APRILIA QUASAR 180 Service Manual

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Summary of Contents

Page 1 - QUASAR 125 - 180

www.serviceaprilia.comworkshopmanualQUASAR 125 - 180 1122 300/2003-098140724UK

Page 2 - FOREWORD

QUASAR 125-180GENERAL INFORMATION1 - 1 - 00Release 00/2003 - 091GENERAL INFORMATION

Page 3

QUASAR 125-180FUEL SYSTEM4 - 3 - 00Release 00/2003 - 094.1 MAINTENANCECheck the condition of the fuel system hoses every six months. Hoses whichare d

Page 4

FUEL SYSTEMQUASAR 125-1804 - 4 - 00Release 00/2003 - 094.2.1 CARBURETTORKey:1) Starter valve2) Circlip 3) Choke4) Maximum flow #1105) Maximum flow #3

Page 5

QUASAR 125-180FUEL SYSTEM4 - 5 - 00Release 00/2003 - 093 124256789411104.3 REMOVING THE CARBURETTORNOTE Close the fuel tap to avoid fuel leaks.Place

Page 6 - UK E D F

FUEL SYSTEMQUASAR 125-1804 - 6 - 00Release 00/2003 - 09NOTES

Page 7 - Ω = megaohm

QUASAR 125-180ELECTRIC SYSTEM5 - 1 - 00Release 00/2003 - 09 5ELECTRIC SYSTEM

Page 8

0234567i91ELECTRIC SYSTEMCONTENTSELECTRIC SYSTEMQUASAR 125-1805 - 2 - 00Release 00/2003 - 095.1 FOREWORD...

Page 9

QUASAR 125-180ELECTRIC SYSTEM5 - 3 - 00Release 00/2003 - 095.1 FOREWORDPlease read the following information before reading this section.NOTE For eas

Page 10 - GENERAL INFORMATION

ELECTRIC SYSTEMQUASAR 125-1805 - 4 - 00Release 00/2003 - 095.2 ELECTRICAL COMPONENTS25 24 416 7 9102181213191718235 6 11 14 220122 153Key:1) Front di

Page 11

QUASAR 125-180ELECTRIC SYSTEM5 - 5 - 00Release 00/2003 - 095.3 TROUBLESHOOTING5.3.1 STARTER MOTOR - BATTERY RECHARGE - GENERATOR Key:1) Jumper 7) Key

Page 12 - - 3 - 00

ELECTRIC SYSTEMQUASAR 125-1805 - 6 - 00Release 00/2003 - 095.3.2 CHECKING THE CHARGE VOLTAGE" After having completely charged the battery, see

Page 13

02345671i91GENERAL INFORMATIONCONTENTSGENERAL INFORMATIONQUASAR 125-1801 - 2 - 00Release 00/2003 - 091.1 CONVENTIONS USED IN THE MANUAL...

Page 14

QUASAR 125-180ELECTRIC SYSTEM5 - 7 - 00Release 00/2003 - 095.4 IGNITION SYSTEMKey:28)Voltage regulator29)Coil30)Spark plug 31)Pick-Up sensor32)Genera

Page 15

ELECTRIC SYSTEMQUASAR 125-1805 - 8 - 00Release 00/2003 - 0912345.4.1 HIGH TENSION COILRead carefully 1.3 (GENERAL SAFETY RULES)." Remove the cy

Page 16

QUASAR 125-180ELECTRIC SYSTEM5 - 9 - 00Release 00/2003 - 09GBiV8 V30 V 40 VGBiVR10,7Ω R20,5Ω R30,8Ω 5.5 CHECKING THE GENERATOR IDLE OPERATION "

Page 17

ELECTRIC SYSTEMQUASAR 125-1805 - 10 - 00Release 00/2003 - 095.8 AUTOMATIC STARTERKey:7)Key-operated switch23)Resistor28)Voltage regulator33)Automatic

Page 18

QUASAR 125-180ELECTRIC SYSTEM5 - 11 - 00Release 00/2003 - 095.9 CHECKING THE C.D.I. CONTROL UNIT" The ignition control unit is of the capacitiv

Page 19

ELECTRIC SYSTEMQUASAR 125-1805 - 12 - 00Release 00/2003 - 098RMNNB/N67455.10 FUEL LEVEL SENSOR " Disconnect the two-way connector (8) from the f

Page 20

QUASAR 125-180ELECTRIC SYSTEM5 - 13 - 00Release 00/2003 - 094231 355.11 SWITCHES" Using a portable tester, check switches continuity. Please, re

Page 21

ELECTRIC SYSTEMQUASAR 125-1805 - 14 - 00Release 00/2003 - 096-786) Front Stop switch 7) Rear Stop switch8) Pedal stop switch CablesRsV/G MONCablesRsV

