125-150 cc VERSION WORKSHOP ENGINE MANUALS aprilia part # (description) 8140684 SPARE PART CATALOGUES aprilia part # (description) 6693 USE AND MAINTENANCE HANDBOOKS aprilia part # (description) CYCLE CHARACTERISTICS WORKSHOP MANUALS aprilia part # (description) 8140754
0.1.3. # < > = = ~ C F a.c A Ah API HV AV/DC bar d.c. cm CO CPU DIN DOHC ECU rpm HC ISC ISO kg kgm km km/h k kPa KS kW ABBREVIATIONS AND SYMBOLS = number = less than = greater than = equal to or less than = equal to or greater than = approximately = infinite = degrees Celsius (centigrade) = degrees Fahrenheit = plus/minus = alternating current = amperes = amperes per hour = American Petroleum Institute = high voltage = Anti-Vibration Double Countershaft = unit of pressure (1 bar =100 kPa) = direct current = cubic centimetres = carbon monoxide = Central Processing Unit = German industrial standards (Deutsche Industrie Norm) = Double Overhead Camshaft = Electronic Control Unit = revs per minute = unburnt hydrocarbons = Idle Speed Control = International Standardisation Organisation = kilograms = kilograms per metre (1 kgm =10 Nm) = kilometres = kilometres per hour = kiloOhm = kiloPascal (1 kPa =0,01 bar) = clutch side (Kupplungseite) = kiloWatt = litres = lap (race track) = Light Emitting Diode = left side = metres per second = maximum = millibar (1 mbar =0,1 kPa) = mile = minimum = miles per hour = flywheel side (Kupplungseite) = megaOhm = Not Available = octane rating motor method = octane rating research method = Newton per metre (1 Nm =0,1 kgm) = ohm = pick-up = bottom dead centre (BDC) = top dead centre (TDC) = Pneumatic Power Clutch
LAP LED LEFT SIDE m/s max mbar mi MIN MPH MS M N.A. N.O.M.M. N.O.R.M. Nm PICK-UP PMI PMS PPC
RIGHT SIDE SAE TEST T.B.E.I. T.C.E.I. T.E. T.P. TSI UPSIDEDOWN V W
= right side = Society of Automotive Engineers = diagnostic test = crowned head with flush-mounted hexagonal bolt = cylinder head with flush-mounted hexagonal bolt = hexagonal head = flat head = Twin Spark Ignition = upside-down sleeves = Volt = Watt = diameter

GENERAL INFORMATION

CONTENTS
1.1. STRUCTURE OF THIS MANUAL...3 1.1.1. HOW TO CONSULT THIS MANUAL....3 1.1.2. SAFETY MESSAGES....4 1.2. GENERAL INSTRUCTIONS....5 1.2.1. GENERAL SAFETY RULES....5 1.3. DANGEROUS ELEMENTS....8 1.3.1. WARNINGS....8 1.4. RUNNING IN....11 1.4.1. RUNNING IN....11 1.5. VEHICLE IDENTIFICATION....12 1.5.1. POSITION OF SERIAL NUMBERS....12
MOJITO 50 - 125 - 150 1.1.

WARNING An over inflated tyre will make the ride harder and uncomfortable, compromising rising comfort. In addition road handling will be compromised, especially on bends and on wet roads. A tyre that is under inflated (pressure too low) may slip on the wheel rim causing the rider to lose control of the vehicle. This will also compromise road holding and the vehicless manoeuvrability, as well as the efficiency of the brakes. Replacing, repairing, maintenance, and balancing are all important operations that must be carried out by trained technicians using suitable equipment. New tyres may be covered in a thin film of protective coating that is slippery. Ride carefully for the first few kilometres (miles). Never use any kind of rubber treatment on the tyres. Especially avoid the tyres coming into contact with liquid fuels, as these would cause the rubber to deteriorate quickly. A tyre that has been in contact with oil or petrol cannot be cleaned and has to be replaced. DANGER Certain tyres originally supplied with the vehicle are fitted with wear indicators. There are various kinds of wear indicators. Contact your Dealer for the information required on the procedure for checking the tyres. Check the tyres for wear visually and replace them when worn. If a tyre goes flat while you are riding the vehicle do not attempt to continue riding. Avoid rapid braking or manoeuvres and do not decelerate too quickly. Slowly turn the accelerator handle to decelerate and mode to the side of the road, using the engines braking action to slow down to a stop. Failure to adhere to these warnings may lead to accidents, with a risk of injury or death. Do not fit tyres with tubes on rims for tubeless tyres and vice versa.

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MOJITO 50 - 125 - 150 1.4.

1.4.1.

