • Page 15: Used Engine Oil And Gearbox Oil

    Used engine oil and gearbox oil CAUTION IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VEHICLE. THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BA- SIS.

  • Page 16: Battery Hydrogen Gas And Electrolyte

    Battery hydrogen gas and electrolyte 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.

  • Page 17: Reporting Of Defects That Affect Safety

    Reporting of defects that affect safety Unless otherwise specified in this Use and Maintenance Booklet, do not remove any mechanical or electrical component. CAUTION SOME CONNECTORS IN THE VEHICLE MAY BE ACCIDENTALLY SWAPPED AND MAY COMPROMISE NORMAL VEHICLE OPERATION IF INCORRECTLY IN- STALLED.

  • Page 19: Vehicle

    CAPONORD Chap. 02 Vehicle...
  • Page 20 02_01...

  • Page 21: Arrangement Of The Main Components

    02_02 Arrangement of the main components (02_02) Legend (Caponord 1200): 1. Front left fork 2. Left headlamp 3. Central headlamp 4. Front left turn indicator 5. Windshield 6. Auxiliary fuses box 7. Clutch fluid reservoir 8. Left rear-view mirror 9. Left light switch 10.
  • Page 22 12. Rider saddle 13. Passenger saddle 14. Left passenger grab handle 15. Taillight 16. Licence plate light 17. Rear left turn indicator 18. Left hand passenger footrest 19. Side stand 20. Left rider footrest 21. Gear lever 22. Front left brake calliper 23.
  • Page 23 02_03...
  • Page 24 02_04 Legend (Caponord 1200 Travel Pack): 1. Front left fork 2. Left headlamp 3. Central headlamp 4. Front left turn indicator 5. Windshield 6. Auxiliary fuses box 7. Clutch fluid reservoir 8. Left rear-view mirror 9. Left light switch 10. Fuel tank cap 11.
  • Page 25 14. Left passenger grab handle 15. Taillight 16. Licence plate light 17. Rear left turn indicator 18. Left side saddle pannier 19. Left hand passenger footrest 20. Centre stand 21. Side stand 22. Left rider footrest 23. Gear lever 24. Front left brake calliper 25.

  • Page 26: Dashboard

    02_05 Dashboard (02_05) Instrument panel / controls location key 1. Clutch control lever 2. Instrument panel 3. Ignition switch /steering lock 4. Front brake lever 5. Throttle grip 6. MODE Control 7. Warning lights Control 8. Horn button 9. Light switch 10.

  • Page 27: Instrument Panel

    12. Cruise control button (if applicable) Instrument panel (02_06, 02_07) 02_06...
  • Page 28 The vehicle is supplied with two keys already programmed. The instrument panel saves a maximum of four keys: contact an Official Aprilia Dealer to enable these keys or to disable a key that has been lost. When the vehicle is delivered and approximately ten seconds after the key is set to ON (the CODE icon will always be blinking), the instrument panel requests a personal five-digit code to be entered.

  • Page 29: Light Unit

    5. Gear in neutral warning light (green) 6. General warning light (red) 7. ABS (Anti-lock Braking System) warning light (orange) 8. ATC (Aprilia Traction Control) warning light (orange) 02_08 Digital lcd display (02_09, 02_10, 02_11, 02_12, 02_13, 02_14, 02_15, 02_16, 02_17, 02_18, 02_19, 02_20, 02_21, 02_22, 02_23,...
  • Page 30 NOTE EVERY TIME THE SELECTOR IS HELD DOWN TO THE RIGHT OR LEFT THE RIDER CAN GO FROM TRIP JOURNAL 1 TO TRIP JOURNAL 2. 02_09 The standard settings that can be viewed on the display are: 1) Any indication relative to power limitation in the ECU; 2) Engine rpm;...
  • Page 31 - Trip odometer - Reserve travel - Travelling time - Average travelling speed - Maximum saved speed - Clock 14) ATC (Aprilia Traction Control) 15) ADD (Aprilia Dynamic Damping) 16) Water temperature 02_10...
  • Page 32 In the middle of the digital display, the indication of the maximum speed (3) is visible in kmph or mph, depending on your Country. NOTE YOU CAN HAVE THE INDICATED VALUE MODIFIED BY CONTACTING AN Offi- cial Aprilia Dealer 02_13...
  • Page 33 FUEL LEVEL On the digital display, center-left, the fuel level in the tank can be viewed through a series of bars (4). When the fuel level drops far enough for all bars to go off on the digital display, the fuel reserve warning light will turn on CAUTION THE DISTANCE TRAVELLED CORRESPONDING TO THE LAST FUEL INDICA-...
  • Page 34 ENGINE MAP In the left part of the digital display, the selected engine map (5) currently in use is visible (TOURING / SPORT / RAIN). 02_16 GEAR ENGAGED In the lower left of the digital display, the indication of the selected gear (6) currently in use can be viewed.
  • Page 35 When the thresholds of the maintenance intervals have been exceeded an adjustable spanner icon will appear (10) in the middle of the digital display. This indicator may be reset once the scheduled service has been completed by an authorised Aprilia Dealer or Service Centre. 02_21...
  • Page 36 HEATED HANDGRIPS (if applicable) If the heated handgrips are activated, the corresponding symbol (11) can be viewed in the middle of the digital display. 02_22 The wording EFI (Electronic Fuel Injection) (12) will appear in the middle of the digital display, should there be problem with the fuel injection.
  • Page 37 ATC (Aprilia Traction Control) The Traction Control operating level (14) currently in use appears on the right side of the digital display. 02_25 ADD (Aprilia Dynamic Damping) The level of the rear shock absorber (15) preload appears in the right side of the digital display, to show the selection made by the rider by way of certain symbols (helmets and suitcases).

  • Page 38: Alarms

    Take your vehicle as soon as possible to an Official Aprilia Dealer. In these cases, the control unit activates a safety procedure that limits the vehicle performance so that the rider is able to reach an Official Apri- lia Dealer at low speed.

  • Page 39: Mapping Selection

    IF IT APPEARS AFTER THE ENGINE HAS BEEN SWITCHED ON (WARNING 02_29 LIGHT ON STEADY), SWITCH IT OFF STRAIGHT AWAY AND, WITH ROAD AS- SISTANCE SERVICE, TAKE THE VEHICLE TO AN Official Aprilia Dealer. Engine overheating alarm The engine overheating alarm is activated when the temperature is higher than or equal to 115 °C (239 °F) and is signalled by all the notch levels turning on and the red...
  • Page 40 The TOURING mode has been thought for smooth tourist riding. In the SPORT mode you get more acceleration; this variant has been thought for a sporting use of the vehicle. CAUTION ONLY EXPERT RIDERS, RIDING ON ROADS WITH GOOD GRIP ARE ADVISED TO USE THIS MODE.