Page 22

QUASAR 125-180ELECTRIC SYSTEM5 - 15 - 00Release 00/2003 - 095.12 STARTING CIRCUIT5.12.1 WIRING DIAGRAM Key 3)Neutral repeater light7)Key-operated swi

Page 23

ELECTRIC SYSTEMQUASAR 125-1805 - 16 - 00Release 00/2003 - 095.12.2 TROUBLESHOOTING THE STARTER MOTOR DOES NOT RUN " Check the ignition relay. &q

Page 24

QUASAR 125-180GENERAL INFORMATION1 - 3 - 00Release 00/2003 - 091.1 CONVENTIONS USED IN THE MANUAL- This manual is divided in sections and subsections

Page 25 - - 16 - 00

QUASAR 125-180ELECTRIC SYSTEM5 - 17 - 00Release 00/2003 - 09CHECKING THE RESISTORS" Disconnect the two-way connector positioned close to resisto

Page 26 - PERIODIC MAINTENANCE

ELECTRIC SYSTEMQUASAR 125-1805 - 18 - 00Release 00/2003 - 095.13 BULBSRead carefully 1.3 (GENERAL SAFETY RULES).Risk of fire. Keep fuel and other f

Page 27

QUASAR 125-180ELECTRIC SYSTEM5 - 19 - 00Release 00/2003 - 0915.13.1 CHANGING THE DIRECTION INDICATOR BULBS Parts:5)Hazard repeater light7)Key-operate

Page 28

ELECTRIC SYSTEMQUASAR 125-1805 - 20 - 00Release 00/2003 - 0912 543675.13.2 CHANGING THE HEADLIGHT BULBSRead carefully 5.13 (BULBS).The headlight con

Page 29

QUASAR 125-180ELECTRIC SYSTEM5 - 21 - 00Release 00/2003 - 09125.13.3 CHANGING THE TAIL LIGHT BULBRead carefully 5.13 (BULBS).To change the bulb, pro

Page 30

ELECTRIC SYSTEMQUASAR 125-1805 - 22 - 00Release 00/2003 - 0943215HIGH-LOW BEAM - PARKING LIGHTS Parts: 2)High beam repeater light 4)Parking light re

Page 31

QUASAR 125-180ELECTRIC SYSTEM5 - 23 - 00Release 00/2003 - 0912125.13.5 ADJUSTING THE HEADLIGHT BEAMTo rapidly check the correct direction of the beam

Page 32

ELECTRIC SYSTEMQUASAR 125-1805 - 24 - 00Release 00/2003 - 09+C-40396111123 547?4689101112 13 14 15116111171819202111122112325272412628291113032313334

Page 33

QUASAR 125-180ELECTRIC SYSTEM5 - 25 - 00Release 00/2003 - 09Key:1) Multiple connectors 2) Parking light repeater light3) Neutral repeater light4) Hi

Page 34

ELECTRIC SYSTEMQUASAR 125-1805 - 26 - 00Release 00/2003 - 09NOTES

Page 35

GENERAL INFORMATIONQUASAR 125-1801 - 4 - 00Release 00/2003 - 091.3 GENERAL SAFETY RULES1.3.1 CARBON OXIDEWhen an operation must be performed with the

Page 36

QUASAR 125-180CYCLE PARTS6 - 1 - 00Release 00/2003 - 09 6CYCLE PARTS

Page 37

0234567i91CYCLE PARTSCONTENTSCYCLE PARTSQUASAR 125-1806 - 2 - 00Release 00/2003 - 096.1 BODYWORK...

Page 38

QUASAR 125-180CYCLE PARTS6 - 3 - 00Release 00/2003 - 096.1 BODYWORKKEY1) Headlight2) Front shield3) Seat4) Horn 5) Right front shock absorber 6) Fron

Page 39

CYCLE PARTSQUASAR 125-1806 - 4 - 00Release 00/2003 - 09KEY1) Tail light2) Rear shock absorber 3) Fuel tank cap 4) Rear-view mirrors5) Drive chain6) G

Page 40

QUASAR 125-180CYCLE PARTS6 - 5 - 00Release 00/2003 - 096.1.1 REMOVING THE SEAT" Use lever (1) to unhook the seat. " Remove the seat (2).6.1

Page 41

CYCLE PARTSQUASAR 125-1806 - 6 - 00Release 00/2003 - 096.1.3 REMOVING THE HEADLIGHT" Disconnect connector (1)."!Loosen and remove the two s

Page 42

QUASAR 125-180CYCLE PARTS6 - 7 - 00Release 00/2003 - 09123 456786.1.4 REMOVING THE HANDLEBARS" Remove the dashboard, see 6.1.2 (REMOVING THE DAS