RUNNING IN
Running the engine in is fundamentally important for its subsequent lifespan and correct functioning. If possible ride on roads with a lot of bends and/or hills where the engine, suspension, and brakes are subject to more efficient running in. Vary your riding speed while running in. This will make it possible to load and subsequently unload the work done by components, cooling some parts of the engine. Although it is important to make the engines components work during running in, be careful not to over exert them. WARNING The vehicles maximum acceleration performance and speed can only be obtained after running in. Follow the instructions below: MOJITO 50 Do not accelerate hard nor open the throttle completely when the engine is running at low rmp both during and af ter running in. 0-100 km (0-62 mi) For the first 100 km (62 mi) use the brakes carefully and avoid hard or prolonged braking. This will allow the friction material on the disc pads to adjust to the disc properly for the disc brakes and the shoes on the drum for the rear wheel. 0-300 (0-187 mi) Do not keep the accelerator handle turned more than half way for long periods of time. 300-500 km (187-312 mi) Do not keep the accelerator handle turned more than for long periods of time. MOJITO 125 - 150 Do not accelerate hard nor open the throttle completely when the engine is running at low revs both during and after running in. 0-100 km (0-62 mi) For the first 100 km (62 mi) use the brakes carefully and avoid hard or prolonged braking. This will allow the friction material on the disc pads to adjust to the disc properly for the disc brakes and the shoes on the drum for the rear wheel. 0-500 km (0-312 mi) Do not keep the accelerator handle turned more than half way for long periods of time. 500-1000 km (312-625 mi) For the first 1000 km (625 mi) do not ride the vehicle at more than 80% of the estimated top speed. Do not maintain a constant speed for long stretches of road. After the first 1000 km (625 mi), progressively increase speed until maximum performance is reached. WARNING After the first 500 km (312 mi) for the Mojito 50 and the first 1000 km (621 mi) for the Mojito 125150, carry out the checks listed in the end of running in column (see ROUTINE MAINTENANCE TABLE), in order to avoid harming yourself, others, and/or the vehicle.

1900 mm 1950 mm 720 mm 900 mm 745 mm 750 mm 1075 mm 1120 mm 137 mm 140 mm 97 kg 1300 mm 1285 mm 2 stroke with controlled ignition horizontal one-cylinder 49.38 cm 41 mm /37.4 mm 11.3 0.5: 1 Electrical + kick starter rpm Automatic dry centrifugal Automatic stepless variator Forced air 7.5 litres 2 litres 130 cm 0,4 l 1 (2 in countries where transporting passengers is allowed) 105 kg 180 kg (in countries where transporting passengers is allowed) Automatic stepless Trapezoidal belt Gears 2,9 0,75 KEIHIN PWS 12 Equivalent diameter 12 mm Vacuum pump Super petrol DIN 51600 (4 stars UK) with a minimum octane rating of 98 (N.O.R.M.) and 88 (N.O.M.M.). Super DIN 51607 lead-free petrol, with a minimum octane rating of 95 (N.O.R.M.) and 85 (N.O.M.M.). Double monobeam
SUSPENSIONS Front Hanger fork Stroke 50 mm Rear Hydraulic shock absorber Stroke 67.5 mm BRAKES Front Disc - 190 mm with hydraulic transmission Rear Drum - 120 mm with mechanic transmission WHEEL RIMS Type Light alloy Front 3.00 x 12 Rear 4.00 x 10 TYRES Type Tubeless Front 120 / 70 12" 51J Rear 130 / 59 J STANDARD INFLATION PRESSURE Front 170 kPa (1.7 bar) Rear 190 kPa (1.9 bar) INFLATION PRESSURE WITH PASSENGER (where drive with passenger is allowed) Front 190 kPa (1.9 bar) Rear 210 kPa (2.1 bar) IGNITION Type C.D.I. / inductive Spark advance before the T.D.C. at 1600 rpm SPARK PLUG Standard NGK R BPR8HS Alternative NGK R BPR7HS Spark plug electrode gap 0.6 0.7 mm ELECTRICAL SYSTEM Battery 12 V 4 Ah Fuses 7.5 A 10A Generator (with permanent magnet) 12 V -115 W BULBS Low / high beam 12 V 35/35/ W Front parking light 12 V -5 W Direction indicators light 12 V -10 W Rear parking / stop / licence plate lights 12 V 5 / 21/ W Dashboard lighting 12 V 2 W Dashboard lighting MOJITO CUSTOM 12 V 1,2 W WARNING LIGHTS Direction indicators 12 V 2 W Oil mixer reserve 12 V 2 W Parking lights and dim headlight 12 V 1,2 W Bright light 12 V 1,2 W Fuel reserve 12 V 2 W

2.1.2. FIXING ELEMENTS

WARNING The fixing elements indicated in the table must be tightened to the torque indicated using a torque wrench and LOCTITE where indicated. Notes: L243=apply Loctite 243 Lub=lubricate Component Rear wheel positioning pin nut Rear wheel nut Nut for fixing the connecting rod to the frame Nut for fixing the connecting rod to the joint Nut for fixing the connecting rod to the engine Screw for fixing the connecting rod silent block to the frame Screw for fixing the handlebar clamp Handlebar safety screw Rear shock absorber connection top screw Rear shock absorber connection lower screw Nut for fixing the silencer to the cylinder Screw for fixing the silencer to the cylinder Rear brake lever fixing nut Front brake caliper fixing screw Brake pump U-bolt fixing screw Screws for fixing the brake pipe to the brake pump Screws for fixing the brake pipe to the brake caliper Fixing bolt for the passengers handgrip Screw for fixing the central stand to the engine Fuel tank fixing screw Starter lever fixing screw Coil fixing screw Electric horn fixing screw Body fixing screws Bodywork fixing bolts Bodywork fixing screws Size M12 M14 M10 M12 M10 M10 M10 M8 M10 M10 M6 M6 M6 M8 M6 M10 M10 M6 M10 M6 M6 M6 M6 M6 M5 Self-tapping Torque Nm Notes