  • Page 41: Control Buttons

    By briefly pressing button "B", it is possible to view the ATC, ADD, ABS functions in cycle. ATC (Aprilia Traction Control) To modify the value of the displayed function, briefly press button "A", which will in- crease the intensity of the system's intervention from level 1 (minimum) to level 3 (maximum).
  • Page 42 CAUTION TO BECOME FAMILIAR WITH THE ATC SYSTEM, IT IS ADVISABLE TO SET THE VALUE "3" TO THEN IDENTIFY THE PREFERRED SETTING FOR THE RIDING STYLE AND FOR THE ROAD AND ENVIRONMENTAL CONDITIONS WHICH MAY APPEAR. LEVEL "1" IS RECOMMENDED FOR USE BY EXPERT RIDERS IN IDEAL ROAD SURFACE CONDITIONS.
  • Page 43 ADD (Aprilia Dynamic Damping) To modify the value of the preload function displayed, briefly press button "A", which will modify the type of intervention according to the driver's needs. The system is identified by a series of symbols that correspond to a certain type of...
  • Page 44 The high beam light will start to blink fast. 02_37 To calibrate the ATC (Aprilia Traction Control) system, ride for approximately 10 sec- onds in a straight line on a flat section of road in second gear and at a speed of 30 +/- 2 Km/h (18.64 +/- 1.24 mph), until the message CAL is no longer shown on the display...
  • Page 45 NOTE ONCE THE WORD CALIBRATION DISAPPEARS FROM THE DISPLAY, TO COM- PLETE THE CALIBRATION PROCEDURE, STOP THE VEHICLE AND SHUT OFF THE PANEL FOR AT LEAST 30 SECONDS. THIS ALLOWS THE CALIBRATION TO BE STORED IN THE MEMORY. NOTE CARRY OUT THE CALIBRATION EACH TIME TYRES TYPE OR DRIVE GEAR- MODE IS CHANGED.
  • Page 46 To quit the function, hold button "B" pressed for a few seconds; the function will au- tomatically quit after 5 seconds. SERVICE FUNCTIONS With control buttons "A" and "B", it is possible to enter or modify the code of the im- mobilizer key.
  • Page 47 Modify code It is possible to reset the existing code. To access the function, hold button "A" pressed for a few seconds Enter code "384", briefly pressing button "B" Enter the old code 02_41 At this point it is possible to insert the new code. 02_42 MODE SWITCH By using the MODE switch, it is possible to view, reset or modify the information in the...
  • Page 48 Trip journal 1 and 2 Two trip journals are available (*). 02_44 Press and hold down the MODE control to the left to select the TRIP JOURNAL 1; icon "1" on the DIGITAL DISPLAY turns on. Press and hold down the MODE control to the right to select the TRIP JOURNAL 2; icon "2"...

  • Page 49: Ignition Switch

    To adjust the clock, the TRIP1 or TRIP2 menu must be scrolled until the function is reached. When pressing the MODE selector for a few seconds, you enter this mode, the minutes of the clock disappear and only the hours remain. Each time the MODE selector is pressed to the right, the hour value increases;...

  • Page 50: Locking The Steering Wheel

    OFF (2): The engine and lights cannot be set to work. The key can be extracted. ON (3): the engine may be started. The key cannot be extracted. Locking the steering wheel To lock the steering: • Turn the handlebar completely to the left. •...

  • Page 51: Switch Direction Indicators

    Press it to activate the horn. 02_47 Switch direction indicators (02_48) Move the switch to the left, to indicate a left turn; move the switch to the right to indicate a right turn. Pressing the switch deactivates the turn indicator. CAUTION IF THE WARNING LIGHT WITH ARROWS FLASHES QUICKLY, IT MEANS THAT ONE OR BOTH TURN SIGNALS LIGHT BULBS ARE BURNT OUT.

  • Page 52: High/Low Beam Selector

    If the vehicle speed reaches zero during this period, the time and distance counts are reset and start again from zero when the vehicle starts moving once again. Switching on the opposite side turn indicators without pressing the switch in the in- termediate reset position causes both the time and distance counters to reset and recommence from zero.

  • Page 53: Heated Handgrip Control

    Heated handgrip control (02_51, 02_52) (IF AVAILABLE) Activation, deactivation and heat level of the handgrips take place by short pressing the control. 02_51 There are 3 heat intensity levels which are activated cyclically from level 1 (minimum) to level 3 (maximum) each time the control is pressed. After level 3, pressing the control again deactivates the function.

  • Page 54: Start-Up Button

    Start-up button (02_53) Press the button and the starter motor spins the engine. CAUTION FIVE SECONDS AFTER THE ENGINE IS STARTED, THIS BUTTON CAN BE USED AS "MAPPING SELECTION" BUTTON. 02_53 Engine stop switch (02_54) It acts as an engine cut-off or emergency stop switch. Press this switch to stop the engine.
  • Page 55 • To activate the function (switching from OFF to ON), press and hold the Cruise Control button for approximately 2 seconds • If the system is on this will be indicated by a flashing warning light on the instrument panel The system can be used in a specific speed range, only for third through sixth gear, even while decelerating with the throttle grip closed, as defined in the table below: SYSTEM ACTIVATION SPEED...
  • Page 56 Once the desired speed is reached, the system may be activated (SET state) by pressing the cruise control button briefly, provided that the following conditions are met: - The engaged gear must not be lower than third and cannot be neutral: - The brakes must not be applied: - The clutch lever must not be in use: The instrument panel indicator lamp lights continuously to indicate that the system is...

  • Page 57: System Abs

    - If the engine RPM limiter intervenes; - If traction control intervenes; - If the motorcycle negotiates a particularly steep uphill or downhill gradient. The system switches off completely (switching from SET to OFF state), the stored speed setting is cancelled and the relative instrument panel indicator lamp extinguish- es in any of the following conditions: - Cruise Control button pressed and held;...
  • Page 58 - stop the vehicle; - key OFF-ON; - ride over 5 km/h (3.1 mph): the ABS warning light must be turned off; - the ABS system is working. If the ABS disabled indication remains: NOTE SHOULD THIS OCCUR, CONTACT AN aprilia Official Dealer.
  • Page 59 IMPORTANT TO CHECK THAT THE DISTANCE BETWEEN TONE WHEEL AND SENSOR IS THE ONE SPECIFIED. FOR CHECKING AND ADJUSTMENT, CON- TACT AN Authorised APRILIA Workshop. IN THE CASE OF A MOTORCYCLE WITH THE ABS SYSTEM, BRAKE PADS WITH FRICTION MATERIALS THAT ARE NOT TYPE APPROVED WILL JEOPARDISE BRAKING, DRASTICALLY REDUCING RIDING SAFETY.