Page 43

CYCLE PARTSQUASAR 125-1806 - 8 - 00Release 00/2003 - 0910912111112" Loosen and remove the two screws (9)." Remove mount (10)." Loosen

Page 44 - 50 ÷ 60 mm

QUASAR 125-180CYCLE PARTS6 - 9 - 00Release 00/2003 - 091233456.1.5 REMOVING THE FRONT SHIELD" Remove handlebars see 6.1.3 (REMOVING THE HEADLIGH

Page 45 - - 20 - 00

CYCLE PARTSQUASAR 125-1806 - 10 - 00Release 00/2003 - 0962134456" Remove the front shield (6).6.1.6 REMOVING THE REAR SHIELD" Remove the ba

Page 46

QUASAR 125-180GENERAL INFORMATION1 - 5 - 00Release 00/2003 - 091.3.5 ENGINE OILUse SUPERMOTOROIL SAE 15W - 40 or F1 SUPERMOTOROIL 15W-40.As an al

Page 47

QUASAR 125-180CYCLE PARTS6 - 11 - 00Release 00/2003 - 091122331236.1.7 REMOVING THE FOOTREST" Loosen and remove the five screws (1). Save washer

Page 48 - - 23 - 00

CYCLE PARTSQUASAR 125-1806 - 12 - 00Release 00/2003 - 095 3 46216.1.9 REMOVING THE BATTERY" Turn main switch to " "." Remove the

Page 49

QUASAR 125-180CYCLE PARTS6 - 13 - 00Release 00/2003 - 0941325676.1.10 REMOVING THE FUEL TANK" Remove the front shield, see 6.1.5 (REMOVING THE F

Page 50

CYCLE PARTSQUASAR 125-1806 - 14 - 00Release 00/2003 - 0921126.1.11 REMOVING THE CONTROL UNITCarefully read see 1.3 (GENERAL SAFETY RULES)." Turn

Page 51

QUASAR 125-180CYCLE PARTS6 - 15 - 00Release 00/2003 - 091 22131324 56.1.13 REMOVING THE REAR BRAKE LEVER " Disconnect brake cable, see 6.1.4 (RE

Page 52

CYCLE PARTSQUASAR 125-1806 - 16 - 00Release 00/2003 - 091223 11236.1.16 REMOVING THE MAIN SWITCH" Remove ignition key." Remove the dashboar

Page 53

QUASAR 125-180CYCLE PARTS6 - 17 - 00Release 00/2003 - 096.1.19 REMOVING THE TAIL LIGHT" Turn main switch to " "." Disconnect conn

Page 54

CYCLE PARTSQUASAR 125-1806 - 18 - 00Release 00/2003 - 0912346.1.21 REMOVING THE EXHAUST PIPE" Remove the rear shield, see 6.1.6 (REMOVING THE RE

Page 55

QUASAR 125-180CYCLE PARTS6 - 19 - 00Release 00/2003 - 09211121341126.1.22 REMOVING THE WHEELS" To remove one or both front wheels, raise the fro

Page 56

CYCLE PARTSQUASAR 125-1806 - 20 - 00Release 00/2003 - 09122 32134656716.1.25 REMOVING THE FRAME" Remove engine, see see 3.1.2 (REMOVING THE ENGI

Page 57

GENERAL INFORMATIONQUASAR 125-1801 - 6 - 00Release 00/2003 - 091.3.7 GENERAL PRECAUTIONS AND INFORMATIONFollow these instructions closely when repair

Page 58

QUASAR 125-180CYCLE PARTS6 - 21 - 00Release 00/2003 - 096.2.2 REMOVING THE STEERING ARM " Remove split pin (1)." Loosen and remove nut (2).

Page 59

CYCLE PARTSQUASAR 125-1806 - 22 - 00Release 00/2003 - 096.2.4 REMOVING THE FRONT SHOCK ABSORBER" Raise frame front part on a suitable stand.&quo

Page 60

QUASAR 125-180CYCLE PARTS6 - 23 - 00Release 00/2003 - 096.3.2 REMOVING THE SWINGING ARM" Remove chain, see 6.7.1 (DISASSEMBLING THE CHAIN)."

