APRILIA QUASAR 125 2003, Workshop Manual

Page 1: ...www serviceaprilia com workshopmanual QUASAR 125 180 1122 3 00 2003 09 8140724 UK ProCarManuals com ...

Page 2: ...QUASAR 125 180 FOREWORD 0 1 00 Release 00 2003 06 1 GENERAL INFORMATION 0 FOREWORD 0 2 PERIODIC MAINTENANCE 3 ENGINE 4 FUEL SYSTEM 5 ELECTRIC SYSTEM 6 CYCLE PARTS ProCarManuals com ...

Page 3: ...1 RELEASE 00 2003 09 UPDATE 0 3 00 0 1 1 MANUAL UPDATES 0 3 00 0 1 2 LIST OF MANUAL PAGES AND UPDATE NUMBERS 0 3 00 0 2 FOREWORD 0 5 00 0 3 REFERENCE MANUALS 0 5 00 0 3 1 OWNER S MANUALS 0 5 00 0 3 2 SPARE PARTS CATALOGUE 0 5 00 0 4 ABBREVIATIONS SYMBOLS CONVENTIONS 0 6 00 ProCarManuals com ...

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Page 6: ...to repair procedures Such changes and modifications are then reflected in the next release of the relevant manual When in doubt about an inspection or repair procedure please contact the Aprilia Consumer Service A C S Department who will be glad to provide full information on the procedure in question as well as on any updates or engineering changes affecting the motorcycle under consideration Apr...

Page 7: ... minute HC unburnt hydrocarbons ISC Idle Speed Control ISO International Standardization Organization Kg kilograms Kgm kilogram per metre 1 kgm 10 Nm km kilometres kph kilometres per hour kΩ kiloohm kPa kiloPascal 1 kPa 0 01 bar KS clutch side from the German Kupplung Seite kW kiloWatt litres LAP racetrack lap LED Light Emitting Diode LEFT SIDE left side m s metres per second max maximum mbar mill...

Page 8: ...QUASAR 125 180 FOREWORD 0 7 00 Release 00 2003 06 T E hexagonal head T P flat head screw TSI Twin Spark Ignition UPSIDE DOWN inverted fork V Volt W Watt Ø Diameter ProCarManuals com ...

Page 9: ...FOREWORD QUASAR 125 180 0 8 00 Release 00 2003 06 NOTE ProCarManuals com ...

Page 10: ...QUASAR 125 180 GENERAL INFORMATION 1 1 00 Release 00 2003 09 1 GENERAL INFORMATION ProCarManuals com ...

Page 11: ... 7 GENERAL PRECAUTIONS AND INFORMATION 1 6 00 1 3 8 BEFORE DISASSEMBLING ANY COMPONENTS 1 6 00 1 3 9 DISASSEMBLING THE COMPONENTS 1 6 00 1 3 10 REASSEMBLING THE COMPONENTS 1 7 00 1 3 11 ELECTRICAL CONNECTORS 1 7 00 1 3 12 TORQUE FIGURES 1 7 00 1 4 WARNINGS REGARDING FUEL LUBRICANTS AND OTHER COMPONENTS 1 8 00 1 4 1 FUEL 1 8 00 1 4 2 LUBRICANTS 1 9 00 1 5 LOCATION OF SERIAL NUMBERS 1 10 00 1 5 1 FR...

Page 12: ...ZD4KY01003TXXXXXX STARTING FROM MODEL YEAR 2003 automatic light switching version Automatic Switch on Device optional 1 2 SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages Safety warning When you find this symbol on the vehicle or in the manual be careful to the potential risk of personal injury Disregarding the instructi...

Page 13: ...to explosion DO NOT RELEASE FUEL INTO THE ENVIRONMENT KEEP AWAY FROM CHILDREN 1 3 3 HOT COMPONENT PARTS The engine and exhaust component parts become hot when the engine is running and will stay hot for some time after the engine has been stopped Wear heat gloves before handling these components or allow for the engine and exhaust system to cool down before proceeding 1 3 4 TRANSMISSION OIL Use PO...

Page 14: ...ins sulphuric acid and can cause burns if spilled on the skin Wear close fitting gloves and protective clothing when handling the battery electrolyte If any battery fluid gets on your skin rinse the affected area with abundant fresh water Take special care to protect your eyes even a small amount of battery acid can cause blindness If battery fluid is spilled into your eyes flush with abundant wat...

Page 15: ...not use alcohol petrol or solvents to clean the rubber and plastic parts and the seat use only water and mild soap Always disconnect the battery negative lead before soldering any electrical components When two or more persons service the same motorcycle together special care must be taken to avoid personal injury Read carefully 1 4 WARNINGS REGARDING FUEL LUBRICANTS AND OTHER COMPONENTS 1 3 8 BEF...

Page 16: ...all joint surfaces oil seal edges and gaskets before assembly Apply a light coat of lithium grease along the edges of oil seals Fit oil seals and bearings with the brand or serial number facing outwards in view 1 3 11 ELECTRICAL CONNECTORS Disconnect electrical connectors as follows failure to follow the instructions can seriously damage the connectors and the wiring Press down on the locking tab ...

Page 17: ... Do not swallow fuel Do not transfer fuel between different containers using a hose In case of contact with the eyes rinse abundantly with clean water and immediately seek medical attention If accidentally swallowed do not induce vomiting Drink abundant milk or cool water and seek medical attention immediately DO NOT RELEASE FUEL INTO THE ENVIRONMENT KEEP AWAY FROM CHILDREN Use only premium grade ...

Page 18: ...contact with lubricant may cause severe skin damage Wash your hands thoroughly after handling engine oil Do not release into the environment Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier When filling the vehicle with lubricant make sure not to spill it Immediately clean up spilled oil as it can damage the motorcycle paint Oil on the tyres can make the...

Page 19: ... warranty invalidation 1 5 1 FRAME NUMBER The motorcycle s frame number is stamped on the front part of the frame under front mudguard support 1 5 2 ENGINE NUMBER The engine number is stamped on the crankcase on the left side of the motor cycle 1 6 SPARE PARTS Use Original Aprilia Spare Parts only for repairs Original Aprilia spare parts are high quality components designed and built expressly for...

Page 20: ...ed circulation via mechanical pump Cooling air air CAPACITY Fuel reserve included 8 l 8 l Fuel reserve 1 5 l 1 5 l Transmission oil 200 cm 200 cm Engine oil 1 engine oil change only 0 9 l 0 9 l 2 change for engine overhaul 1 2 l 1 2 l Seats 2 2 Vehicle max load driver possible luggage 98 Kg GRIP 98 kg HP 98 Kg GRIP 98 kg HP TRANSMISSION Converter automatic continuous automatic continuous Primary w...

Page 21: ... 30 kPa 0 30 bar IGNITION Type C D I C D I Ignition advance 13 2 13 2 SPARK PLUG Standard NGK CR8HSA NGK CR8HSA Spark plug gap 0 6 0 7 mm 0 6 0 7 mm ELECTRIC SYSTEM Battery 12 V 9 Ah 12 V 9 Ah Fuse 15 A 15 A Generator with permanent magnet 12 V 110 W 12 V 110 W BULBS Parking light 12 V 5 W 12 V 5 W Low high beam 12 V 35 35 W 12 V 35 35 W Direction indicators 12 V 10 W 12 V 10 W Rear parking lights...

Page 22: ...L 15W 40 As an alternative to recommended oil it is possible to use high quality oil having equal or higher ratings with respect to A P I SJ eF specifications Bearings and other lubrication points RECOMMENDED AUTOGREASE MP or GREASE 30 As an alternative to recommended fluids it is possible to use high quality grease for bear ings temperature range 30 C 140 C dripping point 150 C 230 C highly corro...

Page 23: ...ific special tools for this vehi cle are listed below If needed order the brand specific special tools see Special Tools Catalogue Always read the instructions supplied with the special tools before use TOOLS Ref Tool designation and application Part number 1 Flywheel and clutch housing locking tool 8900675 2 Universal clutch assembly disassembly tool 8900674 3 Converter locking tool 8900673 4 Rin...