MOJITO 50 - 125 - 150 2.2.
2.2.1. Components Rear shock absorber Transmission cables and controls Battery Terminal fastening Electrolyte level Spark plug Carburettor Idling Variator roller pins and guides Variator belt Steering tube bearings and steering slack Wheel bearings Brake discs Piston rings General running of the vehicle Braking system / brake discs Electric start transmission pin greasing Rear brake cam pin greasing Exhaust/ silencer/exhaust terminal Mixer / accelerator operation Air cleaner Accelerator operation Brake locking operation Light system Wear on the clutch Stop light switch Brake Fluid 2 stroke oil Transmission oil Rear pulley pins Mobile/fixed front pulley Front headlight alignment - operation Spark plug cap Wheels - Tyres Inflation pressure Wheels - Tyres Nut, bolt, screw tightening 2 stroke oil reserve warning light Cylinder head and cylinder Front shock absorber pumping element Fuel pipe Braking system pipe Mixer oil piping Rear brake shoe wear Brake pad wear
ROUTINE MAINTENANCE OPERATIONS
ROUTINE MAINTENANCE CHART After runningin [500 km (312 mi)] Every 4000 km (2500mi) or 12 months 1 every two years: 3 Every 12000 km (7500 mi): 3 Every 8000 km (5000 mi) or 24 months
1 Every 12000 km (7500 mi): 1 Every 500 km (312 mi): 1
Every 12000 km (7500 mi): 3 Every 12000 km (7500 mi): 1 every month: 1 Every 4000 km (2500 mi): 1 / every 4 years: 3 Every 4000 km (2500 mi): 1 / every 4 years: 1 Every 2 years: Every 2000 km (1250 mi): 1
1 = check and clean, adjust, lubricate, or change if necessary. 2 = clean. 3 = change. 4 = adjust. Carry out the maintenance operations more frequently if you use the vehicle in rainy or dusty areas, over on uneven ground, or on race tracks. ( ) = OPERATIONS WHICH CAN BE CARRIED OUT BY THE USER

2.2.2.

AIR CLEANER
Clean the air cleaner every 4000 km (2500 mi) or 12 months. If the vehicle is used on dusty or wet roads, the cleaning operations and replacement should be carried out more frequently. In this case the air cleaner may be partially cleaned after travelling on these types of roads. WARNING Partial cleaning of the air cleaner does not exclude or delay replacing the filter. Do not start the engine while the air cleaner is off.
REMOVING Position the vehicle on the centre stand. Unscrew and remove the four screws.
Rotate the start pedal completely and keep it down. Withdraw the complete filter from below and remove it.
CLEANING Separate the containing grid (1) from the support (2). Remove the filtering element (3). Wash the filtering element with clean, non-inflammable solvents, or with solvents with a high volatility point and let it dry thoroughly. Apply filter oil on the whole surface of the filtering element. DANGER Do not use petrol or solvents to clean the filtering element as this could cause a fire in the fuel supply system, resulting in serious danger to people and the vehicle. WARNING While cleaning the filtration element s sure it is not lacerated. If it is, replace the filtration element.

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2.2.3. IDLING ADJUSTMENT
Adjust the idling after the first 500 km (312 mi) and every time it is irregular. Before adjusting the carburettor make sure that it is properly lubricated, that the spark plug is in good condition, the air cleaner is clean and airtight, and that the exhaust system is completely airtight. Drive for a few miles until the engine reaches the normal running temperature, then stop the engine. Remove the central inspection cover. Connect an electronic revolution counter to the spark plug cable.
Start the engine. The minimum speed of the engine (idling) must be about rpm; in this case the engine does not make the rear wheel rotate. Remove the left inspection cover see 2.5.6 (REMOVING THE RIGHT AND LEFT INSPECTION COVERS
Act on the adjusting screw (1) positioned on the carburettor. When turned clockwise the engine rotation speed increases, and when turned anticlockwise it decreases.
IMPORTANT Do not act on the air adjusting screw (2), to avoid variations on the carburettor setting. Turn the twistgrip up and down several times to check for proper operation and ensure that idling is steady.