Page 61

CYCLE PARTSQUASAR 125-1806 - 24 - 00Release 00/2003 - 0912431 32 4566.4 FRONT BRAKES6.4.1 REMOVING THE BRAKENOTE The following operations apply to bo

Page 62 - " Remove camshaft (2)

QUASAR 125-180CYCLE PARTS6 - 25 - 00Release 00/2003 - 093 2 148 795 66.4.3 CHECKING THE PARTSBRAKE DRUM " Check sliding surface: it shall be fre

Page 63

CYCLE PARTSQUASAR 125-1806 - 26 - 00Release 00/2003 - 0912 3254466.5 REAR BRAKE6.5.1 REMOVING THE BRAKE" Raise frame rear part on a suitable sta

Page 64 - " Remove head (2)

QUASAR 125-180CYCLE PARTS6 - 27 - 00Release 00/2003 - 0951624 311231Direction of rotation26.6 CHECKING THE PARTSBRAKE DRUM " Check sliding surfa

Page 65 - 3.2.16 CHECKS

CYCLE PARTSQUASAR 125-1806 - 28 - 00Release 00/2003 - 09NOTES

Page 66 - - 17 - 00

QUASAR 125-180TROUBLESHOOTING7 - 1 - 00Release 00/2003 - 09 7TROUBLESHOOTING

Page 67

0234567i91TROUBLESHOOTINGCONTENTSTROUBLESHOOTINGQUASAR 125-1807 - 2 - 00Release 00/2003 - 097.1 THE ENGINE DOES NOT START ...

Page 68

QUASAR 125-180GENERAL INFORMATION1 - 7 - 00Release 00/2003 - 091.3.10 REASSEMBLING THE COMPONENTSNever reuse a circlip or snap ring. These parts must

Page 69

TROUBLESHOOTINGQUASAR 125-1807 - 3 - 00Release 00/2003 - 097.1 THE ENGINE DOES NOT STARTPossible causesCheck fuel delivery to carburettor- No fuel -

Page 70

TROUBLESHOOTINGQUASAR 125-1807 - 4 - 00Release 00/2003 - 097.2 POOR PERFORMANCE AT IDLE AND LOW SPEEDPossible causesCheck engine timing - Faulty CDI

Page 71

TROUBLESHOOTINGQUASAR 125-1807 - 5 - 00Release 00/2003 - 097.3 POOR PERFORMANCE AT HIGH SPEEDPossible causesCheck engine timing - Faulty CDI unit or

Page 72

TROUBLESHOOTINGQUASAR 125-1807 - 6 - 00Release 00/2003 - 097.4 EXCESSIVE NOISE LEVEL7.5 EXCESSIVE FUMESPossible causesExcessive noise level- Worn val

Page 73

TROUBLESHOOTINGQUASAR 125-1807 - 7 - 00Release 00/2003 - 097.6 LOW POWERPossible causesRaise wheels from ground and turn them by hand- Locked brake -

Page 74

TROUBLESHOOTINGQUASAR 125-1807 - 8 - 00Release 00/2003 - 097.7 POOR VEHICLE MANEUVERABILITYPossible causesHard steering- Damaged steering bearing- Da

Page 75

TROUBLESHOOTINGQUASAR 125-1807 - 9 - 00Release 00/2003 - 09NOTE

Page 76

TROUBLESHOOTINGQUASAR 125-1807 - 10 - 00Release 00/2003 - 09NOTE

Page 77

aprilia s.p.a.via G.Galilei, 130033 Noale (VE) Italytel. +39 041.5829111fax +39 041.5829190www.serviceaprilia.comwww.aprilia.com

Page 78

GENERAL INFORMATIONQUASAR 125-1801 - 8 - 00Release 00/2003 - 091.4 WARNINGS REGARDING FUEL, LUBRICANTS AND OTHER COMPONENTS1.4.1 FUELThe fuel used to

Page 79

QUASAR 125-180GENERAL INFORMATION1 - 9 - 00Release 00/2003 - 091.4.2 LUBRICANTSCorrect lubrication is essential to the safety of the motorcycle.Failu

Page 80

GENERAL INFORMATIONQUASAR 125-1801 - 10 - 00Release 00/2003 - 091.5 LOCATION OF SERIAL NUMBERSThese numbers are necessary for vehicle registration.NO

Page 81

QUASAR 125-180FOREWORD0 - 1 - 00Release 00/2003 - 061GENERAL INFORMATION0FOREWORD02PERIODIC MAINTENANCE3ENGINE4FUEL SYSTEM5ELECTRIC SYSTEM6CYCLE PART

Page 82 - - 33 - 00

QUASAR 125-180GENERAL INFORMATION1 - 11 - 00Release 00/2003 - 091.7 TECHNICAL DATAQUASAR 125 QUASAR 180DIMENSIONSLength 1790 mm GRIP 1675 mm (HP) 17

Page 83

GENERAL INFORMATIONQUASAR 125-1801 - 12 - 00Release 00/2003 - 09WHEEL RIMSType steel steelFront 10X5.5 10X5.5Rear 8X8.0 8X8.0TYRESType tubeles tubele