  • Page 60: System Atc (Aprilia Traction Control)

    SUCH BEHAVIOUR IS TO BE CONSIDERED NORMAL AND DOES NOT CREATE MALFUNCTIONS IN THE SYSTEM. IF THE GAP FOR ONE OR BOTH SENSORS IS NOT WITHIN THE TOLERANCE INDICATED BELOW, TAKE THE MOTORCYCLE TO AN official Aprilia DEALER- SHIP Characteristic Distance between tone wheel and front sensor 0.3 - 2.00 mm (0.012 - 0.079 in)
  • Page 61 THE TRACTION CONTROL SYSTEM CANNOT PREVENT FALLS WHILE COR- NERING. ACCELERATING SUDDENLY WHILE THE VEHICLE IS INCLINED OR WITH THE HANDLEBARS TURNED WILL PUT THE VEHICLE IN AN UNSTABLE STATE THAT IS EXTREMELY DIFFICULT TO RECTIFY. DO NOT SPEED RECKLESSLY. LIMITS OF GRIP ARE DETERMINED BY LAWS OF PHYSICS WHICH EVEN THE ATC SYSTEM CANNOT OVERCOME.
  • Page 62 - ATC system working correctly. If the 'ATC system deactivated' indication persists: NOTE SHOULD THIS OCCUR, CONTACT AN aprilia Official Dealer. THE ATC SYSTEM ACTS ON REAR WHEEL BY OBTAINING INFORMATION FROM THE ROTATION/LOCKING TONE WHEELS FITTED ON BOTH WHEELS.

  • Page 63: Add System (Aprilia Dynamic Damping)

    0.3 - 2.00 mm (0.012 - 0.079 in) ADD system (Aprilia Dynamic Damping) ADD (Aprilia Dynamic Damping) is an integrated system that controls the semi-active suspensions and electrically operated preload of the rear shock absorber only. The system adjusts the fork and shock absorber damping in real time, to provide the...
  • Page 64 The system works independently via a dedicated ECU; no adjustments are necessary, except for the preload of the rear single shock absorber. With the motorcycle off, the suspensions are rigid, because they are not being oper- ated. The preload of the rear shock absorber can be manually adjusted on four levels, plus a fifth so-called automatic one.

  • Page 65: Immobilizer System Operation

    If there is a failure in the ADD system, the two helmets and the suitcase blink together on the display of the instrument panel, and the red GENERAL WARNING light stays permanently on. Depending on the type of fault, the suspensions may work in either medium rigidity or become fully rigid.

  • Page 66: Opening The Saddle

    DATA STORAGE PROCEDURE CANCELS THE EXISTING CODES. THEREFORE, IF A CUSTOMER WANTS TO PROGRAM SOME NEW KEYS, S/HE SHOULD GO TO THE DEALER TAKING ALL THE KEYS S/HE WANTS TO ENABLE. With the ignition key OFF, immobilizer operation mode is indicated by a warning light (1) placed on the instrument panel The light goes off after 50 h Opening the saddle (02_58, 02_59)

  • Page 67: Glove/Tool Kit Compartment

    BEFORE SETTING OFF, MAKE SURE THAT THE SADDLE IS CORRECTLY LOCKED INTO POSITION. Glove/tool kit compartment (02_60) Remove the passenger saddle to have access to the glove-box / toolkit compartment. 02_60 USB Port (02_61, 02_62, 02_63) There is USB port in the glove-box/toolkit. To use it, remove the cover and the protective plug.
  • Page 68 Blackberry Pearl, Blackberry 8xxx IT IS NOT COMPATIBLE WITH DEVICES FOR MOTOROLA PRODUCTS. IF A USB DEVICE IS CONNECTED, ENSURE THE CORRECT POSITIONING OF THE CABLE TO AVOID THAT IT WILL BE SMASHED. 02_62 To remove the cover, press the locking tongue. 02_63 The USB port is activated once the key is turned to position «ON».

  • Page 69: Identification

    PORT Output voltage (5.00+/-0.25) DC Charge current 1A Max Identification (02_64, 02_65) Write down the chassis and engine number in the specific space in this booklet. The chassis number is handy when purchasing spare parts. CAUTION THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISH- ABLE CRIME.

  • Page 70: Adjusting The Windscreen

    ENGINE NUMBER The engine number is printed on the base of the engine crankcase, left hand side. Engine No..... 02_65 Adjusting the windscreen (02_66) It is possible to adjust the windscreen manually as follows: • upholding the windscreen and working on both its sides, loosen the two knobs.
  • Page 71 DO NOT LOAD MORE THAN 5 kg (11.02 lb) FOR EACH BAG, AN EXCESSIVE LOAD COULD DAMAGE IT COVER OPENING • Rest the vehicle on its stand. • Introduce the key (1) in the pannier cover handle (2). • Turn the key (1) anticlockwise. •...
  • Page 72 02_68 REMOVAL • Lift the safety stopper 02_69 • Introduce the key (1) in the pannier cover handle (2). Turn the key (1) anti- clockwise. • Pull the pannier and free it from the stopper • Lift it and unthread it from the fixing hooks 02_70...
  • Page 73 02_71...

  • Page 75: Use

    CAPONORD Chap. 03...

  • Page 76: Checks

    CLE TO ENSURE CORRECT AND SAFE OPERATION. FAILURE TO DO SO MAY LEAD TO SERIOUS PERSONAL INJURY OR DAMAGE TO THE VEHICLE. DO NOT HESITATE TO CONTACT AN OFFICIAL Aprilia DEALER IF YOU DO NOT UNDERSTAND HOW SOME CONTROLS WORK OR IF A MALFUNCTION IS DE- TECTED OR SUSPECTED.
  • Page 77 RIDE CHECKS Front and rear disc brake Check for proper operation. Check brake lever empty travel and brake fluid level. Check for leaks. Check brake pads for wear. If necessary top-up with brake fluid. Throttle grip Check that the throttle functions smoothly and can be fully opened and closed in all steering positions.
  • Page 78 Steering Check that the rotation is uniform, smooth and there are no signs of clearance or slackness. Side stand / Centre stand (if fitted) Check it works properly. Check that there is no resistance when the side stand is pulled up and down and that the spring tension makes it snap back to its rest position.

  • Page 79: Refuelling

    Lights, warning lights, horn, rear Check function of horn and lights. stop light switch and electrical Replace bulbs or repair any faults devices noted. Tone wheels Check that the tone wheels are perfectly clean good conditions. Refuelling (03_02) To refuel: •...