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2.2.4.
SPARK PLUG 20 Nm (2 kgm).
THIGHTENING TORQUE Spark plug:
Check the spark plug after the first 500 km (312 mi) and successively every 4000 km (2500 mi). Change it every 8000 km (5000 mi). Periodically remove the spark plug, clean any carbon deposits from it; change it if necessary. To reach the spark plug: DANGER Let the engine cool down to ambient temperature. Remove the central inspection cover.
To remove and clean the spark plug: DANGER Never disconnect the spark plug cap when the engine is running as you may suffer a severe electric shock from the ignition system. Take off the cap (1) from the spark plug (2). Remove all the dirt from the base of the spark plug. Put the plug spanner supplied in the tool kit over the spark plug. Unscrew the spark plug and remove it from its seating, taking care that neither dust nor other substances enter the cylinder.
Make sure that there are neither carbon deposits nor corrosion marks on the electrode and on the central porcelain part; if necessary clean them with the special cleaners for spark plugs, and/or a metal brush. If the spark plug has any crackings on the insulating material, corroded electrodes or excessive deposits, the central electrode (3) with a rounded top, it must be changed. WARNING When replacing the spark plug check the pitch and length of the thread. If the thread is too short the carbon deposits will build up on the thread, resulting in a risk of damaging the engine when a spark plug of the correct size is fitted. Use the recommend type of spark plug only, otherwise the life and the performance of the engine may be compromised. To check the gap between the electrodes, use a thread type feeler gauge to avoid damaging the platinum coating. Check the gap between the electrodes using a thread type feeler gauge. This gap must be 0.6 0.7 mm. If necessary, adjust it carefully bending the earth electrode. Make sure that the washer is in good condition. With the washer on, screw the spark plug by hand in order not to damage the thread. Tighten the spark plug by means of the spanner supplied with the tool kit, giving it a half turn to compress the washer.

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WARNING The spark plug must be well tightened, otherwise the engine may overheat and be seriously damaged. Use the recommended type of spark plug only, otherwise the life and performance of the engine may be compromised. Position the cap (1) on the spark plug (2) correctly, so that it does not come loose due to the engine vibrating. Refit the central inspection cover. DANGER Make sure that the cap (1) is correctly positioned on the spark plug (2).

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2.3.1.

FUEL SUPPLY

CARBURETTOR DIAGRAM
Key: 1. Cap 2. Gas valve cover 3. Gasket 4. Spring 5. Plate 6. Metering rod lock 7. Pin 8. Valve 9. Needle valve 10. Air fuel screw 11. Spring 12. Washer 13. O-Ring 14. Starter fixing plate 15. O-Ring 16. Choke valve 17. External cover 18. Screw 19. Screw 20. Fuel unload screw 21. Gasket 22. Float 23. Pin valve 24. Floating pin 25. Screw 26. Main jet
27. 28. 29. 30. 31. 32. 33. 34. 35. 36.
Jet holder Clamp Idle jet Hose O-Ring Pipe fitting Spring O-Ring Hose Adj. Min. eng. speed screw

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2.3.2. REMOVING THE CARBURETTOR Remove the right and left inspection covers see 2.5.6 (REMOVING THE RIGHT AND LEFT INSPECTION COVERS) Remove the rear cowling see 2.5.6 (REMOVING THE REAR COWLING)
Release the hose clamp and disconnect the fuel pipe.
Unscrew the gas valve cover.
Remove the gas cable from the carburettor.

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Disconnect the automatic starter connector.
Release the hose clamp that fixes the carburettor to the filter casing.
Unscrew and remove the two fixing screws for the intake manifold. Remove the carburettor.

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2.3.3. REMOVING THE FUEL LEVEL SENSOR Unscrew and remove the fixing screws for the fuel level sensor cover. Remove the cover.
Disconnect the electrical connector. Unscrew and remove the four fixing nuts for the sensor. Remove the sensor.

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2.3.4.
REMOVING THE FUEL TANK Remove the right and left inspection covers see 2.5.6 (REMOVING THE RIGHT AND LEFT INSPECTION COVERS) Unscrew and remove the fixing screw for the fuel level sensor cover. Remove the cover.
Working on both sides, unscrew and remove the four lower fixing screws for floor panel.

Working on both sides, unscrew and remove the four upper fixing screws for the floor panel. Remove the floor panel.
Disconnect the electrical connector for the fuel level sensor.

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Release the retention hose clamp and remove the fuel tank breather pipe.
Working on both sides, unscrew and remove the two front fixing screws for the lower floor panel guards. Remove the lower floor panel guards.
DANGER Danger of fire. Wait for the engine and the exhaust silencer to cool down completely. Fuel vapours are harmful to your health. Before starting work make sure that the room you are working in is adequately ventilated. Do not inhale fuel vapours. Do not dispose of the fuel into the environment. Prepare a container with a capacity that exceeds that of the fuel tank and put it on the ground under the vehicle. Release the hose clamp and remove the fuel pipe from the coupling and empty the tank. Release the lower retention hose clamp for the upper tank pipe coupling.

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Unscrew and remove the four fixing screws for the tank.
Working on both sides, unscrew and remove the two fixing screws for the body support bracket. Remove the brackets. Remove the lower fuel tank.
FUEL FILLER CAP Remove the fuel cap. Remove the mixer oil cap. Unscrew and remove the two fixing screws for the filler cap.
Remove the filler cup guard.

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Pull the fuel filler cap downwards and remove it from the right side. Release the hose clamp (1) and disconnect the fuel pipe (2). Remove the fuel filler cap.

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2.4.1.