Page 24: ...n to clean dry threads at room temperature NOTE Follow the instructions below to avoid distortion and or improper fit Screw all fasteners finger tight Tighten the opposing parts to half the prescribed torque A and B C and D Repeat sequence tightening to specified torque NOTE This way the load generated by the fasteners is applied evenly across joint surface Screw or bolt Spanner Tightening torque ...

Page 25: ...GENERAL INFORMATION QUASAR 125 180 1 16 00 Release 00 2003 09 NOTE ProCarManuals com ...

Page 26: ...QUASAR 125 180 PERIODIC MAINTENANCE 2 1 00 Release 00 2003 09 PERIODIC MAINTENANCE 2 ProCarManuals com ...

Page 27: ...LUG 2 10 00 2 8 IDLING ADJUSTMENT 2 11 00 2 9 ADJUSTING THE THROTTLE CONTROL 2 11 00 2 10 AIR CLEANER 2 12 00 2 11 FUEL VAPOURS FILTER 2 12 00 2 11 1 ENGINE OIL 2 13 00 2 11 2 CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER 2 14 00 2 12 CHECKING THE TRANSMISSION OIL LEVEL 2 15 00 2 13 CHECKING AND ADJUSTING THE BRAKES 2 16 00 2 14 CHECKING THE STEERING 2 17 00 2 15 INSPECTING THE FRONT SUSPENSIO...

Page 28: ...round and lift it using suitable equipment Be careful of any parts of the engine or exhaust system which may still be hot to the touch to avoid scalds or burns All component parts of the vehicle are inedible Do not bite suck chew or swallow any vehicle parts If not expressly indicated otherwise for the reassembly of the units repeat the disassembly operations in reverse order 2 1 PERIODIC MAINTENA...

Page 29: ...10 1 0 Oil cooler retaining screw 9 0 9 Starter motor screw 14 1 4 Oil pump screw 14 1 4 Stator screw 14 1 4 Engine mount screw 28 28 FRAME Component Nm kgm Note Upper handlebars braces 4 0 4 Steering stem nut 10 1 0 Rear shock absorber retaining nut 40 4 0 Front hub retaining nut 60 6 0 Rear hub retaining nut 95 9 5 Front wheel retaining nut 38 3 8 Rear wheel retaining nut 38 3 8 Steering stem fl...

Page 30: ...y Yearly Throttle and brake cables Battery Spark plug Carburettor idle speed Drive chain Every 10 hours of operation Air cleaner Engine oil filter Light system Stop light switch Engine oil Tyres pressure Always check before use Fuel indicator Ignition advance Transmission cables Brake drums blocks Always check before use Drive belt Steering tube bearing and steering clearance Ties Fuel filter Clut...

Page 31: ...ion 1 HAZARD LIGHT SWITCH Press down the top marked with the symbol to flash all indicators at once 2 DIRECTION INDICATOR LIGHT SWITCH Turn the switch to the left to indicate turning to the left to the right to indicate turning to the right Press the switch to turn off the indicators 3 HORN BUTTON Press to sound the horn 4 LIGHT DIP SWITCH Turn the light switch to to activate the parking and low b...

Page 32: ...when it is in the position The motorcycle is delivered with two keys one spare key NOTE Keep the spare key separate from the motorcycle Position Function Removing the key The engine and lights can not be operated The key may be removed The engine may be started The key may not be removed The parking and low beam lights are operating and the high beam lights may be turned on and the engine started ...

Page 33: ...o operation is necessary excepting occasional checks and the recharge when required If the motorcycle is not to be used for some time disconnect the battery terminals CHECKING AND CLEANING THE TERMINALS Remove the seat see 6 1 1 REMOVING THE SEAT Ensure the main switch is in the position Make sure that the cable terminals 1 and the battery terminals 2 are in good conditions and not corroded or cov...

Page 34: ...ases produced by the battery under charging Switch on the battery charger Reassemble the battery only 5 10 minutes after disconnecting the recharge apparatus since the battery continues to produce gas for a short lapse of time INSTALLING THE BATTERY Ensure the main switch is in the position Remove the seat see 6 1 1 REMOVING THE SEAT NOTE The battery must be positioned in its compartment with the ...

Page 35: ...ean with a plug cleaner or wire brush Blow out with compressed air to stop residues getting into the engine itself If the spark plug has crackings on the insulating material corroded electrodes or excessive deposits it must be changed Check the electrode gap with a thickness gauge Electrode gap should be 0 6 0 7 mm 0 02 0 03 in If it needs adjusting bend the earth electrode carefully Make sure the...

Page 36: ...NG THE THROTTLE CONTROL NOTE Perform the maintenance operations more frequently if the vehicle is used in rainy or dusty areas on uneven surfaces or on racetracks The idle stroke of the throttle lever must be 2 6 mm If not proceed as follows Withdraw the protection elements 1 Slacken the locknut 2 Rotate the adjuster 3 in such a way as to restore the prescribed value After the adjustment tighten t...

Page 37: ...untimely wear of the piston rings and the cylinder may be caused by a faulty or incorrectly positioned filtering element Remove the rear shield see 6 1 6 REMOVING THE REAR SHIELD Release and remove the seven screws 1 Remove the filter case cover 2 Loosen and remove the two screws 3 on the case Remove the filter 4 Change the filter with one having the same features 2 11 FUEL VAPOURS FILTER Carefull...

Page 38: ...k portion in touch with oil with a clean cloth Fully screw plug dipstick inside filler opening 2 Remove plug dipstick 1 again and read the oil level on the stick MAX maximum level MIN minimum level The level is correct when the oil almost reaches the MAX mark on the dipstick Never exceed the MAX mark nor leave the oil below the MIN mark in order to avoid serious damage to the engine If necessary t...

Page 39: ...ollection under engine oil filter Unscrew and remove plug 2 Save engine oil filter 3 Used oil contains dangerous substances for the environment dispose of used oil in compliance with environment protection regulations in force Unscrew and remove the oil drain plug 4 and then drain off all engine oil Clean oil mesh filter 3 with special detergents and refit filter 3 and plug 2 Screw and tighten eng...

Page 40: ...than 200 cm 12 2 cu in under the drain plug 1 Release the filler cap 2 as well as the drain plug 1 Allow the oil to completely drain out of the crankcase and measure the quantity if less than 200 cm 12 2 cu in refill to level with the missing amount see 1 8 LUBRICANT CHART Tighten the drain plug 1 Use a syringe or similar to inject the oil through the input hole NOTE To facilitate filling the cran...

Page 41: ...f the friction material is worn down to nearly 1 mm replace the blocks ADJUSTING THE FRONT BRAKES Operate the right hand brake lever Loosen the lock nuts 1 Adjust the brake adjuster 2 Loosen the lock nuts 1 ADJUSTING THE REAR BRAKE Adjust the adjuster 3 at the side of the rear brake drum Adjust the left side brake adjuster 3 ADJUSTING THE BRAKE PEDAL There are two adjustments brake pedal adjuster ...

Page 42: ... that the headstock base turns freely and evenly without noise otherwise replace the bearings see 6 2 1 REMOVING STEERING YOKE WITH STEM 2 15 INSPECTING THE FRONT SUSPENSIONS Read carefully 1 3 GENERAL SAFETY RULES Check the suspension every six months Check that the shock absorbers are not scratched or grooved If they are replace the damaged parts Carry out the following checks With pulled front ...

Page 43: ...ndlebar and reducing riding comfort and stability when cornering An underinflated tyre will extend the contact patch to include a larger portion of the tyre wall 1 This can result in cuts the tyre moving on the rim or coming away from it thus leading to the rider losing control of the vehicle The tyre may even slip off the rim under hard braking Lastly the vehicle may skid in a bend Inspect tread ...

Page 44: ...the chain even when the wheel turns the slack must be constant in all the rotation phases of the wheel Refit chain tensioner 2 with spring and tighten screw 1 If in some positions the slack is higher than in others this means that there are crushed or seized links in this case replace the chain see 6 7 1 DISASSEMBLING THE CHAIN To prevent the risk of seizures lubricate the chain frequently If the ...