  • Page 80: Rear Shock Absorbers Adjustment

    The fuel cap may only be refitted with the key (2) inserted. • Once the key (2) is inserted, press the cap to close it again. • Remove the key (2). • Close the cover (1). MAKE SURE THE CAP IS TIGHTLY CLOSED. Rear shock absorbers adjustment (03_03, 03_04) (Caponord 1200)
  • Page 81 The rear suspension consists of a spring-shock absorber unit linked to the frame via Silent-block and to the rear fork. To set vehicle suspension, the shock absorber has: - a set screw (1) to adjust the hydraulic rebound damping; - a set knob (2) to adjust spring (3) preloading. NOTE THE MOTORCYCLE REAR HEIGHT CAN BE ADJUSTED TO PERSONALISE THE 03_03...

  • Page 82: Rear Shock Absorbers Setting

    CLE'S USAGE CONDITIONS. IF SPRING PRELOADING IS INCREASED, THE HYDRAULIC REBOUND DAMPING (1) SHOULD BE INCREASED ACCORDINGLY TO AVOID SUDDEN JERKS WHEN RIDING. SHOULD YOU NEED ANY ASSIS- TANCE, CONTACT AN Official aprilia Dealer. (Caponord 1200 Travel Pack) This version is configured for use with semi-active shock absorbers...
  • Page 83 BEFORE PROCEEDING WITH THE ADJUSTMENT OF THE SHOCK ABSORBER, CLOSE THE ADJUSTERS COMPLETELY (CLOCKWISE). 03_05 (Caponord 1200 Travel Pack) This version is configured for use with semi-active shock absorbers CAUTION THE REAR SHOCK ABSORBER IS ELECTRONICALLY MANAGED BY THE VCU...

  • Page 84: Front Fork Adjustment

    • Check the tightening of all the elements and the correct operation of the front and rear suspension joints. CAUTION PLEASE CONTACT AN Official Aprilia Dealer TO HAVE THE FRONT FORK OIL CHANGED AND ITS OIL SEALS REPLACED.
  • Page 85 The front suspension consists of a hydraulic fork connected to the headstock by means of two plates. For adjusting the suspension setup, each stanchion has an upper nut (1) for adjusting the spring preload. The left hand stem is also equipped with an upper adjuster screw (2) for adjusting hydraulic rebound damping.

  • Page 86: Justering Af Greb Til Forbremse

    SCREWS (1 - 2) TO TURN BEYOND THE END OF THE STROKE ON BOTH SIDES SO AS NOT DAMAGE THEM. (Caponord 1200 Travel Pack) This version is configured for use with semi-active shock absorbers Depending on the rider's requirements, it is possible to only modify the preload on the right stanchion, working on the adjustment nut of the upper plug.

  • Page 87: Clutch Lever Adjustment

    Clutch lever adjustment (03_10) CAUTION CLEAN THE CLUTCH LEVER PIN FROM POSSIBLE DIRT ACCUMULATION OF GREASE. THEN LUBRICATE THE PIN IF YOU ARE RIDING IN THE RAIN, ON WET ROADS OR AFTER THE VEHICLE HAS BEEN WASHED For the lubricating type to be used, refer to the recommended products table. Adjust the distance between the lever end and the hand grip by turning the set screw.

  • Page 88: Starting Up The Engine

    That is to permit the adequate adjustment of the pad fric- tion material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE SECTION TO AVOID INJURING YOURSELF, OTH- ERS AND /OR DAMAGING THE VEHICLE.
  • Page 89 EXHAUST FUMES CONTAIN CARBON MONOXIDE, AN EXTREMELY HARMFUL SUBSTANCE IF INHALED. NEVER START THE ENGINE IN A CLOSED OR INSUFFICIENTLY VENTILATED SPACE. FAILURE TO OBSERVE THIS WARNING COULD LEAD TO UNCONSCIOUSNESS AND EVEN DEATH DUE TO SUFFOCATION. CAUTION WITH THE SIDE STAND LOWERED, THE ENGINE MAY ONLY BE STARTED WITH THE GEARBOX IN NEUTRAL.
  • Page 90 IF THE LOW FUEL WARNING LIGHT ON THE INSTRUMENT PANEL TURNS ON, REFUEL THE VEHICLE AT ONCE. 03_12 • Block at least one wheel by operating one brake lever. • Pull the clutch lever (5) completely and set the gearshift lever (6) to neutral (green "N"...
  • Page 91 WHEN THE EFI ICON APPEARS AND THE GENERAL WARNING LIGHT IS PER- MANENTLY ON WHILE THE ENGINE IS NORMALLY RUNNING, IT MEANS THE ECU HAS DETECTED SOME FAULT. CONTACT AN Official Aprilia Dealer ASAP. WHEN THE EFI ICON APPEARS AND THE GENERAL WARNING LIGHT IS BLINK- ING WHILE THE ENGINE IS NORMALLY RUNNING, IT MEANS THE ECU HAS DETECTED SOME SEVERE FAULT.

  • Page 92: Ride By Wire

    Ride by wire The vehicle is fitted with an innovative throttle control system, called RIDE BY WIRE, which ensures optimum engine performance, at all times, taking into account the rid- er's demand, the general operating conditions plus the external conditions (atmos- pheric pressure, temperature).
  • Page 93 To start: • Turn on the engine. • Adjust the inclination of the rear-view mirrors to ensure proper visibility. CAUTION WITH THE VEHICLE AT A STANDSTILL, PRACTICE USING THE REAR-VIEW MIRRORS. THE MIRRORS ARE CONVEX, SO OBJECTS MAY SEEM FARTHER 03_17 AWAY THAN THEY REALLY ARE.
  • Page 94 IF THE ENGINE OIL PRESSURE ICON IS DISPLAYED AND THE GENERAL WARNING LIGHT IS ON DURING REGULAR ENGINE OPERATION, THIS MEANS THAT THE ENGINE OIL PRESSURE IN THE CIRCUIT IS TOO LOW. IF THIS OCCURS, STOP THE ENGINE AND CONTACT AN APRILIA Official Deal-...
  • Page 95 SHIFTING FROM A HIGHER TO A LOWER GEAR, CALLED "DOWNSHIFT", IS CARRIED OUT: • When riding downhill and when braking, in order to increase the braking power by using engine compression. • When going uphill, when the engaged gear does not suit the speed (high gear, moderate speed) and the number of engine revs falls.
  • Page 96 To start: • Turn on the engine. • Adjust the inclination of the rear-view mirrors to ensure proper visibility. CAUTION WITH THE VEHICLE AT A STANDSTILL, PRACTICE USING THE REAR-VIEW MIRRORS. THE MIRRORS ARE CONVEX, SO OBJECTS MAY SEEM FARTHER 03_21 AWAY THAN THEY REALLY ARE.
  • Page 97 IF THE ENGINE OIL PRESSURE ICON IS DISPLAYED AND THE GENERAL WARNING LIGHT IS ON DURING REGULAR ENGINE OPERATION, THIS MEANS THAT THE ENGINE OIL PRESSURE IN THE CIRCUIT IS TOO LOW. 03_24 IF THIS OCCURS, STOP THE ENGINE AND CONTACT AN APRILIA Official Deal-...
  • Page 98 SHIFTING FROM A HIGHER TO A LOWER GEAR, CALLED "DOWNSHIFT", IS CARRIED OUT: 03_25 • When riding downhill and when braking, in order to increase the braking power by using engine compression. • When going uphill, when the engaged gear does not suit the speed (high gear, moderate speed) and the number of engine revs falls.
  • Page 99 THAT THE WARNING LIGHT TURNS OFF. IF THE LEVEL IS THE RIGHT ONE AND/OR IF THE WARNING LIGHT CONTINUES TO STAY ON AFTER TOP-UP, CONTACT AN OFFICIAL Aprilia DEALER, USING A TOW TRUCK.X IF THE TEMPERATURE INDICATOR CONTINUES BLINKING AFTER CHECKING THE COOLANT LEVEL, CONTACT AN Official Aprilia Dealer.