ENGINE

REMOVING THE ENGINE WARNING Before proceeding with these operations, remember that the engine must be removed downwards from the frame. Arrange the necessary equipment accordingly.
Remove the rear cowling see 2.5.6 (REMOVING THE REAR COWLING)
IMPORTANT Set up an hoist and belts for lifting and securing the handlebar beforehand.
Use the belts to secure the handlebar to the board. Connect other belts to the rear of the frame. Lift the arm of the hoist and until the belts are tensioned.
Unscrew and remove the lower bolt that fixes the shock absorber to the engine.

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Remove the gas cable from the carburettor.
Disconnect the automatic starter connector.
Release the clamp and disconnect the fuel supply piping. WARNING When removing the fuel supply pipe and the vacuum pipe, mark them to avoid inverting them accidentally when refitting the engine.
Release the clamp and disconnect the vacuum pipe

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Release the clamp and disconnect the mixer oil pipe.
WARNING Fold the mixer oil pipe over and secure it with a self-locking clamp to prevent the oil spilling.
Remove the battery, fuel tank, and carburettor breather pipes from the guide eyelet.
Unscrew and remove the brake lever adjuster. Remove the rear brake cable.

Working on both sides, unscrew and remove the two upper fixing screws for the engine cowling.
Working on both sides, unscrew and remove the two fixing screw for the front engine cowling.
Unscrew and remove the two screws that fix the reflector to the support.

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Unscrew and remove the three fixing screws for the reflector support. Remove the support.
Unscrew and remove the rear fixing bolt for the engine cowling.
Disconnect the taillight wiring connector. Disconnect the two wiring connectors of the rear turn indicator. Remove the engine cowling.

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2.5.8. FRONT BRAKING SYSTEM DIAGRAM
Key: 1. Front brake pump D12 (Mojito Retr) 2. Brake lever (Mojito Retr) 3. Brake lever pin 4. Cap screw (Mojito Retr) 5. Brake lever stand (Mojito Retr) 6. Pump cover (Mojito Retr) 7. Brake pump portlight 8. Front brake pipe 9. Rubber ring 10. Cable guide (Mojito Custom) 11. Screw (Mojito Custom) 12. Oil pipe screw 13. 10x14x1.6 washer 14. Front brake caliper 15. Brake caliper cover 16. Pads pair 17. Bleeder + cap 18. Pin + brake spring 19. Brake caliper rev. kit 20. M8x25 screw w/flange 21. D190 brake disc 22. Disc cover cup (Mojito Custom) 23. Screw 24. D13 front brake pump (Mojito Custom) 25. Brake lever (Mojito Custom) 26. Oil tank plug (Mojito Custom) 27. Stand (Mojito Custom)

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2.5.9.
REAR BRAKING SYSTEM DIAGRAM
Key: 1. Rear brake lever complete (Mojito Custom) 2. Rear brake lever (Mojito Custom) 3. Brake lever pin (Mojito Custom) 4. U-bolt (Mojito Custom) 5. Screw (Mojito Custom) 6. Brake light switch 7. Nut 8. Rubber spacer 9. Rear brake cable 10. Brake pipe hanger 11. Cable guide 12. M6x16 screw w/flange 13. Plate 14. M6x16 hex socket screw 15. Coil compress. spring 16. Rear brake lever 17. Rear brake lever register 18. Brake cable retainer 19. M6x35 screw w/flange 20. M6 flanged self-locking nut 21. Lever return spring 22. Lining wear indicator 23. Antidust gasket 24. Rear brake cam 25. Brake shoes + springs 26. Rear brake lever complete (Mojito Retr) 27. Rear brake lever (Mojito Retr) 28. Brake lever U-bolt (Mojito Retr) 29. Screw (Mojito Retr) 30. Brake lever pin (Mojito Retr)

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MOJITO 50 - 125 - 150 2.6.

2.6.1.

SYSTEM DIAGRAM

WIRING DIAGRAM MOJITO 50

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Key: 1. Generator 2. CDI 3. Spark plug 4. HT Coil 5. Voltage Regulator 6. Battery 7. Starter motor 8. Start Relay 9. Front stoplight switch 10. Rear stoplight switch 11. 2 stroke oil reserve switch 12. Engine kill 13. Fuel level sensor 14. Rear right direction indicator 15. Tail light 16. Rear left direction indicator 17. Plate light 18. Horn push button 19. Ignition switch / steering lock 20. Control diode 21. Start push button 22. Blinking 23. Dashboard 24. Direction indicator warning light 25. 2 stroke oil reserve warning light 26. Dashboard lights 27. Fuel level instrument 28. Low fuel warning light 29. High beam warning light 30. Front parking light 31. Front right direction indicator 32. Front left direction indicator 33. Front light 34. Low / high beam bulb 35. Horn 36. Pick-up 37. Fuses 38. Multiple connectors 39. Rear parking light / stop light / number plate light 40. 41. Direction indicator deviator 42. Left dimmer switch 43. Low beam and parking light warning light 44. Automatic starter WIRE COLOURS Ar orange Az light blue B blue Bi white G yellow Gr grey M brown N black R red V green Vi violet Ro pink