Page 45: ...icant would be sprayed outwards and dirty the surrounding areas If it tends to rust quickly intensify the maintenance intervals 2 19 MULTIFUNCTION COMPUTER The vehicle is equipped with an electronic device to measure the vehicle speed the elapsed time and to store the distance covered When the vehicle is unused always keep the dial protected against direct sun rays Never remove any part of the mul...

Page 46: ...he units of measurements the instrument will also display the reset value of the wheel diameter press push button 1 to set this value to 168 and store the set data by pressing push button 2 Main functions Before carrying out any setting or adjustment on the multifunction computer working from below fit the dial on its mount on the vehicle Press push button 2 repeatedly so as to make the following ...

Page 47: ...at the same time AVS function d The AVS function indicates the trip average speed To reset the stored speed value press push buttons 1 and 2 at the same time TM function e The TM function indicates the time vehicle is being used The counter will be automatically reset when reaching 12 hours To manually reset counter press push buttons 1 and 2 at the same time MAS function f The MAS function indica...

Page 48: ...Carefully move the vehicle back turning the wheels by 180 so as to align the wheel marks with the axle height Measure the wheelbase between the two marks Calculate the difference between the reading at the back and at the front Toe in 5 mm 10 If the value is outside the specified limits turn both linkages to equally change their length Keep ball joint locked while turning Tighten check nuts Tighte...

Page 49: ...PERIODIC MAINTENANCE QUASAR 125 180 2 24 00 Release 00 2003 09 NOTE ProCarManuals com ...

Page 50: ...QUASAR 125 180 ENGINE 3 1 00 Release 00 2003 09 3 ENGINE ProCarManuals com ...

Page 51: ...ING THE CYLINDER 3 20 00 3 2 25 CHECKING THE PISTON 3 21 00 3 2 26 CHECKING PISTON RINGS 3 22 00 3 2 27 CHECKING PISTON GUDGEON PIN 3 22 00 3 2 28 REFITTING THE PISTON 3 23 00 3 3 ALTERNATOR 3 24 00 3 3 1 REMOVING THE COOLING FAN 3 24 00 3 3 2 REMOVING THE ALTERNATOR 3 24 00 3 3 3 CHECKING THE FLYWHEEL 3 24 00 3 3 4 REMOVING THE FREEWHEELING CLUTCH 3 25 00 3 3 5 CHECKING THE STARTER CLUTCH 3 26 00...

Page 52: ... 00 3 7 1 REMOVING THE CRANKSHAFT 3 43 00 3 7 2 CHECKING THE CRANKCASE THE CRANKSHAFT AND THE CONNECTING ROD 3 44 00 3 7 3 REMOVING ENGINE RUBBER BUSHING 3 44 00 3 7 4 REFITTING THE CRANKCASE 3 45 00 3 7 5 REFITTING THE CRANKSHAFT OIL SEAL 3 46 00 3 8 LUBRICATION SYSTEM 3 47 00 3 8 1 REMOVING THE ENGINE OIL COOLER 3 47 00 3 8 2 REMOVING THE ENGINE OIL LINES 3 47 00 ProCarManuals com ...

Page 53: ...engine installed in the frame TOP END Carburettor Intake manifold Starter Chain tensioner FRONT END Tappet cover Camshaft Engine oil cooler BOTTOM END Exhaust system RIGHT HAND SIDE Fan guard Sprocket Air scoop Flywheel Stator coil Gearbox LEFT HAND SIDE Transmission cover Speed converter unit Clutch unit Drive belt Converter pan Kick start ProCarManuals com ...

Page 54: ...aser brushes and wipers Ensure that no rubber or plastic parts come in contact with detergents and corrosive or penetrating solvents Should you need a steam cleaner do not direct water steam or high pressure air jets towards any of the following parts wheel hubs handlebar controls main warning lights exhaust silencer main switch Remove the exhaust system see 6 1 21 REMOVING THE EXHAUST PIPE Remove...

Page 55: ...care Block off all openings of engine and hoses to prevent the ingress of dirt Remove carburettor see 4 3 REMOVING THE CARBURETTOR Loosen and remove screw 5 and remove clip 5 Disconnect neutral light connector 7 Disconnect reverse gear connectors 8 Disconnect pedal stop switch connector 9 Release wirings from ties 4 6 5 7 8 9 ProCarManuals com ...

Page 56: ...frame Loosen and remove the bottom screw 13 between engine and frame Loosen and remove the two top screws 14 All fixings have now been removed Handle with care Be careful to avoid injury to your hands arms and legs Clear all tools from the area Thoroughly clean the area of the floor where the engine is to be placed Working on the left side loosen and remove nut 15 on vehicle right side Save pin 16...

Page 57: ...re ties Wires and hoses must not be twisted and or crushed Electrical connectors must be fitted to the matching connectors Hoses and pipes and couplings must be securely in place and fastened with suitable clips The throttle cables must slide smoothly inside their housings and must not bind when handlebars are turned Restore engine oil level see 2 11 1 ENGINE OIL and if necessary top up transmissi...

Page 58: ... on frame Remove flywheel housing see 3 2 2 REMOVING FLYWHEEL UPPER AND LOWER HOUSINGS Remove intake manifold see 3 2 3 REMOVING THE INTAKE MANIFOLD Loosen and remove screws 1 2 Loosen and remove screw 3 Remove upper 4 and lower 5 housing 3 2 3 REMOVING THE INTAKE MANIFOLD NOTE Engine can be left assembled on frame Remove carburettor see 4 3 REMOVING THE CARBURETTOR Loosen and remove the two screw...

Page 59: ...and disconnect pipe 2 Loosen and remove the four screws 3 Remove head cover 4 NOTE Change the seal at every reassembly 3 2 5 REMOVING THE TENSIONER NOTE Engine can be left assembled on frame Remove flywheel upper housing see 3 2 2 REMOVING FLYWHEEL UPPER AND LOWER HOUSINGS Loosen and remove the two screws 1 Remove chain tensioner 2 NOTE Change the seal at every reassembly 1 2 4 3 3 2 1 ProCarManua...

Page 60: ...e mount 2 NOTE At reassembly position the mount with the two E X letters facing the exhaust pipe 3 2 7 REMOVING THE ROCKER ARMS NOTE Engine can be left assembled on frame Remove camshaft complete mount see 3 2 9 REMOVING THE CAMSHAFT Position camshaft complete mount on a resting surface Remove the two shafts 1 2 and save the two rocker arms 3 and plate 4 NOTE While removing check the position of t...

Page 61: ... and the two rocker arms 2 onto mount 3 Install the two shafts 4 5 NOTE Make sure that the two shafts 4 5 are correctly positioned Refit the complete camshaft mount and tighten the four screws 6 crossways Refit head cover and tighten the four screws 7 crossways 2 1 3 2 4 5 6 6 7 7 ProCarManuals com ...

Page 62: ... BEARING PARTS Rotate bearings 1 2 by hand They must run smoothly must not jam at any positions and or be quiet No axial play shall be present Change the camshaft if bearings are noisy run hard or have play CAMS Check cams 3 for wear If excessively worn scored or scratched change the camshaft TOOTHED GEAR Check gear 4 teeth for wear If excessively worn change the camshaft ROCKER ARMS Check the amo...

Page 63: ...llel with the head edge Remove tensioner top screw 2 and remove the spring from the inside Push on the stop tooth to move back rocker arm Change seal and refit mount Tighten the two screws 3 Fit spring and tensioner screw then manually turn crankshaft by 3 or 4 turns and check once more timing reference marks correct positioning Before turning crankshaft by hand check that spark plug is not into i...

Page 64: ...ler gauge measure the gap between rocker arm and valve stem Perform this operation on both valves Clearance must be 0 08 mm 0 003 in 3 2 13 REMOVING THE HEAD Remove camshaft see 3 2 9 REMOVING THE CAMSHAFT Loosen and remove the two screws 1 Remove head 2 3 2 14 CHECKING VALVES SEALING CAPACITY To perform this test fill intake and exhaust ducts with fuel In case of leaks proceed to grinding see 3 2...