  • Page 100: Stopping The Engine

    NEVER RIDE WITH THE ENGINE OFF WHEN GOING DOWNHILL. WHEN RIDING ON WET SURFACES OR WITH POOR GRIP (SNOW, ICE, MUD, ETC.) RIDE AT A MODERATE SPEED AVOIDING SUDDEN BRAKING OR MA- NOEUVRES THAT MAY LEAD TO LACK OF GRIP AND CONSEQUENTLY TO FALLS.

  • Page 101: Catalytic Silencer

    CAUTION TO MOVE THE MOTORCYCLE, WITH ONE HAND GRAB THE HANDLEBAR AND WITH THE OTHER ONE THE PASSENGER HANDLE. CAUTION PARK ON SAFE AND LEVEL GROUND TO PREVENT THE VEHICLE FROM FALL- ING. DO NOT LEAN THE VEHICLE AGAINST A WALL OR LAY IT ON THE GROUND. ENSURE THAT THE VEHICLE AND, IN PARTICULAR, PARTS OF THE VEHICLE WHICH MAY BECOME HOT (ENGINE, OIL RADIATOR AND LINES, EXHAUST SYSTEM, BRAKE DISCS) ARE NOT A HAZARD TO PERSONS OR CHILDREN.
  • Page 102 Check the muffler/exhaust silencer and the silencer pipes, make sure there are no signs of rust or holes and that the exhaust system works properly. If you not an increase in exhaust noise, take your vehicle to an Official Aprilia Dealer at once.

  • Page 103: Stand

    Stand (03_27, 03_28, 03_29) THE SIDE AND CENTRE STANDS SHOULD TURN SMOOTHLY, GREASE THE JOINT IF NECESSARY. SIDE STAND If the stand has been folded up for any manoeuvre (for example, when the vehicle is in motion), place the vehicle on the stand again as follows: •...

  • Page 104: Suggestion To Prevent Theft

    A safety switch is installed on the side stand to inhibit ignition or to stop the engine when a gear is engaged and the side stand is lowered. 03_28 CENTRE STAND (if applicable) If the stand has been folded up for any manoeuvre (for example, when the vehicle is in motion), place the vehicle on the stand again as follows: •...
  • Page 105 NEVER leave the ignition key in the lock and always use the steering lock. Park the vehicle in a safe place such as a garage or a place with guards. Whenever possible, use an additional anti-theft device. Make sure all vehicle documents are in order and the road tax paid.

  • Page 106: Basic Safety Rules

    03_31 Basic safety rules (03_31) Follow the instructions given below attentively to avoid injuring persons, damaging property or the vehicle in the event of the rider or the passenger falling off the vehicle and/or the vehicle falling or overturning. When getting on and off the vehicle, make sure nothing is restricting your movements; do not hold any objects in your hands (helmet, gloves or goggles not put on).
  • Page 107 The stand has been designed to support the weight of the vehicle and a minimum load, without the added weight of rider and passenger. The purpose of the side stand is to prevent the vehicle from falling or overturning while rider and passenger get on the vehicle and get ready to ride;...
  • Page 108 SWING YOUR RIGHT LEG OVER THE SEAT IN A CONTROLLED MOVEMENT SO AS NOT TO HIT THE REAR PART OF THE VEHICLE (TAIL FAIRING OR LUG- GAGE) AND COMPROMISE STABILITY. GETTING ON THE VEHICLE • Grip the handlebar correctly and get on the vehicle without resting your weight on the side stand CAUTION IF YOU CAN NOT REACH THE GROUND WITH BOTH FEET WHEN SEATED,...
  • Page 109 MAKE SURE THAT THE GROUND ON WHICH THE MOTORCYCLE IS PARKED IS STABLE, EVEN AND FREE OF OBSTACLES. • With the left shoe heel, lower and extend the side stand completely. CAUTION IF YOU CAN NOT REACH THE GROUND WITH BOTH FEET WHEN SEATED, PLACE YOUR RIGHT FOOT ON THE GROUND (IF YOU LOSE BALANCE, THE SIDE STAND WILL PREVENT A FALL ON THE LEFT SIDE) AND BE READY TO PUT YOUR LEFT FOOT ON THE GROUND.
  • Page 110 CAUTION MAKE SURE THE VEHICLE IS STABLE.

  • Page 111: Maintenance

    CAPONORD Chap. 04 Maintenance...

  • Page 112: Engine Oil Level Check

    Engine oil level check (04_01, 04_02, 04_03) Check the engine oil level frequently. NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECI- FIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDI- TIONS, OFF ROAD OR FOR TRACK USE. 04_01 ENGINE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM.

  • Page 113: Engine Oil Top-Up

    • Switch off the engine and wait at least five minutes to allow the lubricant to drain back into the sump. • Keep the vehicle upright on a level surface and with both wheels on the ground. • Check the oil level from the sight glass on the clutch case. MAX = maximum level.

  • Page 114: Engine Oil Change

    Top-up the oil in the reservoir until you reach the correct level. Engine oil change CAUTION TO CHANGE THE ENGINE OIL, PLEASE CONTACT AN Official aprilia Dealer. IF YOU ARE ADEQUATELY TRAINED AND EXPERIENCED, REFER TO THE IN- STRUCTIONS IN THE WORKSHOP BOOKLET AVAILABLE ALSO AT ANY DEAL-...

