APRILIA Quasar 50 Manual
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APRILIA Quasar 50 Manual

APRILIA Quasar 50 Manual

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QUASAR 50-100
Release 00/2003 - 06
FOREWORD
0
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FUEL SYSTEM
ELECTRIC SYSTEM
CYCLE PARTS
FOREWORD
0
1
2
3
4
5
6
0
- 1 -
00

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Summary of Contents for APRILIA Quasar 50

  • Page 1 FOREWORD QUASAR 50-100 FOREWORD GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE FUEL SYSTEM ELECTRIC SYSTEM CYCLE PARTS - 1 - Release 00/2003 - 06...

  • Page 2: Table Of Contents

    FOREWORD QUASAR 50-100 FOREWORD CONTENTS RELEASE 00/2002-10 UPDATE ..................... 0-4-00 0.1.1 MANUAL UPDATES ............................. 0-4-00 0.1.2 LIST OF MANUAL PAGES AND UPDATE NUMBERS ..................0-4-00 FOREWORD........................... 0-4-00 REFERENCE MANUALS ........................ 0-5-00 0.3.1 OWNER'S MANUALS ............................0-5-00 0.3.2 SPARE PARTS CATALOGUE..........................0-5-00 ABBREVIATIONS/SYMBOLS/CONVENTIONS ................

  • Page 3: Release 00/2002-10 Update

    FOREWORD QUASAR 50-100 RELEASE 00/2003-10 UPDATE Issue date of original release (Release 00) and subsequent releases: First edition (Release 00)........July 2003 0.1.1 MANUAL UPDATES Always keep manual updated to the latest release you have received. Add the latest release pages to the manual and destroy all superseded pages (even if they belong to the release before last).
  • Page 4 FOREWORD QUASAR 50-100 pag.# Release 6-9 -03 ......06 6-10 -03 ......06 6-11 -03 ......06 6-12 -03 ......06 6-13 -03 ......06 6-14 -03 ......06 6-15 -03 ......06 6-16 -03 ......06 6-17 -03 ......06 6-18 -03 ......06 6-19 -03 ......06 6-20 -03 ......06 6-21 -03 ......06...

  • Page 5: Foreword

    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. aprilia reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual.

  • Page 6: Abbreviations/Symbols/Conventions

    FOREWORD QUASAR 50-100 ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = is less than > = is more than < = is less than or equal to > = is more than or equal to = approximately ∞ = infinite °C = degrees Celsius (centigrade) °F...
  • Page 7 FOREWORD QUASAR 50-100 = Society of Automotive Engineers TEST = diagnostic check T.B.E.I. = crowned-head Allen screw T.C.E.I. = cheese-headed Allen screw T.E. = hexagonal head T.P. = flat head screw = Twin Spark Ignition UPSIDE- DOWN = inverted fork...
  • Page 8 FOREWORD QUASAR 50-100 NOTE - 8 - Release 00/2003 - 06...
  • Page 9 GENERAL INFORMATION QUASAR 50-100 GENERAL INFORMATION - 1 - Release 00/2003- 06...
  • Page 10 GENERAL INFORMATION QUASAR 50-100 GENERAL INFORMATION CONTENTS CONVENTIONS USED IN THE MANUAL..................1-3-00 SAFETY WARNINGS ........................1-3-00 GENERAL SAFETY RULES ......................1-4-00 1.3.1 CARBON OXIDE ..............................1-4-00 1.3.2 FUEL..................................1-4-00 1.3.3 HOT COMPONENT PARTS ..........................1-4-00 1.3.4 TRANSMISSION OIL............................. 1-4-00 1.3.5...

  • Page 11: Conventions Used In The Manual

    GENERAL INFORMATION QUASAR 50-100 CONVENTIONS USED IN THE MANUAL - This manual is divided in sections and subsections, each covering a set of the most significant components. For quick reference, see the summary of sections on page 0-1. - Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure.

  • Page 12: General Safety Rules

    GENERAL INFORMATION QUASAR 50-100 GENERAL SAFETY RULES 1.3.1 CARBON OXIDE When an operation must be performed with the engine running, position the motorcycle out of doors or in a well-ventilated area. Never operate the engine in an enclosed place. Use an exhaust emission extraction plant when working indoors.