Page 65: ...hly clean mating surfaces Do not damage them Thoroughly clean the combustion chamber Remove any carbon deposits Take care not to score valve seats while cleaning these parts 3 2 16 CHECKS Check the combustion chamber for cracks or damage Using a scale check that cylinder head bottom surface is perfectly flat Take measurements as shown in the figure see 3 2 20 CHECKING THE HEAD AND CYLINDER 3 2 17 ...

Page 66: ... area end Calculate the gap between stem and guide Allowed limit intake 0 08 mm 0 003 in exhaust 0 10 mm 0 004 in NOTE If excessively worn change head and valves 3 2 19 GRINDING To ensure optimum sealing proceed to valve grinding Use fine lapping compound with extreme care While carrying out this operation keep the head with valve axes in horizontal position in order to avoid any lapping compound ...

Page 67: ...sits from the cylinder head combustion chamber Then measure head flatness If necessary restore head flatness 0 05 mm limit as follows rest a metal scale on cylinder head and check flatness with a feeler gauge If the value is outside the specified limits restore flatness using 400 600 soaked emery cloth and working following a 8 movement Repeat the same check on the cylinder Check that cylinder wal...

Page 68: ...ctly assembled spring underneath which is compressed could suddenly slip off its seat and injure the operator Using a plastic or a wood hammer gently tap on valve stems to settle collets into their seats Make sure that valve is free to move inside its working area Carry out this operation with great care since parts could be damaged and the operator injured Refit head to engine Change head gasket ...

Page 69: ...ck off casing opening with a clean cloth to prevent them from falling into the engine Remove gudgeon pin 2 circlip 1 Remove gudgeon pin 2 Remove piston 3 3 2 24 CHECKING THE CYLINDER Check that cylinder inner walls are not seized or excessively worn Measure cylinder inner diameter using a bore gauge Wear limit 0 10 mm 0 004 in beyond cylinder nominal size see Coupling table Measure the diameter at...

Page 70: ...t If hard carbon deposits are present soak the whole piston in a suitable liquid such as that used to clean carburettors Hard carbon detergents are very dangerous their vapours can cause severe diseases and the contact with skin or eyes causes immediate severe injuries Always use the recommended protective equipment such as goggles and gloves and thoroughly follow the instructions and the warnings...

Page 71: ...ring inside its original location on cylinder upper side 3 2 27 CHECKING PISTON GUDGEON PIN Carefully inspect gudgeon pin it must be perfectly smooth without scorings steps or blueish stains due to overheating In case of scores or steps or if blueish greyish stains are present change the gudgeon pin In case the gudgeon pin colour is slightly matt do not change it Measure gudgeon pin outer diameter...

Page 72: ...seats Centre ring shall be fitted with the tooth facing down Fit piston 1 with the IN mark on intake valve side Install gudgeon pin and fit the new gudgeon pin circlips 2 Position gudgeon pin circlip opening along the cylinder axis NOTE When fitting the gudgeon pin piston assembly block off the casing opening with a clean cloth to prevent gudgeon pin circlips from falling inside the engine Fit cyl...

Page 73: ... 1 with washer Using the special Flywheel puller part no 8910600 remove the flywheel and save the key The flywheel nut is strongly tightened proceed with extreme care not to hurt your hands Disconnect connectors 3 4 from wiring Take care not to damage seal and cable Loosen and remove the two screws 5 Save the plate Loosen and remove the two screws 6 Loosen and remove the two screws 7 Remove the st...

Page 74: ... 3 3 2 REMOVING THE ALTERNATOR Loosen and remove the seven screws 1 Remove the casing 2 Remove the starter motor gear 3 Loosen and remove the locking ring nut 4 using the special tool Ring nut spanner part no 8910599 Save the spacer Remove the freewheeling clutch 5 with the toothed gear 6 and the roller bearing 7 ProCarManuals com ...

Page 75: ...eeth freewheeling clutch 1 outer and inner surface and roller bearing for wear If excessivley worn change them Check roller bearing 2 for wear 3 3 6 REFITTING THE FREEWHEELING CLUTCH Fit the roller bearing 1 and the toothed gear 2 on the freewheeling clutch 3 Fit the complete freeweheeling clutch on the crankshaft Position shim and tighten locking ring nut 4 Fit starter motor gear 5 Change gasket ...

Page 76: ...il see 2 11 2 CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER Remove starter clutch see 3 6 5 REMOVING THE CLUTCH AND THE SECONDARY BELT ROLLER Loosen and remove the two screws 1 Save the plate 2 Loosen and remove nut 3 Remove the toothed gear 4 Save the chain Loosen the two screws 5 Remove the oil pump 6 ProCarManuals com ...

Page 77: ...ot seem to work properly check the pump drive gear for wear and if necessary change it 3 4 3 REFITTING THE OIL PUMP Fit pump 1 and tighten the two screws 2 Fit the toothed gear 2 with chain and tighten nut 4 Fit plate 5 and tighten the two screws 6 Refit the starter clutch see 3 6 5 REMOVING THE CLUTCH AND THE SECONDARY BELT ROLLER Fill engine oil see 2 11 2 CHANGING THE ENGINE OIL AND THE ENGINE ...

Page 78: ...art check electrical connections and if necessary restore them Loosen and remove the screw 2 Disconnect connector 3 Loosen and remove the two screws 4 3 5 2 REFITTING THE STARTER MOTOR Make sure that the O ring 1 is correctly seated apply a thin layer of special grease for oil seals see 1 8 LUBRICANT CHART Refit the starter motor 2 Position and tighten the two screws 3 Reconnect connector 4 and ti...

Page 79: ... see 6 1 7 REMOVING THE FOOTREST Loosen clip 1 and remove filter 2 Loosen and remove screw 3 Remove the kick start pedal 4 Loosen and remove the eight screws 5 Remove the casing 6 Remove the converter see 3 6 3 REMOVING THE PRIMARY BELT ROLLER Spring 7 is pre loaded Using a pair of pincers release the lever 7 return spring Remove the starter shaft 8 Remove the sliding gear 9 ProCarManuals com ...

Page 80: ...it while hooking If over stretched the spring could yield Danger Refit the sliding gear 4 first and then the spring Slightly move the starter shaft 2 so as to make gear fitting easier NOTE Make sure that the reference mark 5 on the sliding gear is facing the crankshaft 6 axis NOTE Grease the spring and the toothed part with the recommended grease see 1 8 LUBRICANT CHART Refit the converter see 3 6...

Page 81: ...converter locking spanner part no 8900673 Remove the tapered washer 2 NOTE At reassembly make sure that washer 2 is correctly positioned Remove primary fixed belt roller 3 Remove bushing 4 primary mobile belt roller 5 and block holder at the same time Do not disassemble belt roller from block holder as the six inner blocks could fall to the ground Separate belt roller from block holder and remove ...

Page 82: ...shing runs smoothly and without jams inside the primary mobile belt roller If it runs hard or in case of excessive play change both belt roller and bushing Check block outer diameter it shall not be below the max wear limit If necessary change them Change blocks in case their cylindrical side is faceted Wear limit 14 6 mm Check block holder and the 3 driving blocks for wear If excessively worn cha...

Page 83: ...d proceed with extreme care not to hurt your hands Slide out belt and remove clutch housing 2 Remove the secondary belt roller unit 3 Compress the unit with the special tool universal tool to disassemble assemble clutch units part no 8900674 and remove the clutch nut 4 The spring is compressed Remove the clutch blocks mount 5 first then the counter spring 6 the spring seat 7 and the complete secon...

Page 84: ...3 4 3 6 6 CHANGING THE CLUTCH BLOCKS Remove the clutch see 3 6 5 REMOVING THE CLUTCH AND THE SECONDARY BELT ROLLER Remove the three snap rings 1 Remove plate 2 Release the three springs 3 with a stretching hook Remove the three blocks 4 ProCarManuals com ...