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2.6.2. WIRING DIAGRAM MOJITO CUSTOM 50

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Key: 1. Generator 2. CDI 3. Spark plug 4. HT Coil 5. Voltage Regulator 6. Battery 7. Starter motor 8. Start Relay 9. Front stoplight switch 10. Rear stoplight switch 11. 2 stroke oil reserve switch 12. Automatic choke 13. Fuel level sensor 14. Rear right direction indicator 15. Taillight 16. Rear left direction indicator 17. Left dimmer switch 18. Right dimmer switch 19. Ignition switch / steering lock 20. Control diode 21. Plate light 22. Blinking 23. Dashboard 24. Direction indicator warning light 25. 2 stroke oil reserve warning light 26. Dashboard lights 27. Fuel level instrument 28. Low fuel warning light 29. High beam warning light 30. Front parking light 31. Front right direction indicator 32. Front left direction indicator 33. Front light 34. Low / high beam bulb 35. Horn 36. Pick-up 37. Fuses 38. Multiple connectors 39. Rear parking light / stop light / number plate light 40. 41. Low beam and parking light warning light WIRE COLOURS Ar orange Az light blue B blue Bi white G yellow Gr grey M brown N black R red V green Vi violet Ro pink

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125 - 150 CC VERSION
3.1. TECHNICAL INFORMATION.... 3 3.1.1. TECHNICAL DATA.... 3 3.1.2. FIXING ELEMENTS..... 5 3.1.3. LUBRICANT TABLE..... 6 3.1.4. ARRANGEMENT OF THE MAIN ELEMENTS... 7 3.2. ROUTINE MAINTENANCE OPERATIONS.... 9 3.2.1. ROUTINE MAINTENANCE CHART.... 9 3.2.2. AIR CLEANER..... 10 3.2.3. IDLING ADJUSTMENT.... 11 3.2.4. SPARK PLUG..... 13 3.2.5. CHECKING THE ENGINE OIL LEVEL AND TOPPING UP... 15 3.2.6. CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER.. 16 3.3. FUEL SUPPLY.... 17 3.3.1. CARBURETTOR DIAGRAM.... 17 3.3.2. REMOVING THE CARBURETTOR.... 18 3.3.3. REMOVING THE FUEL LEVEL SENSOR.... 20 3.3.4. REMOVING THE FUEL TANK.... 21 3.4. ENGINE...... 24 3.4.1. REMOVING THE ENGINE..... 24 3.5. CYCLE CHARACTERISTICS.... 28 3.5.1. FRONT FORK DIAGRAM.... 28 3.5.2. REMOVING THE FORK.... 29 3.5.3. FRONT BODY DIAGRAM.... 31 3.5.4. CENTRAL BODY DIAGRAM.... 32 3.5.5. REAR BODY DIAGRAM.... 33 3.5.6. REMOVING THE RIGHT AND LEFT INSPECTION COVERS... 34 3.5.7. REMOVING THE REAR COWLING.... 35 3.5.8. FRONT BRAKING SYSTEM DIAGRAM... 37 3.5.9. REAR BRAKING SYSTEM DIAGRAM.... 38 3.6. ELECTRICAL SYSTEM..... 39 3.6.1. COMPONENT CHECK.... 39 3.6.2. WIRING DIAGRAM MOJITO 125 - 150... 42
MOJITO 50 - 125 - 150 3.1.

3.1.1.

DIMENSIONS Max. length 1980 mm Max. width 720 mm Max. width for the MOJITO CUSTOM 920 mm Seat height 780 mm Seat height for the MOJITO CUSTOM 755 mm Max. height (headlight included) 1090 mm Max. height (headlight included) for the MOJITO CUS- 1135 mm TOM Min. ground clearance 85 mm Weight ready for starting 115 kg Distance between centres 1350 mm ENGINE 125 cc Version Mcc Version M191 Type 4 stroke with controlled ignition Number of valves 2 Number of cylinders Horizontal one-cylinder Total displacement 125 cc 124.0 cm Total displacement 150 cc 149.58 cm Bore / stroke 125 cc 57.0 mm /48.6 mm Bore / stroke 150 cc 62.5 mm /48.6 mm Compression ratio from 10.1 to 11.1 : 1 Starting Electric Engine rpm when idling rpm Clutch Automatic dry centrifugal Change gear Automatic stepless variator Lubrication system With wet sump, forced circulation by a mechanical pump, level check using dipstick with cap. Cooling With forced air CAPACITY Fuel (reserve included) 8 litres Fuel reserve 2 litres Engine oil only changing oil and oil filter 1000 cm Transmission oil 85 cm Seats 2 Max motorcycle load (rider + luggage) 105 kg Vehicle max. load (driver + passenger + luggage) 180 kg TRANSMISSION Speed change gear Automatic and stepless Primary V-belt Secondary with gears Ratios minimum for stepless change: 2.701 maximum for stepless change 0.809 CARBURETTOR Model WALBRO WVF - 6 Choke tube Equivalent diameter 24 mm FUEL SUPPLY Fuel Leaded or ulnleaded premium grade petrol (4 stars UK), min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.). FRAME Type One beam split in two at the rear Steering inclination angle 2415 Forepart 52 mm

Engine oil

Bearings and other lubrication points
RECOMMENDED: AUTOGREASE MP or GREASE 30. As an alternative to the recommended product, use high quality grease for rolling bearings, working temperature range -30C to +140C, dripping point 150C to 230C, high protection against corrosion, good resistance to water and oxidation. Neutral grease or vaseline IMPORTANT Only use new brake fluid. Do not mix different brands or types of fluid without checking that their bases are compatible. Autofluid FR. DOT 4 (compatibility The braking system is filled with DOT 5) or BRAKE 5.1, DOT 4 (compatibility DOT 5).