  • Page 13: Hydrogen Gas And Battery Electrolyte

    GENERAL INFORMATION QUASAR 50-100 1.3.5 HYDROGEN GAS AND BATTERY ELECTROLYTE Battery electrolyte fluid is toxic and caustic. It contains sulphuric acid and can cause burns if spilled on the skin. Wear close-fitting gloves and protectuve clothing when handling the battery electrolyte.

  • Page 14: General Precautions And Information

    GENERAL INFORMATION QUASAR 50-100 1.3.6 GENERAL PRECAUTIONS AND INFORMATION Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components. Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or inspecting the motorcycle: stop the engine and remove the key from the ignition switch;...

  • Page 15: Reassembling The Components

    All bearings must rotate freely with no hardness or noise. Replace any bearings that do not meet these requirements. - Use ORIGINAL aprilia SPARE PARTS only. - Use the specified lubricants and consumables. - Where possible, lubricate a part before assembly.

  • Page 16: Torque Figures

    GENERAL INFORMATION QUASAR 50-100 1.3.11 TORQUE FIGURES Do not forget that the tightening torques of all fastenings on wheels, brakes, wheel spindles and other suspension components are essential to ensuring safe operation of the motorcycle and must be set to the indicated values.

  • Page 17: Lubricants

    GENERAL INFORMATION QUASAR 50-100 1.4.2 LUBRICANTS Correct lubrication is essential to the safety of the motorcycle. Failure to maintain the lubricant level or the use of incorrect, old or dirty lubricant can cause the engine or transmission to seize, resulting in accidents, serious injury or death.

  • Page 18: Location Of Serial Numbers

    Use Original aprilia Spare Parts only for repairs. Original aprilia spare parts are high-quality components designed and built expressly for aprilia motorcycles. Using any parts OTHER THAN original aprilia parts may lead to loss of performance and damage. - 10 -...

  • Page 19: Specifications

    GENERAL INFORMATION QUASAR 50-100 SPECIFICATIONS QUASAR 50 QUASAR 100 DIMENSIONS Length 1395 mm 1395 mm Width 860 mm 900 mm Max. height (at handlebar) 900 mm 960 mm Seat height 630 mm 690 mm Distance between centres 895 mm 895 mm Min.
  • Page 20 GENERAL INFORMATION QUASAR 50-100 QUASAR 50 QUASAR 100 FUEL SUPPLY Premium-grade unleaded petrol (DIN Premium-grade unleaded petrol (DIN Fuel 51607), minimum octane rating 95 51607), minimum octane rating 95 (N.O.R.M.) and 85 (N.O.M.M.) (N.O.R.M.) and 85 (N.O.M.M.) CARBURETTOR Type MIKUNI...
  • Page 21 GENERAL INFORMATION QUASAR 50-100 QUASAR 50 QUASAR 100 BULBS Parking lights 12V - 5W 12V - 5W Low/high beam 12V - 35/35W 12V - 35/35W Direction indicators 12V - 10W 12V - 10W Rear parking / stop light 12V - 5/21W...

  • Page 22: Lubricant Chart

    GENERAL INFORMATION QUASAR 50-100 LUBRICANT CHART LUBRICANT PRODUCT RECOMMENDED: PONTIAX HDI SAE 85W - 140 or ROTRA MP 85W-140. As an alternative to recommended fluids it is possible to use high-quality fluids having equal Transmission oil or higher ratings with respect to A.P.I. GL-5 specifications.

  • Page 23: Special Tools

    GENERAL INFORMATION QUASAR 50-100 SPECIAL TOOLS Special tools have been developed to ensure proper disassembly, re-assembly and adjustment without the risk of damaging any components. Using inadequate tools and/or improvised procedures may lead to irreparable damage. Model-specific special tools for this vehicle are listed below.

  • Page 24: Torque Figures

    GENERAL INFORMATION QUASAR 50-100 1.10 TORQUE FIGURES The table below reports the standard torque figures for metric size screws and bolts in accordance with ISO standards. Tightening Screw or Span- torque bolt thread M 10 M 12 M 14 M 16 13,0 For vehicle-specific fastenings see 2.2 (FASTENERS).
  • Page 25 GENERAL INFORMATION QUASAR 50-100 NOTES - 17 - Release 00/2003- 06...
  • Page 26 GENERAL INFORMATION QUASAR 50-100 NOTES - 18 - Release 00/2003- 06...
  • Page 27 PERIODIC MAINTENANCE QUASAR 50-100 PERIODIC MAINTENANCE - 1 - Release 00/2003 - 06...
  • Page 28 PERIODIC MAINTENANCE QUASAR 50-100 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE CHART ....................2-3-00 FASTENERS..........................2-4-00 PERIODIC MAINTENANCE CHART ....................2-5-00 LUBRICATION ..........................2-6-00 2.4.1 COMMUTATOR..............................2-6-00 2.4.2 MAIN SWITCH............................... 2-7-00 BATTERY ............................2-8-00 CHECKING THE ELECTROLYTE BATTERY LEVEL ..............2-9-00 2.6.1 RECHARGING THE BATTERY ..........................