Page 85: ...ecessary change clutch blocks see 3 6 6 CHANGING THE CLUTCH BLOCKS 3 6 8 CHECKING THE SECONDARY BELT ROLLER Check that the secondary belt roller is not worn and that it runs smoothly and without jams If it runs hard or if excessively worn change the belt roller Check the groove the stop teeth the two O rings 1 and the two oil seals 2 If damaged or worn change them Measure secondary belt roller cou...

Page 86: ...1 see 1 8 LUBRICANT CHART Apply a stripe of adhesive tape around the belt roller end to avoid oil seal lips overturning while fitting the belt roller Fit the two stop teeth 3 and apply some grease inside the mobile belt roller 2 groove Before assembling grease also the O rings 4 on the mobile secondary belt roller Fit the spring 5 seat and check that belt roller and return spring run smoothly Remo...

Page 87: ...llect any oil leaks Loosen and remove the seven screws 1 Remove the right casing 2 Working on the left casing remove the following parts in the given order reverse gear shaft 3 forward gear shaft 4 clutch shaft 5 The following operations apply to the right casing Remove from shaft 6 the following parts in the given order the snap ring the fixed washer 7 the toothed gear 8 the fixed washer 9 the sn...

Page 88: ...ed gear 14 Remove the circlip 15 Remove the toothed gear 14 from shaft 6 3 6 12 REMOVING THE SELECTOR SHAFT Remove the final drive gears see 3 6 11 REMOVING THE FINAL DRIVE GEARS Loosen and remove nut 1 Remove arm 2 Loosen and remove screw 3 Remove the complete selector shaft 4 ProCarManuals com ...

Page 89: ...bled on frame Remove clutch see 3 6 5 REMOVING THE CLUTCH AND THE SECONDARY BELT ROLLER Loosen and remove the gear selector spindle seat 1 Remove the gear selector spindle 2 and the spring 3 3 6 14 REMOVING THE GEAR LEVER MOUNT NOTE Engine can be left assembled on frame Remove the lever Loosen and remove mount 1 ProCarManuals com ...

Page 90: ... 2 clutch shaft 3 forward gear toothed gear 4 gear selector lever 5 and gear disengagement mechanism 6 reverse gear toothed gear 7 chain sprocket shaft 8 are not worn Change those parts which are excessively worn Check bearings for scores and seizure If necessary change them Check that gear selector can run smoothly and in case of malfunctioning change it ProCarManuals com ...

Page 91: ...casing To fit selector 3 to shaft 1 engage the selector arm tooth 4 with the selector 3 slot Fit the following parts onto shaft 1 in the given order snap ring 5 fixed washer 6 toothed gear 7 fixed washer 8 snap ring The following operations apply to the left casing Fit the clutch shaft 9 first and then the oil seal Then fit the forward gear 10 and the reverse gear 11 Join the two pans Change the g...

Page 92: ...emove the oil pump gear and the drive chain see 3 4 1 REMOVING THE OIL PUMP Loosen and remove screw 1 Gently tap with a rubber hammer on the right casing 2 to separate it from crankshaft 3 Loosen and remove screw 4 on lower chain sliding shoe 5 Remove lower chain sliding shoe 5 Using special tool Gear puller part no 8910601 remove kick start pedal gear 6 Gently tap with a rubber hammer on the cran...

Page 93: ...r scoring Check connecting rod It shall not be bent and must perfectly run at right angles with the crankshaft 3 7 3 REMOVING ENGINE RUBBER BUSHING NOTE The following operations refer to the removal of a single rubber bushing but apply to the four of them Heat the casing with an automatic heater up to about 150 C 10 minutes Using an hydraulic press remove rubber bushing 1 working from the outside ...

Page 94: ... start pedal gear 4 with the chamfered edge facing downwards onto crankshaft Refit lower chain sliding shoe 5 and secure it in place with screw 6 Refit kick start pedal system see 3 6 2 REFITTING THE STARTING SYSTEM To carry out the following operations work on engine right side Refit gear and pump drive chain see 3 4 3 REFITTING THE OIL PUMP Refit the electric starting system see 3 6 2 REFITTING ...

Page 95: ...st then the snap ring and the centring bushing 2 Grease the oil seal lip see 1 8 LUBRICANT CHART To make this operation easier use a tube with a suitable diameter Once finished make sure that the oil seal 1 lip is properly seated inside the casing 3 as shown in the figure Working on engine right side fit the oil seal as described above ProCarManuals com ...

Page 96: ...two O rings Loosen and remove the two screws 3 Remove the oil cooler 4 3 8 2 REMOVING THE ENGINE OIL LINES Drain all oil out of the circuit see 2 11 2 CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER Put a container under the engine oil pipe Loosen and remove screw 1 Save the two washers Loosen and remove the two screws 2 Remove engine oil pipe 3 Save the O rings If necessary repeat the same proc...

Page 97: ...ENGINE QUASAR 125 180 3 48 00 Release 00 2003 09 NOTES ProCarManuals com ...

Page 98: ...QUASAR 125 180 FUEL SYSTEM 4 1 00 Release 00 2003 09 4 FUEL SYSTEM ProCarManuals com ...

Page 99: ... CONTENTS FUEL SYSTEM QUASAR 125 180 4 2 00 Release 00 2003 09 4 1 MAINTENANCE 4 3 00 4 2 DRAINING THE FUEL TANK 4 3 00 4 2 1 CARBURETTOR 4 4 00 4 2 2 CARBURETTOR FEATURES 4 4 00 4 3 REMOVING THE CARBURETTOR 4 5 00 ProCarManuals com ...

Page 100: ...T RELEASE FUEL INTO THE ENVIRONMENT The engine should be off and completely cold Prepare a container of more than adequate capacity to contain the amount of fuel in the tank Place the container on the floor on the right hand side of the motorcycle Remove the fuel tank filler cap 1 Use a manual pump or similar system to drain the fuel tank After draining the tank close the fuel filler cap 1 To drai...

Page 101: ...lter 8 Needle valve 9 Cable guide 10 Fitting 4 2 2 CARBURETTOR FEATURES COMPONENTS FEATURES Intake manifold ø 22 2 23 0 x 21 0 Throttle valve ø 24 0 Intake hole ø 38 0 Maximum flow 110 Maximum air flow 90 Taper needle MGM 3 3 Nozzle ø 2 6 Minimum flow 35 Minimum air flow 90 Fuel level 29 5 Air screw 2 1 2 turn Float 6 g 6 9 2 10 1 7 8 5 3 4 ProCarManuals com ...

Page 102: ...spillage Disconnect fuel 1 and vacuum 2 lines from tap 3 Disconnect vacuum line 2 from manifold 4 Loosen clip and disconnect air hose 5 Loosen clip 6 and remove carburettor 7 from manifold 4 Plug the intake hose 4 with a clean cloth Loosen the two nuts 8 Slide out cable 9 Remove the carburettor 7 Loosen and remove the two screws 10 and remove the automatic starter 11 from carburettor 7 ProCarManua...

Page 103: ...FUEL SYSTEM QUASAR 125 180 4 6 00 Release 00 2003 09 NOTES ProCarManuals com ...

Page 104: ...QUASAR 125 180 ELECTRIC SYSTEM 5 1 00 Release 00 2003 09 5 ELECTRIC SYSTEM ProCarManuals com ...

Page 105: ...6 CHECKING THE ALTERNATOR CONTINUITY 5 9 00 5 7 CHECKING THE IGNITION COIL 5 9 00 5 7 1 CHECKING THE PICK UP SENSOR 5 9 00 5 8 AUTOMATIC STARTER 5 10 00 5 9 CHECKING THE C D I CONTROL UNIT 5 11 00 5 9 1 CHECK DATA 5 11 00 5 10 FUEL LEVEL SENSOR 5 12 00 5 11 SWITCHES 5 13 00 5 12 STARTING CIRCUIT 5 15 00 5 12 1 WIRING DIAGRAM 5 15 00 5 12 2 TROUBLESHOOTING 5 16 00 5 12 3 CHECK DATA 5 16 00 5 13 BUL...

