Table Of Contents - APRILIA SR MAX 125 ie Service Station Manual

Table of Contents

Product View4
Index Of Topics5
General Specifications7
Safety Rules7
Maintenance Rules7
Characteristics8
Vehicle Identification8
Dimensions And Mass9
Overhaul Data11
Assembly Clearances11
Cylinder - Piston Assy.11
Wheels And Tyres11
Engine Coupling Categories12
Crankcase - Crankshaft - Connecting Rod14
Crankcase - Crankshaft Coupling/Crankshaft Half-Bearing14
Crankshaft/Crankcase Axial Clearance15
Cylinder Head16
Crankshaft Category Identification16
Head Bearings17
Standard Valve Length18
Standart Diameter18
Minimum Admissable Diameter18
Exhaust19
Intake19
Standard Height21
Admissable Limits21
Slot Packing System22
Products23
Models With Metal Head Gasket23
Recommended Products Table23
Unit Of Measure - Conversion23
Tooling25
Specific Tools25
Maintenance Chart37
Scheduled Maintenance Table37
Spark Plug37
Hub Oil Check38
Hub Oil Replacement39
Air Filter39
Engine Oil Replacement40
Engine Oil Check41
Engine Oil Filter42
Oil Pressure Warning Light42
Cooling System43
Braking System44
Level Check44
Top-Up44
Headlight Adjustment45
Troubleshooting47
Electrical System51
Components Arrangement53
Conceptual Diagrams58
Ignition58
Battery Recharge And Starting59
Level Indicators And Enable Signals Section60
Devices And Accessories61
Lights And Turn Indicators63
Checks And Inspections65
Immobiliser65
Virgin Circuit66
Diagnostic Codes67
Diagnostic Code - 2 Flashes67
Diagnostic Code - 3 Flashes68
Ignition Circuit69
No Spark Plug69
Stator Check71
Voltage Regulator Check73
Recharge System Voltage Check73
Turn Signals System Check74
Lights List74
Fuses75
Dashboard76
Sealed Battery77
Battery Installation78
Connectors82
Instrument Panel Connector82
Tone Wheel Connector82
Control Unit Connector83
Antitheft Connector83
Voltage Regulator Connector84
Engine From Vehicle86
Exhaust Assy. Removal86
Removal Of The Engine From The Vehicle87
Support The Vehicle Adequality87
Engine93
Automatic Transmission93
Transmission Cover93
Air Duct93
Removing The Driven Pulley Shaft Bearing94
Refitting The Driven Pulley Shaft Bearing94
Removing The Driven Pulley95
Inspecting The Clutch Drum95
Inspecting The Clutch96
Removing The Clutch97
Pin Retaining Collar98
Removing The Driven Half-Pulley Bearing99
Inspecting The Driven Fixed Half-Pulley100
Inspecting The Driven Sliding Half-Pulley101
Refitting The Driven Half-Pulley Bearing101
Movable Driven Half-Pulley Dimensions101
Fit The Ball Bearing With The Visible Shielding102
Refitting The Driven Pulley103
Inspecting The Clutch Spring103
Refitting The Clutch104
Drive-Belt105
Removing The Driving Pulley106
Inspecting The Rollers Case107
Refitting The Driving Pulley108
Refitting The Transmission Cover109
End Gear110
Removing The Hub Cover110
Removing The Wheel Axle110
Removing The Hub Bearings111
Removing The Wheel Axle Bearings111
Inspecting The Hub Shaft113
Inspecting The Hub Cover114
Refitting The Wheel Axle Bearing114
Refitting The Hub Cover Bearings116
Refitting The Hub Bearings117
Refitting The Hub Cover117
Flywheel Cover118
Removing The Stator119
Refitting The Stator120
Refitting The Flywheel Cover120
Flywheel And Starting121
Removing The Starter Motor121
Removing The Flywheel Magneto121
Inspecting The Flywheel Components122
Starter Gear Rim123
Intermediate Gear123
Refitting The Free Wheel123
Refitting The Flywheel Magneto124
Refitting The Starter Motor125
Cylinder Assy. And Timing System125
Removing The Intake Manifold125
Removing The Rocker-Arms Cover125
Removing The Timing System Drive126
Removing The Cam Shaft127
Removing The Cylinder Head128
Removing The Valves128
Removing The Cylinder - Piston Assy.130
Inspecting The Small End131
Inspecting The Wrist Pin131
Inspecting The Piston131
Inspecting The Piston Rings131
Removing The Piston132
Choosing The Gasket132
Refitting The Piston Rings133
Refitting The Cylinder134
Inspecting The Cylinder Head135