3.1.4.

ARRANGEMENT OF THE MAIN ELEMENTS
Key: 1. Left rear-view mirror 2. Glove compartment 3. Left inspection cover 4. Central inspection cover 5. Passenger left footrest 6. Air cleaner 7. Passenger grab rail 8. Saddle lock 9. Central stand 10. Engine oil filler cap 11. Battery 12. Side stand (OPT)
Key: 1. Helmet / glove compartment 2. Right inspection cover 3. Fuel tank plug 4. Ignition switch / steering lock 5. Bag hook 6. Fuse box 7. Right rear-view mirror 8. Brake fluid reservoir (front brake) 9. Horn 10. Fuel tank 11. Anti-theft hook [for the aprilia Body-Guard armoured cable (OPT)] 12. Spark plug 13. Passenger right footrest
MOJITO 50 - 125 - 150 3.2.
3.2.1. Components Rear shock absorber Carburettor CO value Transmission cables and controls Battery Terminal fastening Electrolyte level Spark plug Carburettor Idling Variator roller pins and guides Variator belt Steering tube bearings and steering slack Wheel bearings Brake discs Engine oil filter General running of the vehicle Valve clearance Speed change gear grease Braking systems Exhaust silencer / exhaust terminal Air cleaner Accelerator operation Brake locking operation Light system Clutch wear Stop light switch Brake Fluid Engine oil Transmission oil Headlight beam direction - operation Spark plug cap Wheels/Tyres Inflation pressure Wheels - Tyres Inflation pressure Nut, bolt, screw tightening Engine oil pressure warning light (operation) Cylinder head nut fastening and silencer/exhaust manifold fastening. Front shock absorber pumping element Fuel pipe Braking system pipe Rear brake shoe wear Rear brake pad wear

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3.5.3. FRONT BODY DIAGRAM
Key: 1. Headlight chromed ring nut 2. Headlight support 3. Dashboard panel 4. Dashboard chromed ring nut 5. RH electrical control housing 6. LH electrical control housing 7. M4x10 hex socket screw 8. Self-tapping screw 9. Self-tapping screw 10. Self-tapping screw 11. M4 clip 12. Front cowling 13. Front collar, chr. 14. Rear collar, chr. 15. M5x16 screw w/flange 16. M4x10 hex socket screw 17. 4.3x9x0.8 washer 18. 4.2x16 cap screw 19. M5 clip 20. Panel, chr. 21. Front shield 22. Internal shields 23. Water protection 24. Screw clip D4,2 25. Self-tapping screw
26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.
M6x16 screw w/flange M5x16 screw w/flange 4.3x12x1 washer T bush Self-tapping screw Front mudguard Front mudguard finish Front mudguard lockup Self-tapping screw Plastic rivet M5x12 screw w/flange LH connecting rod cover, chr. RH connecting rod cover, chr. M5x40 screw w/flange 5.3x10x1 washer Rear reflector support Amber reflector Flanged self-locking nut M5

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3.5.4.

CENTRAL BODY DIAGRAM

Key: 1. Glove compartment door 2. Top box gasket 3. Glove compartment 4. Self-tapping screw. 5. Front glove compartment lock 6. Lock nut 7. Battery holder 8. Clip for self-tapping screw D5,5 9. Battery cover 10. Black adhesive sponge 6x60 11. Adhesive sponge 12. Floor panel 13. Type appr. data cover 14. Inspection cover 15. 5.5x20 cap screw 16. 4.2x16 cap screw 17. 5.5x22 cap screw 18. 15x5.5 washer 19. RH side panel
20. 21. 22. 23. 24. 25. 26.
LH side panel Lower protective fairing Clip for self-tapping screw D4,2 Clip for self-tapping screw D5,5 LH rear stand masking M4 clip M4x12 cap screw