Page 106: ...ors as follows Press down on the locking tab where fitted Never separate two connectors by pulling on the wiring Grasp both connectors and pull them in opposite directions until they become separated Remove any dirt rust moisture etc from inside the connector blowing with compressed air Ensure that the wires are securely crimped to the terminals inside each connector NOTE A connector will only loc...

Page 107: ...icators 3 Tail light 4 Headlight 5 Left hand switch 6 Dashboard 7 Hazard lights relay 8 Voltage stabiliser 9 Rectifier 10 Engine Control Unit 11 Battery 12 Warning horn 13 Starting relay 14 Fuse 15 Number plate light 16 Coil 17 Stoplight switch 18 Starter motor 19 Spark plug 20 Fuel sensor 21 Sensors control unit 22 Automatic starter 23 Earth 24 Neutral sensor 25 Reverse gear sensor ProCarManuals ...

Page 108: ...ARGE GENERATOR Key 1 Jumper 7 Key operated switch 11 Left dip switch 24 Starter relay 25 Starter motor 26 Fuse 27 Battery 28 Voltage regulator 31 Pick Up sensor 32 Generator 15A G G R M N R R R N N N N B N V V V V R G V G V G Bi Bi 28 27 25 26 7 11 1 24 32 31 Start logic Brakes consent Lights ProCarManuals com ...

Page 109: ... rpm If the measured value is incorrect check the rectifier see 5 3 3 RECTIFIER 5 3 3 RECTIFIER Disconnect the four way connector 1 coloured green Set a multimeter to the x 1 M range and measure the resistance of each terminal from the rectifier side inner male terminals This test method provides an approximate measure of resistance Where possible fit a substitute rectifier known to be in good wor...

Page 110: ...LECTRIC SYSTEM 5 7 00 Release 00 2003 09 5 4 IGNITION SYSTEM Key 28 Voltage regulator 29 Coil 30 Spark plug 31 Pick Up sensor 32 Generator 34 C D I 32 31 34 29 30 28 G N G V N G V V G Bi B V Bi B Bi V ProCarManuals com ...

Page 111: ... 3 2 2 REMOVING FLYWHEEL UPPER AND LOWER HOUSINGS Remove the spark plug 1 and refit its cap 2 Touch the spark plug to the head fins Do not touch the metal parts Electrical shock hazard Hold the spark plug only by its cap 2 Turn the key to and press the start button 3 Check that the electrodes spark If this does not happen replace the coil 4 ProCarManuals com ...

Page 112: ... R3 resistance standard value 0 1 1 Ω Resistance between stator cables and mount standard value 5 7 CHECKING THE IGNITION COIL Carry out this test with a portable tester Check primary and secondary windings continuity The reading expressed in ohm shall not be perfect but if the windings are not damaged the following ohm resistance values shall be measured Disconnect spark plug cap before any readi...

Page 113: ...ATIC STARTER Key 7 Key operated switch 23 Resistor 28 Voltage regulator 33 Automatic starter Disconnect the red two way connector and using a portable tester measure the ambient temperature resistance 24 C R 31Ω 10 V G G N R G V M G R N G V 33 23 7 28 ProCarManuals com ...

Page 114: ...rting enabling B Earth 1 Coil control 2 Earth 3 Pick up sensor input 4 Gear shift logic 5 9 1 CHECK DATA Checking the ignition relay To check relay correct operation proceed as follows Feed the two terminals with 12 V Using a tester set on the resistance meter function check the continuity between the two terminals Correct value of the powered relay 0 Ω Correct value of the unpowered relay If the ...

Page 115: ... white black B N and black N cables of connector 8 wiring side Check that pointer 6 goes on 4 4 with a 5 tolerance Repeat this operation using a 100 Ω resistance and check that pointer 6 goes to 0 zero with a 5 tolerance 6 Fuel level instrument 7 Key operated switch 45 Fuel level sensor Between cables Resistance Correct reading White Black B N Black N 5 6 Ω 4 4 5 White Black B N Black N 84 1 Ω 0 5...

Page 116: ...ck switches continuity Please refer to the special diagram In case of faults change the part 1 Horn button 2 Dip switch 3 Direction indicators 4 Start button 5 Ignition switch Cables Rs RO N Cables Rs G N G R V N G Cables Rs M Bi Gr scr V scr Gr Gr scr V scr Cables Rs B Bi N Cables Rs Ar V OPEN ProCarManuals com ...

Page 117: ...ELECTRIC SYSTEM QUASAR 125 180 5 14 00 Release 00 2003 09 6 7 8 6 Front Stop switch 7 Rear Stop switch 8 Pedal stop switch Cables Rs V G M ON Cables Rs V R V G ON Cables Rs V G M ON ProCarManuals com ...

Page 118: ...t Stop switch 13 Right Stop switch 14 Integral braking Stop switch 15 Neutral switch 16 Reverse gear switch 34 C D I NOTE To ensure max safety the engine can be started by pressing button only after one of the two brake levers has been pulled R M M V Bi Gr V Bi M M M N Bi B N N Ar N N N 34 22 15 3 14 12 7 13 16 To rectifier To inition relay ProCarManuals com ...

Page 119: ...e ignition relay CHECKING THE IGNITION RELAY 5 12 3 CHECK DATA CHECKING THE IGNITION RELAY Disconnect all cables from relay 1 Using a tester set on resistance meter function measure the continuity between power terminals screws M5 Correct value infinite resistance Feed connector control cables with a 12 V battery Using a tester set on resistance meter function measure the continuity between power ...

Page 120: ...he pressed and released positions based on the existing connections MAIN WIRING DIAGRAM THE STOP LIGHT IS ALWAYS ON Check connections on tail light Check front STOP switch CHECKING THE FRONT AND REAR STOP SWITCH Check the rear STOP switch CHECKING THE FRONT AND REAR STOP SWITCH THE STOP LIGHT DOES NOT COME ON Check bulb and bulb holder Check stop light circuit cables connectors Check main power su...

Page 121: ...ition and wait a few minutes so that the bulb cools down Change the bulb wearing clean gloves or using a clean and dry cloth Do not leave fingerprints on the bulb since these may cause its overheating and consequent breakage If you touch the bulb with bare hands remove any fingerprint with alcohol in order to avoid any damage DO NOT FORCE THE ELECTRIC CABLES NOTE Before changing a bulb check the f...

Page 122: ...ction indicator Read carefully 5 13 BULBS Remove the protection screen 1 from the indicator mount by pushing on its sides with a screwdriver Make sure not to damage the protection screen while removing it Extract the damaged bulb and replace it with a new one of the same type NOTE When refitting assemble the protection screen 1 carefully to its mount R Ro N N N M M M M Gr Gr Gr M M Bi V SCR N N N ...

Page 123: ...ect connector 1 Loosen and remove screw 2 Save washer Loosen and remove the two screws 3 Remove the headlight body 4 from the two shells 5 HALOGEN HIGH LOW BEAM BULB To remove the bulb holder 6 turn it counter clockwise Remove bulb and change it with one of the same rating PARKING LIGHT Grasp the bulb holder 7 and pull to extract Withdraw the bulb and replace it with one of the same type ProCarMan...

Page 124: ...wo screws 1 Remove the lens 2 Extract the damaged bulb and replace it with a new one of the same type STOP LIGHTS Parts 7 Key operated switch 12 Left Stop switch 13 Right Stop switch 14 Integral braking Stop switch 18 Rear twin light bulb R M N M M M V G V G V G V G G R 7 12 13 14 18 To rectifier To inition relay for inition logic Parking ligth to key operated switch ProCarManuals com ...

Page 125: ...ometer light 5 13 4 CHANGING THE HANDLEBAR COVER LIGHTS The handlebar cover contains 1 High beam warning light blue 2 Hazard light red 3 Parking low beam warning light green 4 Neutral light green To change the bulbs proceed as follows NOTE Remove the handlebar cover see 6 1 2 REMOVING THE DASHBOARD Disconnect the two connectors for the warning light being replaced Unscrew the nut 5 Remove the warn...

Page 126: ... RULES Do not repair faulty fuses Never use fuses different from the recommended ones The use of unsuitable fuses may cause damages to the electric system or in case of short circuit even a fire NOTE If a fuse blows frequently there probably is a short circuit or an overload in the electric system If an electric component does not work or works irregularly or if the vehicle fails to start it is ne...