Page 84

QUASAR 125-180GENERAL INFORMATION1 - 13 - 00Release 00/2003 - 091.8 LUBRICANT CHARTLUBRICANT PRODUCTTransmission oilRECOMMENDED: PONTIAX HDI SAE 85

Page 85 - - 36 - 00

GENERAL INFORMATIONQUASAR 125-1801 - 14 - 00Release 00/2003 - 091.9 SPECIAL TOOLSSpecial tools have been developed to ensure proper disassembly, re-a

Page 86 - - 37 - 00

QUASAR 125-180GENERAL INFORMATION1 - 15 - 00Release 00/2003 - 091.10 TORQUE FIGURESThe table below reports the standard torque figures for metric siz

Page 87

GENERAL INFORMATIONQUASAR 125-1801 - 16 - 00Release 00/2003 - 09NOTE

Page 88

QUASAR 125-180PERIODIC MAINTENANCE2 - 1 - 00Release 00/2003 - 09 PERIODIC MAINTENANCE2

Page 89

0234567i91PERIODIC MAINTENANCECONTENTSPERIODIC MAINTENANCEQUASAR 125-1802 - 2 - 00Release 00/2003 - 092.1 PERIODIC MAINTENANCE CHART...

Page 90 - - 41 - 00

QUASAR 125-180PERIODIC MAINTENANCE2 - 3 - 00Release 00/2003 - 09Outlined in this section are the recommended procedures for the periodic maintenance

Page 91

PERIODIC MAINTENANCEQUASAR 125-1802 - 4 - 00Release 00/2003 - 092.2 FASTENERSThe fasteners reported in the chart must be tightened to the specified t

Page 92

0234567i91FOREWORDCONTENTSFOREWORDQUASAR 125-1800 - 2 - 00Release 00/2003 - 060.1 RELEASE 00/2003-09 UPDATE...

Page 93 - - 44 - 00

QUASAR 125-180PERIODIC MAINTENANCE2 - 5 - 00Release 00/2003 - 092.3 PERIODIC MAINTENANCE CHARTKEY# Check, clean and lubricate, adjust, top up or chan

Page 94

PERIODIC MAINTENANCEQUASAR 125-1802 - 6 - 00Release 00/2003 - 092.4 LUBRICATIONProper lubrication is critical to ensuring smooth operation and preser

Page 95 - - 46 - 00

QUASAR 125-180PERIODIC MAINTENANCE2 - 7 - 00Release 00/2003 - 0912.4.2 MAIN SWITCHThe main switch (1) is at the right side of the motorcycle, on the

Page 96

PERIODIC MAINTENANCEQUASAR 125-1802 - 8 - 00Release 00/2003 - 09122.5 BATTERYRead carefully 1.3.6 (HYDROGEN GAS AND BATTERY ELECTROLYTE).Risk of fir

Page 97 - - 48 - 00

QUASAR 125-180PERIODIC MAINTENANCE2 - 9 - 00Release 00/2003 - 0912.6 CHECKING THE ELECTROLYTE BATTERY LEVELThe vehicle is equipped with a maintenance

Page 98 - FUEL SYSTEM

PERIODIC MAINTENANCEQUASAR 125-1802 - 10 - 00Release 00/2003 - 0912.7 SPARK PLUGRead carefully 1.3 (GENERAL SAFETY RULES).Check the spark plug every

Page 99

QUASAR 125-180PERIODIC MAINTENANCE2 - 11 - 00Release 00/2003 - 0911235 42.8 IDLING ADJUSTMENTRead carefully 1.3 (GENERAL SAFETY RULES).Adjust the id

Page 100 - Release 00/2003 - 09

PERIODIC MAINTENANCEQUASAR 125-1802 - 12 - 00Release 00/2003 - 09121 13421232.10 AIR CLEANERRead carefully 1.3 (GENERAL SAFETY RULES).Check the cond

Page 101 - - 4 - 00

QUASAR 125-180PERIODIC MAINTENANCE2 - 13 - 00Release 00/2003 - 09212.11.1 ENGINE OILCarefully read 1.3 (GENERAL SAFETY RULES).Change engine oil afte

Page 102

PERIODIC MAINTENANCEQUASAR 125-1802 - 14 - 00Release 00/2003 - 0912 342.11.2 CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER Carefully read 1.3 (G

Page 103 - - 6 - 00

QUASAR 125-180FOREWORD0 - 3 - 00Release 00/2003 - 062-29 -00 ...092-30 -00 ...093-1 -00 ...