  • Page 29: Periodic Maintenance Chart

    PERIODIC MAINTENANCE CHART In order to preserve the motorcycle in sleek running order, aprilia recommends that you strictly observe the periodic maintenance intervals recommended for the different component parts.

  • Page 30: Fasteners

    PERIODIC MAINTENANCE QUASAR 50-100 FASTENERS The fasteners reported in the chart must be tightened to the specified torque using a torque wrench. Items highlighted with ( ) are especially important for safety. ENGINE Description Screw / nut Notes Stator nut M10x1.25...

  • Page 31: Periodic Maintenance Chart

    PERIODIC MAINTENANCE QUASAR 50-100 PERIODIC MAINTENANCE CHART Post running-in checks Components Monthly Six-monthly Yearly (after 2 weeks) Throttle and brake cables Battery Spark plug Carburettor/idling Transmission cables Brake blocks Drive belt Headstock bearing and steering play Piston rings Air cleaner...

  • Page 32: Lubrication

    PERIODIC MAINTENANCE QUASAR 50-100 LUBRICATION Proper lubrication is critical to ensuring smooth operation and preserving vehicle life. IMPORTANT Before lubricating any part, clean off any oxidation deposits, grease, dirt or dust. Parts subject to oxidation must be lubricated with engine oil or grease, see 1.8 (LUBRICANT CHART).

  • Page 33: Main Switch

    PERIODIC MAINTENANCE QUASAR 50-100 2.4.2 MAIN SWITCH The main switch (1) is at the right side of the motorcycle, on the front fairing. IMPORTANT The key turns the main switch and enables the use of the light dip switch, when it is in the "...

  • Page 34: Battery

    PERIODIC MAINTENANCE QUASAR 50-100 BATTERY Read carefully 1.3.5 (HYDROGEN GAS AND BATTERY ELECTROLYTE). Risk of fire. Keep fuel and other flammable substances away from the electrical components. Never invert the connection of the battery cables. Connect and disconnect the battery with the main switch in position "...

  • Page 35: Checking The Electrolyte Battery Level

    PERIODIC MAINTENANCE QUASAR 50-100 CHECKING THE ELECTROLYTE BATTERY LEVEL The vehicle is equipped with a maintenance-free battery, which does not require any check of the electrolyte level. 2.6.1 RECHARGING THE BATTERY IMPORTANT You can tell that the battery is nearly flat when you hear a rattling sound from the starter relay when pressing the starter button "...

  • Page 36: Spark Plug

    PERIODIC MAINTENANCE QUASAR 50-100 On refitting, connect the positive (+) lead first, then the negative (-) lead. Connect the positive terminal (+) with its screw. Connect the negative terminal (-) with its screw. Cover the terminals of the cables and of the battery with neutral grease or vaseline.

  • Page 37: Idling Adjustment

    PERIODIC MAINTENANCE QUASAR 50-100 IDLING ADJUSTMENT Read carefully 1.3 (GENERAL SAFETY RULES). Adjust the idling every time it is irregular. To carry out this operation, proceed as follows: Ride the motorcycle for a few kilometres to allow it to warm up, then adjust the screw (1) from the front of the vehicle.

  • Page 38: Adjusting The Throttle Control

    PERIODIC MAINTENANCE QUASAR 50-100 ADJUSTING THE THROTTLE CONTROL IMPORTANT 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.

  • Page 39: Fuel Tap

    PERIODIC MAINTENANCE QUASAR 50-100 Make sure that the filtering element is positioned correctly, in such a way as to prevent non-filtered air from entering. Remember that the untimely wear of the piston segments and the cylinder may be caused by a faulty or uncorrectly positioned filtering element.