Page 127: ... B M Bi G N B Bi R M N V G G R N M Bi N M Gr B Bi Bi B N G R B Bi M Gr M Bi M M Ro V R V G G V Bi R R N G N V R R V scr N N M scr N G R V G G R N V G M M V G Gr N V Bi N V scr N B B Bi N G R N M scr Gr Bi Ar M G V Bi Ar N V Bi B V N G V M V G V G B V G Bi V N G V M N Bi N G R N N Ar Bi N N G R B Bi B Bi M N Bi B Az M N Az G R V N M R B N B Bi B Bi N B G R V R V Bi G B Bi N N N N V scr Az Az N N N ...

Page 128: ...17 Right rear direction indicator 18 Rear twin light bulb 19 Tail light 20 Left rear direction indicator 21 Number plate light 22 Gear shift logic control unit 23 Resistor 24 Starting relay 25 Starter motor 26 Fuse 27 Battery 28 Voltage regulator 29 Coil 30 Spark plug 31 Pick up sensor 32 Generator 33 Automatic starter 34 C D I 35 Right supplementary front headlight connector 36 Left supplementary...

Page 129: ...ELECTRIC SYSTEM QUASAR 125 180 5 26 00 Release 00 2003 09 NOTES ProCarManuals com ...

Page 130: ...QUASAR 125 180 CYCLE PARTS 6 1 00 Release 00 2003 09 6 CYCLE PARTS ProCarManuals com ...

Page 131: ...1 18 REMOVING THE HORN 6 16 00 6 1 19 REMOVING THE TAIL LIGHT 6 17 00 6 1 20 REMOVING THE REAR DIRECTION INDICATORS 6 17 00 6 1 21 REMOVING THE EXHAUST PIPE 6 18 00 6 1 22 REMOVING THE WHEELS 6 19 00 6 1 23 REMOVING THE FRONT SUBFRAME 6 19 00 6 1 24 REMOVING THE FOOTREST MOUNT 6 19 00 6 1 25 REMOVING THE FRAME 6 20 00 6 2 STEERING SYSTEM 6 20 00 6 2 1 REMOVING STEERING YOKE WITH STEM 6 20 00 6 2 2...

Page 132: ...se 00 2003 09 6 1 BODYWORK KEY 1 Headlight 2 Front shield 3 Seat 4 Horn 5 Right front shock absorber 6 Front and rear brake pedal 7 Right footpeg 8 Rear shield 9 Gear lever 10 Fuel tank 11 Dashboard 10 1 11 2 4 5 7 6 9 3 8 ProCarManuals com ...

Page 133: ...2 Rear shock absorber 3 Fuel tank cap 4 Rear view mirrors 5 Drive chain 6 Glove tool kit compartment 7 Left front shock absorber 8 Battery 9 Fuse 10 Left footpeg 11 Kick start lever 12 Transmission air cleaner 13 Air cleaner 13 3 7 12 10 11 2 5 1 4 8 9 6 ProCarManuals com ...

Page 134: ...EMOVING THE SEAT Use lever 1 to unhook the seat Remove the seat 2 6 1 2 REMOVING THE DASHBOARD Loosen the two screws 1 Remove the dashboard 2 Disconnect the dashboard connectors Mark cables to avoid their wrong positioning at reassembly 1 2 1 2 ProCarManuals com ...

Page 135: ...E PARTS QUASAR 125 180 6 6 00 Release 00 2003 09 6 1 3 REMOVING THE HEADLIGHT Disconnect connector 1 Loosen and remove the two screws 2 Remove the complete headlight with subframe 3 1 2 3 ProCarManuals com ...

Page 136: ... HEADLIGHT Loosen adjusting nut 1 Remove rear brake cable 2 from its seat Fully loosen the two locking washers 3 Fully tighten the two adjusters 4 Remove front brake cables 5 Loosen the two screws 6 Remove cover 7 Remove throttle cable 8 from its seat Disconnect switch stop light and direction indicators connectors Mark cables to avoid their wrong positioning at reassembly ProCarManuals com ...

Page 137: ...RTS QUASAR 125 180 6 8 00 Release 00 2003 09 10 9 12 11 11 12 Loosen and remove the two screws 9 Remove mount 10 Loosen and remove the four screws 11 Remove the two braces 12 Remove handlebars ProCarManuals com ...

Page 138: ...EMOVING THE HEADLIGHT Disconnect direction indication connectors 1 2 Loosen and remove the five screws 3 Save washers and nuts Loosen and remove the front screw 4 Save the washer Loosen and remove the two screws 5 Loosen and remove fuel tank cap Block off tank opening to avoid any foreign matter from entering ProCarManuals com ...

Page 139: ... Remove the battery see 6 1 9 REMOVING THE BATTERY Release tool kit elastic strip Remove the supplied tool kit 1 Loosen and remove the four screws 2 Loosen and remove the two screws 3 Loosen and remove the five screws 4 Save nuts and washers Disconnect direction indicator connectors 5 Remove the rear shield 6 ProCarManuals com ...

Page 140: ... above procedure to remove the other footrest 6 1 8 REMOVING THE AIR FILTER CASE Remove the rear shield see 6 1 6 REMOVING THE REAR SHIELD Remove pipe 1 Remove breather from its seat Loosen and remove the two screws 2 Save the two washers Loosen clip 3 Remove filter case Block off intake manifold with a clean cloth to prevent any foreign matter from entering the intake ducts At reassembly make sur...

Page 141: ...ise the red protective gaiter 3 Loosen and remove screw 4 on positive terminal Move positive terminal 5 aside Do not overpull electric cables Wear latex gloves and grasp battery 6 Raise it to remove it from its compartment Store the removed battery in a safe place and out of the children s reach At reassembly connect the cable on positive terminal first and then that on the negative terminal NOTE ...

Page 142: ...nt shield see 6 1 5 REMOVING THE FRONT SHIELD Release clips and remove carburettor 1 and vacuum 2 pipes Loosen and remove pressure tap 4 screw 3 Disconnect fuel level sensor connector 5 Loosen and remove tank front screw 6 Save washer Loosen and remove tank rear screw 7 Remove fuel tank with tap ProCarManuals com ...

Page 143: ...onnect control unit 1 connectors At reassembly make sure that connectors are properly coupled To remove control unit 2 slide it out of frame 6 1 12 REMOVING THE ELECTRICAL CONTROLS Carefully read see 1 3 GENERAL SAFETY RULES Turn main switch to Disconnect the three electrical connectors 1 Loosen and remove the two screws 2 Remove the two shells ProCarManuals com ...

Page 144: ...en and remove screw 2 Remove brake lever 6 1 14 REMOVING THE RIGHT CONTROL Disconnect brake and throttle cables and the stop switch wiring see 6 1 4 REMOVING THE HANDLEBARS Remove twistgrip 1 Loosen and remove screw 2 Take out right control 3 6 1 15 REMOVING THE BRAKE PEDAL Remove right footrest see 6 1 7 REMOVING THE FOOTREST Remove spring pin 1 Save washer 2 Release spring 3 Release brake cable ...

Page 145: ...move retainer 1 Remove main switch 2 from outside the dashboard 6 1 17 REMOVING THE FRONT DIRECTION INDICATORS Disconnect the two connectors 1 Loosen and remove screw 2 Remove direction indicator 3 NOTE If necessary repeat the above procedure to remove the other direction indicator 6 1 18 REMOVING THE HORN Disconnect the two electrical connectors 1 Loosen and remove screw 2 Remove horn 3 ProCarMan...

Page 146: ...osen and remove the two nuts 2 Save washers Remove tail light 3 6 1 20 REMOVING THE REAR DIRECTION INDICATORS Disconnect the two electrical connectors 1 Loosen and remove nut 2 Save screw Remove direction indicator 3 NOTE If necessary repeat the above operations to remove the other direction indicator 1 2 3 2 1 3 ProCarManuals com ...