Page 104 - ELECTRIC SYSTEM

QUASAR 125-180PERIODIC MAINTENANCE2 - 15 - 00Release 00/2003 - 09122.12 CHECKING THE TRANSMISSION OIL LEVELDO NOT RELEASE OIL INTO THE ENVIRONMENTCar

Page 105 - - 2 - 00

PERIODIC MAINTENANCEQUASAR 125-1802 - 16 - 00Release 00/2003 - 092134562.13 CHECKING AND ADJUSTING THE BRAKESRead carefully 1.3 (GENERAL SAFETY RULE

Page 106

QUASAR 125-180PERIODIC MAINTENANCE2 - 17 - 00Release 00/2003 - 092.14 CHECKING THE STEERINGRead carefully 1.3 (GENERAL SAFETY RULES).Run the first c

Page 107

PERIODIC MAINTENANCEQUASAR 125-1802 - 18 - 00Release 00/2003 - 0912.16 INSPECTING THE REAR SUSPENSIONRead carefully 1.3 (GENERAL SAFETY RULES).Check

Page 108 - - 5 - 00

QUASAR 125-180PERIODIC MAINTENANCE2 - 19 - 00Release 00/2003 - 092150 ÷ 60 mm335 54 42.18 DRIVE CHAINAn excessive slackening of the chain may cause n

Page 109

PERIODIC MAINTENANCEQUASAR 125-1802 - 20 - 00Release 00/2003 - 09If the chain rollers are damaged, the pins are loose and/or the O-ringsare damaged o

Page 110 - - 7 - 00

QUASAR 125-180PERIODIC MAINTENANCE2 - 21 - 00Release 00/2003 - 09Main components1) "SET / RESET" push button for timer start/stop2) Functio

Page 111

PERIODIC MAINTENANCEQUASAR 125-1802 - 22 - 00Release 00/2003 - 09Speed function (a)The speed function is automatically enabled upon battery installat

Page 112 - Secondary 3 Kohm ± 10%

QUASAR 125-180PERIODIC MAINTENANCE2 - 23 - 00Release 00/2003 - 092.20 TOE INPark the vehicle on an even ground with the front wheels facing ahead. Ma

Page 113 - - 10 - 00

PERIODIC MAINTENANCEQUASAR 125-1802 - 24 - 00Release 00/2003 - 09NOTE

Page 114 - - 11 - 00

FOREWORDQUASAR 125-1800 - 4 - 00Release 00/2003 - 064-5 -00 ...094-6 -00 ...095-1 -00 ...

Page 115 - " Check pointer

QUASAR 125-180ENGINE3 - 1 - 00Release 00/2003 - 093ENGINE

Page 116 - - 13 - 00

0234567i91ENGINECONTENTSENGINEQUASAR 125-1803 - 2 - 00Release 00/2003 - 093.1.1 COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE INSTALLED ...

Page 117 - - 14 - 00

QUASAR 125-180 / ENGINE3 - 3 - 00Release 00/2003 - 09ENGINEINDEX3.6.15 CHECKING THE TRANSMISSION UNIT ...

Page 118 - - 15 - 00

ENGINEQUASAR 125-1803 - 4 - 00Release 00/2003 - 093.1.1 COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE INSTALLEDThe parts listed below can be removed

Page 119 - 5.12.3 CHECK DATA

QUASAR 125-180ENGINE3 - 5 - 00Release 00/2003 - 093.1.2 REMOVING THE ENGINE FROM THE FRAMERead carefully 1.3 (GENERAL SAFETY RULES).Switch off the e

Page 120

ENGINEQUASAR 125-1803 - 6 - 00Release 00/2003 - 09" Disconnect the spark plug cap (4).Due to the weight and size of the parts, work with the gre

Page 121 - - 18 - 00

QUASAR 125-180ENGINE3 - 7 - 00Release 00/2003 - 09" Remove chain, see 6.7.1 (DISASSEMBLING THE CHAIN)." Loosen and remove the five screws

Page 122 - - 19 - 00

ENGINEQUASAR 125-1803 - 8 - 00Release 00/2003 - 093.1.3 FITTING THE ENGINE IN THE FRAMERead carefully 1.3 (GENERAL SAFETY RULES).NOTE To refit the

Page 123

QUASAR 125-180ENGINE3 - 9 - 00Release 00/2003 - 093.2 HEAD UNIT3.2.1 REMOVING PROTECTION FAN NOTE Engine can be left assembled on frame. " Remov

Page 124 - " Remove the lens (2)

ENGINEQUASAR 125-1803 - 10 - 00Release 00/2003 - 093.2.4 REMOVING THE HEADNOTE Engine can be left assembled on frame." Drain off all engine oil,

Page 125 - " Unscrew the nut (5)

QUASAR 125-180FOREWORD0 - 5 - 00Release 00/2003 - 060.2 FOREWORD- This manual provides the information required for normal servicing.- The informatio