Inspecting The Timing System Components135
Inspecting The Valve Sealings135
Inspecting The Valves136
Residual Stroke Check136
Refitting The Valves139
Inspecting The Cam Shaft139
Refitting The Head And Timing System Components140
Refitting The Rocker-Arms Cover142
Refitting The Intake Manifold142
Crankcase - Crankshaft142
Splitting The Crankcase Halves142
Crankcase Opening143
Inspecting The Crankshaft Components144
Inspecting The Crankshaft Alignment144
Inspecting The Crankcase Halves145
Inspecting The Crankshaft Plain Bearings146
Coupling Chart146
Refitting The Crankcase Halves146
Studs148
Lubrication149
Oil Pressure Check150
Crankshaft Oil Seals Removal151
Crankshaft Oil Seals Refitting151
Oil Pump152
Oil Pump Removal153
Oil Pump Inspection153
Oil Pump Refitting154
Removing The Oil Sump155
Inspecting The By-Pass Valve156
Refitting The Oil Sump156
Injection158
Miu Injection System159
Transparency159
Precautions161
Troubleshooting Hints161
Terminals Setup163
Terminal Layout163
Ems Circuit Diagram164
Troubleshooting Procedure165
Engine Does Not Start165
Starting Difficulties165
Engine Stops At Idle166
Engine Does Not Rev Down166
Exhaust Backfires In Deceleration167
Engine Revs Irregularly167
Poor Performance At Full Throttle167
Engine Knocking168
Fuel Supply System168
Removing The Butterfly Valve169
Refitting The Butterfly Valve171
Pump Supply Circuit171
Injection Loads172
Electrical Data172
Circuit Leak Test176
Fuel Filter Check177
Inspecting The Injector Circuit178
Inspecting The Injector Hydraulics183
Components Location184
Tachometer185
Ht Coil187
Coolant Temperature Sensor192
Zeroing The Throttle193
Lambda Probe194
Signal Control194
Front Suspensions201
Removing The Front Wheel201
Front Wheel Hub Overhaul201
Refitting The Front Wheel204
Handlebar Removal205
Handlebar Refitting205
Front Fork Removal205
Overhaul206
Component Check208
Front Fork Refitting210
Steering Column Removal213
Steering Column Refitting214
Steering Bearing Removal217
Steering Fifth Wheel Track Removal217
Steering Bearing Refitting218
Steering Fifth Wheel Track Fitting218
Rear Suspensions221
Removing The Rear Wheel221
Refitting The Rear Wheel223
Swing-Arm Removal223
Swing-Arm Overhaul225
Swing-Arm Refitting228
Shock Absorbers228
Shock Absorber Removal229
Shock Absorber Refitting229
Centre-Stand Removal229
Centre-Stand Fitting229
Side Stand Fitting230
Rear Brake Calliper Removal232
Rear Brake Calliper Overhaul232
Rear Brake Calliper Refitting233
Front Brake Calliper Removal234
Front Brake Calliper Overhaul234
Front Brake Calliper Refitting235
Rear Brake Disc Removal236
Rear Brake Disc Refitting236
Rear Brake Disc Inspection236
Front Brake Disc Removal238
Front Brake Disc Refitting238
Front Brake Disc Inspection238
Front Brake Pads Removal239
Front Brake Pads Refitting240
Rear Brake Pads240
Rear Brake Pads Removal241
Rear Brake Pads Refitting241
Fill - Bleeding The Braking System242
Rear - Combined242
Front243
Front Brake Pump Removal243
Cooling System Circuit Diagram246
Technical Specifications246
System Bleed247
Chassis250
Seat250
Rear Handlebar Cover250
Instrument Panel251
Front Handlebar Cover251
Headlight Assy.252
Frame Central Cover252
Legshield254
Side Fairing254
Front Lower Frame254
Front Upper Frame255
Front Turn Indicators256
Front Shield256
Knee-Guard257
Lower Shield Back Plate259
Removing The Ignition Key-Switch When On *Off*260
Front Wheel Housing260
Taillight Assy.261
Footrest261
Passenger Footrest261
Right And Left Footrest262
Rider Footrest262
Side Fairings263
License Plate Holder264
Rear Mudguard265
Helmet Bay266
Spoiler267
Front Mudguard268
Fuel Tank268
Rear Central Cover269
Radiator Fan270
Expansion Tank270
Handles And Top Side Fairings271
Flyscreen272
Pilot Lights Kit272
Battery273
Pre-Delivery275
Aesthetic Inspection275
Tightening Torques Inspection275
Levels Check276
Road Test276
Static Test277
Functional Inspection277
Index278