  • Page 40: Checking The Transmission Oil Level

    PERIODIC MAINTENANCE QUASAR 50-100 With the tap set to OFF, fuel will not flow from the tank. Set the tap to this position when not using the motorcycle. When the tap is set to RES, the fuel will flow from the reserve tank to the carburettor.

  • Page 41: Checking And Adjusting The Brakes

    PERIODIC MAINTENANCE QUASAR 50-100 2.13 CHECKING AND ADJUSTING THE BRAKES Read carefully 1.3 (GENERAL SAFETY RULES). The brakes are essential to safety and must be kept in perfect working condition. Always check them before using the motorcycle. The motorcycle is equipped with three drum brakes, two front and one rear.

  • Page 42: Checking The Steering

    PERIODIC MAINTENANCE QUASAR 50-100 2.14 CHECKING THE STEERING Read carefully 1.3 (GENERAL SAFETY RULES). Run the first check after the first two weeks, then every month thereafter. Place a support (1) under the frame at the front, so as to leave the wheels free to turn.

  • Page 43: Inspecting The Rear Suspension

    PERIODIC MAINTENANCE QUASAR 50-100 2.16 INSPECTING THE REAR SUSPENSION Read carefully 1.3 (GENERAL SAFETY RULES). Check the rear suspension every month. Check that the shock absorber is not leaking oil, or scratched or grooved. Check the fastening of all the components and the functionality of the rear suspension joints, see 6.3.1 (REMOVING THE REAR SHOCK ABSORBER).

  • Page 44: Drive Chain

    PERIODIC MAINTENANCE QUASAR 50-100 2.18 DRIVE CHAIN An excessive slackening of the chain may cause noise or make the chain rattle. Periodically check the slack and adjust it if necessary. Incorrect maintenance may cause the untimely wear of the chain and/or damages to the pinion and/or the crown.
  • Page 45 PERIODIC MAINTENANCE QUASAR 50-100 CHECKING THE SLACK To check the slack, proceed as follows: Stop the engine. Make sure that the vertical oscillation, in an intermediate point between pinion and crown in the upper part of the chain, is about 15∼20 mm.

  • Page 46: Multifunction Computer

    PERIODIC MAINTENANCE QUASAR 50-100 CLEANING AND LUBRICATION Carry out the adjustment, lubrication, cleaning and change of the chain with great care. Never wash the chain with water jets, steam jets, high-pressure water jets and highly inflammable solvents. Wash the chain with naphtha or kerosene. If it tends to rust quickly, intensify the maintenance intervals.
  • Page 47 When setting the units of measurements, the instrument will also display the reset value of the wheel diameter; press push button (1) to set this value to 128 for Quasar 50, 144 for Quasar 100 and store the set data by pres- sing push button (2).
  • Page 48 PERIODIC MAINTENANCE QUASAR 50-100 NOTES - 22 - Release 00/2003 - 06...
  • Page 49 ENGINE QUASAR 50-100 ENGINE - 1 - Release 00/2003 - 06...
  • Page 50 ENGINE QUASAR 50-100 ENGINE CONTENTS 3.1.1 COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE INSTALLED ..........3-3-00 3.1.2 REMOVING THE ENGINE FROM THE FRAME ....................3-4-00 3.1.3 FITTING THE ENGINE IN THE FRAME........................ 3-6-00 HEAD UNIT ........................... 3-7-00 3.2.1 REMOVING THE HEAD ............................3-7-00 3.2.2...

  • Page 51: Components That Can Be Removed With The Engine Installed

    ENGINE QUASAR 50-100 3.1.1 COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE INSTALLED The parts listed below can be removed with the engine installed in the frame. TOP END - Carburettor - Intake manifold - Starter - Reed valve unit...

  • Page 52: Removing The Engine From The Frame

    ENGINE QUASAR 50-100 3.1.2 REMOVING THE ENGINE FROM THE FRAME Read carefully 1.3 (GENERAL SAFETY RULES). Switch off the engine and wait for the engine and exhaust system to cool down. Remove both fairings, see 6.1.4 (REMOVING THE FRONT FAIRING) and see 6.1.5 (REMOVING THE REAR FAIRING).
  • Page 53 ENGINE QUASAR 50-100 Due to the weight and size of the parts, work with the greatest care. Block off all openings of engine and hoses to prevent the ingress of dirt. Release and remove the nut (7) and collect the washer.