  • Page 115: Tyres

    REFER TO THE INSTRUCTIONS IN THE WORKSHOP BOOKLET AVAILABLE ALSO AT ANY DEALER. Tyres This vehicle is fitted with tyres without inner tubes (Tubeless). CHECK TYRE INFLATION PRESSURE REGULARLY, AT LEAST ONCE A MONTH, AT AMBIENT TEMPERATURE. MEASUREMENTS MAY BE INCORRECT IF TYRES ARE WARM. CHECK PRESSURE MAINLY BEFORE AND AFTER LONG TRIPS.

  • Page 116: Spark Plug Dismantlement

    BE CARRIED OUT USING THE SPECIFIC TOOLS AND WITH THE ADEQUATE KNOWLEDGE. IT IS THEREFORE ESSENTIAL TO TAKE YOUR VEHICLE TO AN Official Aprilia Dealer OR SPECIALISED TYRE WORKSHOP TO CARRY OUT THE OPERATIONS ABOVE. NEW TYRES MAY BE COATED WITH A SLIPPERY COATING: RIDE WITH CAUTION DURING THE FIRST KILOMETRES.

  • Page 117: Removing The Air Filter

    Removing the air filter CAUTION TO REMOVE, CHECK AND REPLACE THE AIR FILTER, PLEASE CONTACT AN Official Aprilia Dealer. IF YOU ARE ADEQUATELY TRAINED AND EXPERI- ENCED, REFER TO THE INSTRUCTIONS IN THIS WORKSHOP BOOKLET AVAIL- ABLE ALSO AT ANY DEALER.
  • Page 118 GINE IS HOT AS THE COOLANT IS UNDER PRESSURE AND AT A HIGH TEM- PERATURE. CONTACT WITH SKIN OR CLOTHES MAY CAUSE SERIOUS BURNS AND/OR INJURIES. NOTE TAKE YOUR VEHICLE TO AN Official APRILIA Dealer TO HAVE THE COOLANT CHANGED. WARNING WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING- UP THE COOLANT LEVEL.

  • Page 119: Checking The Brake Oil Level

    Otherwise: • Remove the filler cap (1). • Top-up with recommended coolant until the coolant level is near the "MAX" reference mark. Do not exceed this level or the coolant will spill out when the engine is turning. • Refit and lock the filler cap (1). 04_06 CAUTION IN THE EVENT OF COOLANT CONSUMPTION OR IF THE RESERVOIR IS EMP-...

  • Page 120: Braking System Fluid Top Up

    Braking system fluid top up CAUTION TO HAVE THE BRAKING SYSTEM FLUID TOPPED-UP, PLEASE CONTACT AN Official Aprilia Dealer. IF YOU ARE SUITABLY AND EXPERIENCED, FOLLOW THE INSTRUCTIONS IN THE WORKSHOP BOOKLET, WHICH IS AVAILABLE FROM ANY DEALER. Checking clutch fluid (04_09) •...

  • Page 121: Topping Up Clutch Fluid

    Topping up clutch fluid CAUTION FOR CLUTCH FLUID TOP-UP, PLEASE CONTACT AND Official Aprilia Dealer. IF YOU ARE ADEQUATELY TRAINED AND EXPERIENCED, REFER TO THE IN- STRUCTIONS IN THIS WORKSHOP BOOKLET AVAILABLE ALSO AT ANY DEALER. Battery removal (04_10, 04_11, 04_12) •...

  • Page 122: Checking The Electrolyte Level

    • Slightly lift the battery • Unscrew and remove the screw (3) from the negative terminal clamp (-); • Move the negative lead (4) aside; • Unscrew and remove the screw (5) of the positive terminal (+); • Move the positive lead (6) aside; •...
  • Page 123 • Get an adequate battery charger. • Set the battery charger for the recharge type indicated. • Connect the battery to the battery charger. CAUTION WHEN RECHARGING OR USING THE BATTERY, BE CAREFUL TO HAVE THE ROOM ADEQUATELY AIRED. DO NOT BREATH GASES RELEASED WHEN THE BATTERY IS RECHARGING.

  • Page 124: Long Periods Of Inactivity

    Long periods of inactivity IF THE VEHICLE IS OUT OF USE FOR MORE THAN TWENTY DAYS, DISCON- NECT THE 30 A FUSE TO PREVENT BATTERY DETERIORATION CAUSED BY CURRENT CONSUMPTION BY THE MULTIFUNCTION COMPUTER. CAUTION REMOVING THE 30 A FUSES RESETS THESE FUNCTIONS: DIGITAL CLOCK, TRIP INFORMATION AND CHRONOMETER TIMES.

  • Page 125: Fuses

    THE RISK OF FIRE. CAUTION A FUSE THAT BLOWS FREQUENTLY MAY INDICATE A SHORT CIRCUIT OR OVERLOAD. IF THIS OCCURS, CONSULT AN APRILIA Official Dealer. To check: • Set the ignition switch to "OFF" to avoid an accidental short circuit.
  • Page 126 • Remove the flap. 04_14 SECONDARY FUSES (front left side, above the water radiator) (Caponord 1200) 1 A - Recovery logic relay (safety), Stop, Horn, Daylight running light, License plate light (10 A). 2 - Instrument panel power supply, anti-theft power supply (if installed), EVC power supply, arrangement + bludeash key (7.5 A).
  • Page 127 NOTE THREE FUSES (8) ARE SPARE FUSES SECONDARY FUSES (front left side, above the water radiator) (Caponord 1200 Travel Pack) 1 A - Recovery logic relay (safety), Stop, Horn, Daylight running light, License plate light (10 A). 2 - Instrument panel power supply, anti-theft power supply (if installed), VCU power supply, arrangement + bludeash key (7.5 A).

  • Page 128: Lamps

    B - Permanent ECU ABS positive (20 A). C - Electrical socket, heated handgrips (if installed), anti-theft, GPS power supply (7.5 NOTE THREE FUSES (D) ARE SPARE FUSES Lamps CAUTION BEFORE REPLACING A BULB, TURN THE IGNITION SWITCH TO «KEY OFF» AND WAIT A FEW MINUTES FOR THE BULB TO COOL OFF.

  • Page 129: Low/High Beam Lamp Replacement

    In the taillight there are: - 10 LED Low/High beam lamp replacement (04_17, 04_18) REPLACEMENT OF LOW BEAM BULB • Rest the vehicle on its stand. • Disconnect the connector (1) 04_17 • Turn the bulb holder (2) anticlockwise and remove it; •...

  • Page 130: Position Light Replacement

    Position light replacement (04_19, 04_20) Replacement of the Daylight running light bulb • Rest the vehicle on its stand. • Disconnect the connector (1) 04_19 • Turn the bulb holder (2) anticlockwise and remove it; • Replace the bulb 04_20 Front light group NOTE IN CASE OF MOTORCYCLE WASH OR IN CASE OF BOUNCING VARIATIONS,...