Page 147: ... THE REAR SHIELD Remove right footrest see 6 1 7 REMOVING THE FOOTREST Loosen and remove the two screws 1 Loosen and remove screw 2 Loosen and remove screw 3 Save washer Push down brake pedal Turn the exhaust pipe 4 slightly and remove it from behind NOTE At reassembly change the gasket between exhaust pipe and engine ProCarManuals com ...

Page 148: ...r axle Loosen and remove the four screws 1 Save washers Remove wheel 2 6 1 23 REMOVING THE FRONT SUBFRAME Loosen and remove the four screws 1 Remove visor 2 Loosen and remove the two screws 3 Remove front subframe 4 6 1 24 REMOVING THE FOOTREST MOUNT Remove footrest see 6 1 7 REMOVING THE FOOTREST Loosen and remove the four screws 1 Remove the footrest mount 2 NOTE If necessary repeat the above pr...

Page 149: ...6 1 24 REMOVING THE FOOTREST MOUNT Disconnect number plate holder light connector 1 Loosen and remove the four screws 2 Remove the number plate holder 3 Remove electrical parts from frame and release all cable clips 6 2 STEERING SYSTEM 6 2 1 REMOVING STEERING YOKE WITH STEM Remove the front shield see 6 1 5 REMOVING THE FRONT SHIELD Loosen and remove the two nuts 1 Save plate 2 cable ring 3 clamp ...

Page 150: ...sen and remove nut 4 Remove steering arm 5 NOTE If necessary repeat the above procedure to remove the other steering arm 6 2 3 REMOVING THE BALL JOINT Remove the brake see 6 4 1 REMOVING THE BRAKE Remove split pin 1 Loosen and remove nut 2 Remove steering arm see 6 2 2 REMOVING THE STEERING ARM Remove the ball joint 3 1 2 4 3 5 2 1 3 ProCarManuals com ...

Page 151: ...ve front shock absorber see 6 2 4 REMOVING THE FRONT SHOCK ABSORBER Remove ball joint see 6 2 3 REMOVING THE BALL JOINT Loosen and remove screw 1 Save nut Loosen and remove screw 2 Save nut Remove suspension arm 3 6 3 SWINGING ARM 6 3 1 REMOVING THE REAR SHOCK ABSORBER Raise frame rear part on a suitable stand Loosen and remove nut 1 Save screw 2 Remove split pin 3 and remove spindle 4 Remove the ...

Page 152: ...HE CHAIN Loosen and remove the two nuts 1 Loosen and remove the two cables 2 Save springs Remove rear shock absorber see 6 3 1 REMOVING THE REAR SHOCK ABSORBER Loosen and remove nut 3 Remove swinging arm spindle 4 Save washer Remove the complete swinging arm NOTE If necessary remove the single parts 2 1 3 4 ProCarManuals com ...

Page 153: ...emove nut 1 Save washer Remove wheel with brake drum Disconnect the two brake cables 2 3 Remove the brake block plate 4 6 4 2 DISASSEMBLING THE BRAKE DRUM Remove the complete wheel see 6 4 1 REMOVING THE BRAKE Working from outside the wheel remove the following parts in the given order spacer 1 oil seal 2 bearing 3 spacer 4 Working from inside the wheel remove the following parts in the given orde...

Page 154: ...urn inner ring 4 by hand It should run smoothly silently and should not jam at any position Check also for any axial play Change any faulty bearing SEALS Check seals for wear If excessively damaged or worn change them BRAKE BLOCKS Check friction material 5 for wear Min thickness 1mm Check springs 6 Change them if yielded Check the following parts for wear brake cam 7 block holder plate 8 brake lev...

Page 155: ...cables see 6 3 2 REMOVING THE SWINGING ARM Remove split pin Loosen and remove nut 1 Save washer Remove the complete left wheel Loosen and remove the three screws 2 Remove drum cover 3 Bend washer so as to loosen nuts Loosen and remove the four screws 4 Working from left side remove the following parts in the given order brake drum 5 and brake blocks 6 ProCarManuals com ...

Page 156: ... DISASSEMBLING THE CHAIN Carefully read see 1 3 GENERAL SAFETY RULES Slacken chain tension see 6 7 CHAIN Turn rear wheels until having the master link exposed Remove clip 1 and the plate underneath Working on the opposite side remove the master link 2 Remove chain If the chain is excessively worn change the whole unit front and rear sprockets and chain 6 7 2 REFITTING THE CHAIN Make sure that chai...

Page 157: ...CYCLE PARTS QUASAR 125 180 6 28 00 Release 00 2003 09 NOTES ProCarManuals com ...

Page 158: ...QUASAR 125 180 TROUBLESHOOTING 7 1 00 Release 00 2003 09 7 TROUBLESHOOTING ProCarManuals com ...

Page 159: ...elease 00 2003 09 7 1 THE ENGINE DOES NOT START 7 3 00 7 2 POOR PERFORMANCE AT IDLE AND LOW SPEED 7 4 00 7 3 POOR PERFORMANCE AT HIGH SPEED 7 5 00 7 4 EXCESSIVE NOISE LEVEL 7 6 00 7 5 EXCESSIVE FUMES 7 6 00 7 6 LOW POWER 7 7 00 7 7 POOR VEHICLE MANEUVERABILITY 7 8 00 ProCarManuals com ...

Page 160: ...circuited ignition coil Broken or short circuited spark plug wire Faulty pick up sensor Faulty ignition switch Missing or weak spark Check cylinder compression Worn cylinder and or worn piston rings Damaged cylinder head gasket Poor compression Start engine Damaged or blocked starter Disconnected starter power wire Wrong air screw adjustment Wrong engine timing Too weak air fuel mixture The engine...

Page 161: ...d air screw adjustment Wrong air screw adjustment Check for leaks at the intake manifold Damaged O ring Check spark plugs Loose or disconnected ignition system wires The spark plug is faulty wet or with carbon deposits Faulty alternator Faulty CDI unit Faulty ignition switch Faulty ignition coil Faulty pick up sensor Damaged spark plug electrode Faulty engine stop switch ProCarManuals com ...

Page 162: ...heck engine timing Faulty CDI unit or ignition coil Check fuel delivery to carburettor No fuel Obstructed fuel line Obstructed fuel filter Obstructed fuel tank cap breather hole Blocked fuel flow Remove carburettor and check jets Clean jets Obstructed Check filter Clean or change filter Dirty ProCarManuals com ...

Page 163: ...ustment Jammed valve or broken valve spring Damaged rocker arms or shaft or camshaft Damaged or worn chain Damaged or worn chain tensioner Worn camshaft sprocket teeth Possible causes Excessive fumes Worn cylinder piston or piston rings Wrong piston ring assembly Scores or scratches on piston or on cylinder walls Damaged valve stem seal ProCarManuals com ...

Page 164: ...ngine timing Faulty CDI unit Faulty pick up sensor Check cylinder compression Leaks at head gasket Worn cylinder and or piston rings Poor pressure Check carburettor Clean fuel jets Clean floater Dirty Check spark plug Clean adjust electrodes gap Faulty spark plug Wrong spark plug heat rating Dirty or with an abnormal colour Check for engine overheating Wrong type of fuel Too weak air fuel mixture ...

Page 165: ...t rim Wheel hub assembled in a wrong position Excessive play at the wheel bearing Damaged suspension Bent frame Excessive wear at the swinging arm bush Bent shaft The vehicle does not run straight Bent linkage Linkage wrong adjustment Wrong rear tyre pressure Wrong wheel toe in Bent frame Poor braking efficiency Worn brake shoes Worn brake drum Dirty or oily greasy friction material Wrong brake ad...

Page 166: ...TROUBLESHOOTING QUASAR 125 180 7 9 00 Release 00 2003 09 NOTE ProCarManuals com ...

Page 167: ...TROUBLESHOOTING QUASAR 125 180 7 10 00 Release 00 2003 09 NOTE ProCarManuals com ...

Page 168: ...aprilia s p a via G Galilei 1 30033 Noale VE Italy tel 39 041 5829111 fax 39 041 5829190 www serviceaprilia com www aprilia com ProCarManuals com ...