Page 126

QUASAR 125-180ENGINE3 - 11 - 00Release 00/2003 - 093.2.6 REMOVING CAMSHAFT COMPLETE MOUNTNOTE Engine can be left assembled on frame." Remove hea

Page 127 - - 24 - 00

ENGINEQUASAR 125-1803 - 12 - 00Release 00/2003 - 093.2.8 REFITTING THE ROCKER ARMS " Position plate (1) and the two rocker arms (2) onto mount (

Page 128 - - 25 - 00

QUASAR 125-180ENGINE3 - 13 - 00Release 00/2003 - 093.2.9 REMOVING THE CAMSHAFTNOTE Engine can be left assembled on frame." Remove chain tensione

Page 129 - - 26 - 00

ENGINEQUASAR 125-1803 - 14 - 00Release 00/2003 - 0912344553.2.11 REFITTING THE CAMSHAFT" Remove flywheel housing, see 3.2.2 (REMOVING FLYWHEEL

Page 130 - CYCLE PARTS

QUASAR 125-180ENGINE3 - 15 - 00Release 00/2003 - 09213.2.12 ADJUSTING VALVE CLEARANCETurn engine by hand and re-align the reference marks on toothed

Page 131

ENGINEQUASAR 125-1803 - 16 - 00Release 00/2003 - 093.2.15 REMOVING VALVES" Remove the head, see 3.2.13 (REMOVING THE HEAD)." Use the speci

Page 132

QUASAR 125-180ENGINE3 - 17 - 00Release 00/2003 - 09SI NOSSNGVV3.2.18 CHECKING VALVES AND VALVE SEATS Valves must show no signs of burning, grooves

Page 133

ENGINEQUASAR 125-1803 - 18 - 00Release 00/2003 - 093.2.20 CHECKING THE HEAD AND CYLINDER Using a rounded soft scraper, remove any carbon deposits fro

Page 134

QUASAR 125-180ENGINE3 - 19 - 00Release 00/2003 - 0913.2.21 REFITTING VALVES AND HEAD " Fit plate and oil seal. " Lubricate valve stems and

Page 135

ENGINEQUASAR 125-1803 - 20 - 00Release 00/2003 - 09124312 33.2.22 REMOVING THE CYLINDER" Remove the head, see 3.2.13 (REMOVING THE HEAD)."

Page 136

FOREWORDQUASAR 125-1800 - 6 - 00Release 00/2003 - 060.4 ABBREVIATIONS/SYMBOLS/CONVENTIONS# = number< = is less than> = is more than<= is les

Page 137

QUASAR 125-180ENGINE3 - 21 - 00Release 00/2003 - 093.2.25 CHECKING THE PISTONRemove piston rings taking care not to over-enlarge them.Then, using a r

Page 138

ENGINEQUASAR 125-1803 - 22 - 00Release 00/2003 - 093.2.26 CHECKING PISTON RINGSMeasure piston rings side clearance with a feeler gauge.Side clearance

Page 139

QUASAR 125-180ENGINE3 - 23 - 00Release 00/2003 - 09124 33.2.28 REFITTING THE PISTON" Refit piston rings as shown in the figure and taking care n

Page 140

ENGINEQUASAR 125-1803 - 24 - 00Release 00/2003 - 091122134585673.3 ALTERNATOR3.3.1 REMOVING THE COOLING FANNOTE Engine can be left assembled on frame

Page 141

QUASAR 125-180ENGINE3 - 25 - 00Release 00/2003 - 09211 1347563.3.4 REMOVING THE FREEWHEELING CLUTCH" Remove the alternator, see 3.3.2 (REMOVING

Page 142

ENGINEQUASAR 125-1803 - 26 - 00Release 00/2003 - 092113254677 73.3.5 CHECKING THE STARTER CLUTCH Check the starter clutch. Push needle roller bearing

Page 143

QUASAR 125-180ENGINE3 - 27 - 00Release 00/2003 - 092134563.4 OIL PUMP3.4.1 REMOVING THE OIL PUMP" Drain off all engine oil, see 2.11.2 (CHANGING

Page 144

ENGINEQUASAR 125-1803 - 28 - 00Release 00/2003 - 092143563.4.2 CHECKING THE OIL PUMPCarefully check the oil pump. Even if really seldom, excessive we

Page 145

QUASAR 125-180ENGINE3 - 29 - 00Release 00/2003 - 0923412143543.5 STARTER MOTOR3.5.1 REMOVING THE STARTER MOTORNOTE Engine can be left assembled on fr

Page 146

ENGINEQUASAR 125-1803 - 30 - 00Release 00/2003 - 0921435 555 569 783.6 STARTING SYSTEM3.6.1 REMOVING THE STARTING SYSTEMNOTE Engine can be left assem