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3.5.5. REAR BODY DIAGRAM
Key: 1. RH side cover 2. LH side cover 3. Under saddle hook, cpl. 4. M4x35 cap screw 5. 4.2x16 cap screw 6. RH undersaddle 7. LH undersaddle 8. 5.5x20 cap screw 9. Clip for self-tapping screw D4,2 10. Clip for self-tapping screw D5,5 11. RH rear footrest cover 12. LH rear footrest cover 13. M4 clip 14. M4,2x20 cap screw 15. Fairing 16. Self-tapping screw. 17. Oval finish 18. Amber oval reflector (AU-DK-EU) 19. Reflector decal (USA) 20. 4.3x16 washer 21. M4 low self-locking nut 22. Self-tapping screw 23. LH direction light place 24. LH turn indicator 25. RH direction light place 26. RH turn indicator 27. 4.2x16 cap screw 28. Rear mudguard 29. M5x12 screw w/flange
30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48.
Insulating washer M6x16 screw w/flange 8.4x13 washer Bush 6.6x18x1.6 M4-M5-M6 clip Water protection LH turn indicator RH turn indicator 7x15x1.5 washer Washer for D5 shafts Red reflector Reflector support Number plate holder (Mojito Custom USA) Number plate holder plate (Mojito Custom USA) Number plate support (AU-DK-EU) Rear splash guard Reflector support (Mojito Custom USA) Red reflector (Mojito Custom USA)

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3.5.6.

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3.5.7. REMOVING THE REAR COWLING Lift the saddle. Unscrew and remove the five screws. Remove the rear handle from the engine cowling. WARNING Handle chromed and painted components carefully so as not to scratch or ruin them. Remove the side inspection covers see 2.5.6 (REMOVING THE RIGHT AND LEFT INSPECTION COVERS)
Working on both sides, unscrew and remove the two fixing screws for the upper engine cowling.

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Disconnect the taillight wiring connector. Remove the engine cowling.

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3.5.8. FRONT BRAKING SYSTEM DIAGRAM
Key: 1. Front wheel 2. Front tyre 120/70-12 3. Tubeless valve 4. Brake disc D190 5. Screw 6. Front wheel spindle 7. Front wheel spacer 8. Bearing 9. Drive key 10. Seal ring D40x50x4 11. Odometer gear 12. 12.2x22x2 flat metal washer 13. M12x1,25 low self-locking nut 14. Front brake pipe 15. Rubber spacer 16. Cable guide 17. Cable guide 18. Oil pipe screw 19. 10x14x1.6 washer 20. Front brake caliper 21. Brake caliper cover
Bleeder +cap Caliper pin + spring M8x25 screw w/flange F. anti-whistle plate-pair Pads pair Caliper revision kit M4x10 hex socket screw Front brake pump D13 (Mojito Custom) Front brake lever (Mojito Custom) Lever pin cpl. (Mojito Custom) Oil tank cap (Mojito Custom) Brake pump portlight (Mojito Custom) U-bolt (Mojito Custom) Front brake pump D12 (Mojito Retr) Front brake lever (Mojito Retr) Lever screw (Mojito Retr) Nut (Mojito Retr) U-bolt (Mojito Retr) Cap screw (Mojito Retr) Oil level cap (Mojito Retr) Tank cap (Mojito Retr) Pump cover screw (Mojito Retr)

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3.5.9.
Key: 1. Rear wheel 2. Tubeless valve 3. Rear tyre 130/70-12 4. Ring 5. Rear wheel nut 6. Cap 7. Split pin 8. Brake shoes + springs 9. Rear brake cam 10. Seal ring 11. Plate 12. Rear brake lever 13. M6x30 screw w/flange 14. Square nut 15. Rear brake lever adjuster 16. Brake cable retainer 17. 6.6x18x1.6 washer 18. 6.5x10x19 spacer 19. Coil compress spring 20. Rear brake cable 21. Cable guide 22. Self-tapping TE screw 4.8x12 23. Plate 24. Clamp 25. M6x35 screw 26. Brake shoes return spring 27. Rear wheel spacer
28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38.
Rear brake lever complete (Mojito Custom) Rear brake lever (Mojito Custom) Brake lever pin (Mojito Custom) U-bolt (Mojito Custom) Screw (Mojito Custom) Nut (Mojito Retr) Rear brake lever complete (Mojito Retr) Rear brake lever (Mojito Retr) Brake lever pin (Mojito Retr) Screw (Mojito Retr) U-bolt (Mojito Retr)

TechnicalSpecifications ApriliaMojito125
Engine Displacement Bore and stroke Fuel Compression ratio Maximum power Max torque Fuel system Alternator Ignition Lubrication Gearbox Clutch Primary drive Final drive Frame Front suspension Rear suspension Brakes Tyres Overall length Wheelbase Seat height Fuel tank capacity Horizontal single cylinder 124 cc 57.0 mm/48.6 mm Unleaded petrol 10.6 0.5:1 7.2 kW (9.8 HP) at 8,250 rpm 9.0 Nm at 7,250 rpm Keihin carburettor (125 cc) 165 W Inductive CDI. Forced circulation with mechanical pump and wet sump Automatic with continuous speed variation. Automatic centrifugal dry clutch. V belt. Gearbox. Twinned single beam. Trailing link. Wheel Travel 45 mm Hydraulic mono shock, wheel travel 72 mm Front: 190mm disc, hydraulically operated. Rear: 140mm drum Tubeless. Front: 120 / 70 x 12 Rear: 130 / 70 x 10 1,980mm 1,350mm 755mm 9.0 Litres (2Lreserve)
The motorcycle specifications are indicative only and subject to change without notice. Please contact your local dealer for specific information.
John Sample Automotive Pty Ltd www.aprilia.com.au