  • Page 131: Headlight Adjustment

    Headlight adjustment (04_21, 04_22, 04_23, 04_24, 04_25, 04_26) NOTE IN COMPLIANCE WITH LOCAL LEGISLATION, SPECIFIC PROCEDURES MUST BE FOLLOWED WHEN ALIGNING THE LIGHTS. 04_21 To quickly and easily check the alignment of the front light, place the vehicle on a level surface 10 m (32.8 ft) away from a vertical wall.
  • Page 132 • Remove the fixing screws (3) and remove the protection lid (4) 04_24 • Working from underneath the windshield, operate on the relevant screw (5). SCREW it (clockwise) to move the light beam up; UNDO it (anticlockwise) to move the light beam down. 04_25 In order to carry out horizontal adjustment of the light beam: •...

  • Page 133: Front Direction Indicators

    PROPERLY. 04_27 Rear optical unit CAUTION TO REMOVE, CHECK AND REPLACE THE BULB, PLEASE CONTACT AN Official Aprilia Dealer. IF YOU ARE ADEQUATELY TRAINED AND EXPERIENCED, RE- FER TO THE INSTRUCTIONS IN THIS WORKSHOP BOOKLET AVAILABLE ALSO AT ANY DEALER.

  • Page 134: Rear Turn Indicators

    Rear turn indicators (04_28) • Rest the vehicle on its stand. • Loosen and remove screw (1). • Remove glass (2). • Press bulb (3) slightly and turn it anticlockwise. • Pull the bulb (3) out of its fitting. • Insert a bulb of the same type adequately.

  • Page 135: Rear-View Mirrors

    • Remove the bulb (3) from the bulb holder (2). • Insert a bulb of the same type adequately. 04_30 Rear-view mirrors (04_31, 04_32) • Park the vehicle on its centre stand on safe and level ground. • Move the protection casing (1). HOLD THE REAR-VIEW MIRROR (4) TO AVOID DROPPING IT BY ACCIDENT.

  • Page 136: Front And Rear Disc Brake

    • Remove the rear-view mirror (4). CAUTION REPEAT THE PROCEDURE TO REMOVE THE OTHER MIRROR. AFTER REFITTING, ADJUST THE REAR-VIEW MIRRORS CORRECTLY AND TIGHTEN THE NUTS IN ORDER TO ENSURE STABILITY. After refitting: • Adjust the rear-view mirror angle correctly. 04_32 Front and rear disc brake (04_33, 04_34) THOROUGHLY DRY THE BRAKE DISCS WHEN YOU HAVE FINISHED CLEAN-...
  • Page 137 CAUTION CHECK THE BRAKE PAD WEAR BEFORE EACH TRIP AND EVERY 5000 km (3106 mi). To perform a quick pad wear check: • Rest the vehicle on its stand. • Carry out a visual inspection of brake disc and pads as follows: - at the front, for the front brake callipers;...

  • Page 138: Periods Of Inactivity

    If the friction material thickness (even of one front or rear pad) is reduced to a value of about 1.5 mm (0.06 in) (or even if one of the wear indicators is not very visible), contact an Official Aprilia Dealer to have all the calliper pads replaced. Periods of inactivity (04_35) Take some measures to avoid the side effects of not using the scooter.

  • Page 139: Cleaning The Vehicle

    NOTE PULL OUT THE PLASTIC BAG FROM THE PIPE OPENING. • Uncover and clean the vehicle. • Check the battery for correct charge and install it. • Refill the fuel tank. • Carry out the pre-ride checks. CAUTION AS A TEST, RIDE THE MOTORCYCLE FOR A FEW KILOMETRES AT A MODER- ATE SPEED AND AWAY FROM TRAFFIC AREAS.
  • Page 140 CAUTION BEFORE WASHING THE VEHICLE, COVER THE ENGINE AIR INTAKES AND THE EXHAUST PIPES. CAUTION CLEAN THE INSTRUMENT PANEL WITH A SOFT CLOTH MOISTENED WITH WATER. CAUTION BEFORE WASHING THE WINDSCREEN, SOFTEN THE DIRT WITH WATER. THEN CLEAN WITH A SOFT CLOTH MOISTENED WITH WATER. CAUTION AFTER CLEANING YOUR MOTORCYCLE, BRAKING EFFICIENCY MAY BE TEM- PORARILY AFFECTED DUE TO THE PRESENCE OF WATER ON THE FRICTION...
  • Page 141 leather. To clean the engine outer parts, use degreasing detergent, brushes and old cloths. Wash anodised or painted aluminium parts with neutral soap and water. Using aggressive detergents may damage the surface treatment of these components. TO CLEAN THE HEADLIGHTS USE A SPONGE SOAKED IN WATER AND MILD DETERGENT, RUBBING THE SURFACE GENTLY AND RINSING FREQUENTLY WITH PLENTY OF WATER.
  • Page 142 CAUTION DO NOT APPLY PROTECTIVE WAX ON THE SADDLE AS IT MAY BECOME SLIP- PERY. WHEN USING A HIGH PRESSURE CLEANING SYSTEM (AFTER ENSURING THAT THE DETERGENT USED IS COMPATIBLE WITH THE MOTORCYCLE FIN- ISH), MAINTAIN A DISTANCE OF AT LEAST HALF A METRE BETWEEN THE NOZZLE AND THE SURFACE BEING CLEANED.

  • Page 143: Transport

    04_38 CLEAN THE VEHICLE IMMEDIATELY WITH COLD WATER AFTER RIDING ON A ROAD TREATED WITH SALT: SALT IS HIGHLY CORROSIVE. Transport (04_39) NOTE BEFORE TRANSPORTING THE VEHICLE, IT IS NECESSARY TO EMPTY THE FUEL TANK AND THE CARBURETTOR ADEQUATELY, CHECKING THAT THEY ARE DRY.

  • Page 144: Transmission Chain

    IN CASE OF FAILURE, DO NOT TOW THE VEHICLE BUT CONTACT A ROAD ASSISTANCE SERVICE INSTEAD TO HAVE THE INFLAMMABLE FLUIDS DRAINED . Transmission chain DO NOT ALTER THE FINAL DRIVE RATIO 17/42 OR THE NUMBER OF CHAIN LINKS (112). Characteristic Final drive gear ratio 17/42...

  • Page 145: Chain Backlash Check

    TO AVOID RISK OF SEIZURE, LUBRICATE THE CHAIN ON A REGULAR BASIS. Chain backlash adjustment CAUTION TO ADJUST THE CHAIN BACKLASH, PLEASE CONTACT AN Official Aprilia Dealer. IF YOU ARE ADEQUATELY TRAINED AND EXPERIENCED, REFER TO THE INSTRUCTIONS IN THIS WORKSHOP BOOKLET AVAILABLE ALSO AT ANY DEALER.