Page 147

QUASAR 125-180FOREWORD0 - 7 - 00Release 00/2003 - 06T.E. = hexagonal headT.P. = flat head screwTSI = Twin Spark IgnitionUPSIDE-DOWN = inverted fork

Page 148

QUASAR 125-180ENGINE3 - 31 - 00Release 00/2003 - 096 124 358 888 8791011123.6.2 REFITTING THE STARTING SYSTEM " Refit the return spring (1) firs

Page 149

ENGINEQUASAR 125-1803 - 32 - 00Release 00/2003 - 09123453.6.3 REMOVING THE PRIMARY BELT ROLLERNOTE Engine can be left assembled on frame. " Remo

Page 150

QUASAR 125-180ENGINE3 - 33 - 00Release 00/2003 - 093.6.4 CHECKING THE PRIMARY BELT ROLLER Check the primary (fixed and mobile) belt roller and the bu

Page 151

ENGINEQUASAR 125-1803 - 34 - 00Release 00/2003 - 091324657 8911 103.6.5 REMOVING THE CLUTCH AND THE SECONDARY BELT ROLLER " Remove the converter

Page 152

QUASAR 125-180ENGINE3 - 35 - 00Release 00/2003 - 0912343.6.6 CHANGING THE CLUTCH BLOCKS" Remove the clutch, see 3.6.5 (REMOVING THE CLUTCH AND T

Page 153

ENGINEQUASAR 125-1803 - 36 - 00Release 00/2003 - 091223.6.7 CHECKING THE CLUTCH Check clutch inner surface. In case of scoring or rust, remove and cl

Page 154

QUASAR 125-180ENGINE3 - 37 - 00Release 00/2003 - 0935 1423.6.10 REFITTING THE SECONDARY BELT ROLLERBefore fitting the belt roller, thoroughly clean t

Page 155

ENGINEQUASAR 125-1803 - 38 - 00Release 00/2003 - 0922 11134567891012111363.6.11 REMOVING THE FINAL DRIVE GEARS " Drain off all transmission oil,

Page 156 - Direction of rotation

QUASAR 125-180ENGINE3 - 39 - 00Release 00/2003 - 09146614151243" Remove shaft (6) with toothed gear (14)." Remove the circlip (15)." R

Page 157 - - 28 - 00

ENGINEQUASAR 125-1803 - 40 - 00Release 00/2003 - 09113 213.6.13 REMOVING THE GEAR SELECTOR SPINDLENOTE Engine can be left assembled on frame. "

Page 158 - TROUBLESHOOTING

FOREWORDQUASAR 125-1800 - 8 - 00Release 00/2003 - 06NOTE

Page 159

QUASAR 125-180ENGINE3 - 41 - 00Release 00/2003 - 09123456873.6.15 CHECKING THE TRANSMISSION UNITCheck that the following gears: - reverse gear shaft

Page 160

ENGINEQUASAR 125-1803 - 42 - 00Release 00/2003 - 09123148765111091212123.6.16 REFITTING THE TRANSMISSION UNITThe following operations apply to the ri

Page 161

QUASAR 125-180ENGINE3 - 43 - 00Release 00/2003 - 092145 6633.7 CRANKCASE - CRANKSHAFT 3.7.1 REMOVING THE CRANKSHAFT" Remove piston, see 3.2.23

Page 162

ENGINEQUASAR 125-1803 - 44 - 00Release 00/2003 - 0913.7.2 CHECKING THE CRANKCASE, THE CRANKSHAFT AND THE CONNECTING ROD - Thoroughly check crankshaft

Page 163

QUASAR 125-180ENGINE3 - 45 - 00Release 00/2003 - 091 2365 43.7.4 REFITTING THE CRANKCASEGrease oil seals and oil bearings to prevent crankshaft (1) f

Page 164

ENGINEQUASAR 125-1803 - 46 - 00Release 00/2003 - 092131133.7.5 REFITTING THE CRANKSHAFT OIL SEAL " Working on engine left side, refit the oil se

Page 165 - - 8 - 00

QUASAR 125-180ENGINE3 - 47 - 00Release 00/2003 - 091 12431233.8 LUBRICATION SYSTEM3.8.1 REMOVING THE ENGINE OIL COOLER" Put a container under th

Page 166 - - 9 - 00

ENGINEQUASAR 125-1803 - 48 - 00Release 00/2003 - 09NOTES

Page 167

QUASAR 125-180FUEL SYSTEM4 - 1 - 00Release 00/2003 - 094FUEL SYSTEM

Page 168

0234567i91FUEL SYSTEMCONTENTSFUEL SYSTEMQUASAR 125-1804 - 2 - 00Release 00/2003 - 094.1 MAINTENANCE.............

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