  • Page 146: Chain Lubrication And Cleaning

    FIND DRY OR RUSTY PARTS. FLATTENED OR JAMMED CHAIN LINKS SHOULD BE LUBRICATED AND GOOD OPERATING CONDITIONS RESTORED. IF RE- PAIR IS NOT POSSIBLE, CONTACT AN Official Aprilia Dealer TO HAVE IT REPLACED. For the type of grease to be used, refer to the recommended products table.
  • Page 147 MOST ATTENTION IS REQUIRED WHEN ADJUSTING, LUBRICATING, WASHING OR REPLACING THE CHAIN. CHAIN LUBRICANTS AVAILABLE ON THE MARKET CAN CONTAIN SUBSTAN- CES THAT DAMAGE THE CHAIN'S RUBBER O-RINGS. NEVER USE THE VEHICLE JUST AFTER LUBRICATING THE CHAIN, AS THE LUBRICANT WOULD BE SPRAYED OUTWARD AND SPREAD OUT IN THE SUR- ROUNDING AREA.

  • Page 149: Technical Data

    CAPONORD Chap. 05 Technical data...
  • Page 150 1440 mm (56.69 in) windshield) Saddle height 870 mm (34.25 in) Wheelbase 1,555 mm (61.22 in) Kerb weight (Caponord 1200) 251 kg (553.36 lb) Kerb weight (Caponord 1200 265 kg (584.22 lb) Travel Pack) Dry weight (without fuel) 233 kg (513.68 lb)
  • Page 151 Type 90° longitudinal V-twin, 4-stroke, 4 valves per cylinder, 2 overhead camshafts. No. of cylinders Total engine capacity 1,197 cm³ (73.05 cu in) Bore / stroke 106 x 67.8 mm (4.17 x 2.67 in) Compression ratio 12.0 +/- 0.5: 1 Electric Electric starter Engine idle speed...
  • Page 152 EARBOX Type Mechanical, 6 speeds with foot lever on the left hand side of the engine APACITY Fuel tank (reserve included) 24 l (5.28 UK gal; 6.34 US gal) Fuel reserve 4 l (0.88 UK gal; 1.06 US gal) Engine oil 3.1 l (without oil filter change) (0.68 UK gal;...
  • Page 153 1st gear ratio 14/36 (secondary) 2nd gear ratio 17/32 (secondary) 3rd gear ratio 20/30 (secondary) 4th gear ratio 22/28 (secondary) 5th gear ratio 23/26 (secondary) 6th gear ratio 24/25 (secondary) Final drive gear ratio 17/42 RIVE CHAIN Type Endless (without master link) and with sealed links.
  • Page 154 43mm diameter (adjustment of hydraulic brake extended on left stanchion and compression on right stanchion and of spring preload on both) Front (Caponord 1200 Travel Telescopic fork "UPSIDE- Pack) DOWN" (upside-down stanchions) fork with stanchions with 43mm diameter, hydraulic braking...
  • Page 155 Rear (Caponord 1200 Travel Pack) Oscillating swingarm connected with cantilever type link to a Sachs single shock absorber, with adjustment of hydraulic braking during extension and compression (semi-active Aprilia Dynamic Damping technology) with "piggy-...
  • Page 156 calliper with four Ø 32 mm (1.26 in) pistons and two calliper pads Rear 240 mm (9.45 in) diam. disc brake with 35 mm (1.38 in) diam. single piston calliper HEEL RIMS Type Light alloy rims with extractable bolt Front 3.50 x 17"...
  • Page 157 Rear tyre 180/55 ZR17" (73W) 190/55 ZR17" (75W) (*) Rear tyre pressure rider only: 2.6 bar (260 kPa) (37.71 PSI) rider + passenger: 2.8 bar (280 kPa) (40.61 PSI) PARK PLUGS Standard spark plugs NGK CR8EKB Spark plug electrode gap 0.6 - 0.7 mm (0.024 - 0.028 in) Resistance 5 kOhm...
  • Page 158 ULBS Low-/ high beam light 12V - 55W H11 Front daylight running lights 12V - 5W Turn indicators 12V - 10W (White light) Rear daylight running light / stop light Licence plate light 12V - 5W Multifunction display lighting ARNING LIGHTS Turn indicators High beam light Fuel reserve...

  • Page 159: Kit Equipment

    Kit equipment (05_01) The tools supplied are: • 3; 4; 5; 6 mm (0.12 0.16 0.20 0.24 in) L-shaped hex Allen keys (1); • One 10 - 13 mm (0.39 - 0.51 in) double open ended spanner (2); • Pliers to extract fuses (3); •...

  • Page 161: Programmed Maintenance

    CAPONORD Chap. 06 Programmed maintenance...

  • Page 162: Scheduled Maintenance Table

    Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum function and performance. To this end, Aprilia offers a set of checks and maintenance services (at the owner's expense), that are summarised in the table shown on the following page. Any minor faults must be reported without delay to an Authorised Aprilia Dealer or Sub-Deal- er without waiting until the next scheduled service to solve it.
  • Page 163 (7) Lubricate if you are riding in the rain, on wet roads or after the vehicle has been washed OUTINE MAINTENANCE TABLE km x 1,000 Rear shock absorber Spark plug Drive chain (7) Transmission cables and controls Steering bearings and steering clearance Wheel bearings Control unit diagnosis...
  • Page 164 km x 1,000 Clutch control fluid (2) Brake fluid (2) Coolant (2) Fork oil (1) Engine oil Light aiming Fork oil seals Flexible coupling (6) Clutch lever pin (7) Tyres - pressure/wear (5) Wheels Bolts and nuts tightening Stand joint Suspension and setting Fault warning light on instrument panel (4)
  • Page 165 - JASO MA2 specifications. FUCHS TITAN SAF 1091 Fork oil (Caponord 1200) OJ RACING FORK OIL TYPE 01 Fork oil (Caponord 1200 Travel Pack) FUCHS TITAN SAF 1091 Actuator oil of the active rear single shock absorber (Caponord 1200 Travel Pack)
  • Page 167 TABLE OF CONTENTS Display: 29 Scheduled maintenance: ABS: 57 Identification: 69 Shock absorbers: 80, 82 Accessories: 70 Immobilizer: 65 Spark plug: 116 Air filter: 117 Instrument panel: 27 Stand: 16, 103 Engine oil: 15, 112–114 Alarms: 38 Start-up: 54 Engine stop: 54 Stop switch: 54 Maintenance: 111, 161, 162 Battery: 16, 121, 122...
  • Page 168 The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding it, its regular maintenance and the use of original Aprilia spare parts only are essential factors! For information on the nearest Official Dealer and/or Service Centre consult our website: www.aprilia.com...

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