  • Page 54: Fitting The Engine In The Frame

    ENGINE QUASAR 50-100 3.1.3 FITTING THE ENGINE IN THE FRAME Read carefully 1.3 (GENERAL SAFETY RULES). IMPORTANT To refit the engine in the frame, reverse the removal procedure, see see 3.1.2 (REMOVING THE ENGINE FROM THE FRAME). Before proceeding, however, you will have to perform the operations detailed below.

  • Page 55: Head Unit

    ENGINE QUASAR 50-100 FOREWORD The engine must be on the workbench for disassembly. Operations that can be done without removing the engine from the frame will be indicated by a note. The manufacturer assumes no responsibility for damage resulting from the use of unsuitable tools for the removal and refitting of the engine or any part of it.

  • Page 56: Removing The Piston

    ENGINE QUASAR 50-100 3.2.3 REMOVING THE PISTON Remove the cylinder, 3.2.2 (REMOVING THE CYLINDER). Before removing the piston pin retaining ring, cover the crankcase opening with a clean cloth so as to prevent the ring from falling into the crankcase; before removing the piston pin, carefully deburr the retaining ring groove and the adjoining part of the pin insertion hole.

  • Page 57: Checking The Piston

    ENGINE QUASAR 50-100 3.2.5 CHECKING THE PISTON Remove the piston rings taking care not to part their ends more than necessary. To decoke the piston top, use a scraper with a slightly rounded edge. Clean the piston ring grooves with a spare ring.

  • Page 58: Checking The Piston Rings

    ENGINE QUASAR 50-100 3.2.6 CHECKING THE PISTON RINGS Measure the side clearance of the piston rings using a thickness gauge. Side clearance: 0.02 ÷ 0.06 mm Check that the piston rings show no signs of anomaly, and that the gap between the ring ends is 0.75 mm.

  • Page 59: Refitting The Power Plant

    ENGINE QUASAR 50-100 3.2.8 REFITTING THE POWER PLANT Fit the new upper ring (1) and lower ring (2) on the piston with the tapered side facing upwards. Refer to pins (3). Failure to observe this procedure will make it virtually impossible to fit the cylinder on the piston, and will result in breakage of the piston rings, and possibly more serious damage during engine assembly.

  • Page 60: Alternator

    ENGINE QUASAR 50-100 ALTERNATOR 3.3.1 REMOVING THE COOLING FAN IMPORTANT There is no need to remove the engine from the frame. Remove the fan guard, see 6.1.8 (REMOVING THE FAN GUARD). Unscrew and remove the three screws (1) and collect the washers.

  • Page 61: Oil Pump

    ENGINE QUASAR 50-100 OIL PUMP 3.4.1 REMOVING THE OIL PUMP Remove the alternator, see 3.3.2 (REMOVING THE ALTERNATOR). Release and remove the two screws (1). Extract the pump (2) together with the oil feed pipe (3) and the pipe that delivers oil to the carburettor (4).

  • Page 62: Checking The Oil Pump

    ENGINE QUASAR 50-100 3.4.2 CHECKING THE OIL PUMP Check the general condition of the oil pump. Remember that wear or malfunction can alter the settings of the pump itself. This, however, occurs very rarely. Should the pump appear to be malfunctioning, check the feed duct.

  • Page 63: Refitting The Oil Pump

    ENGINE QUASAR 50-100 3.4.3 REFITTING THE OIL PUMP Fit the oil seal stop plate (1) and fasten it with the fixing screw. Fit, in the following order, the pin, pump driving gear (2), washer and the circlip (3). Fit the pump (4) paying special attention to the passage of the oil delivery pipe, and then fasten it with the two screws (5).

  • Page 64: Starter Motor

    ENGINE QUASAR 50-100 STARTER MOTOR 3.5.1 REMOVING THE STARTER MOTOR If the starter motor (1) fails to operate, check and if necessary restore the electrical connections before removing the motor. Disconnect the connector (2). Release and remove the two screws (3).

  • Page 65: Starting System

    ENGINE QUASAR 50-100 STARTING SYSTEM 3.6.1 REMOVING THE STARTING SYSTEM IMPORTANT There is no need to remove the engine from the frame. Remove the crankcase guard, see 6.1.11 (REMOVING THE CRANKCASE COVER). Release and remove the ten screws (1). Collect the two brackets.

  • Page 66: Refitting The Starting System

    ENGINE QUASAR 50-100 3.6.2 REFITTING THE STARTING SYSTEM Refit, in the following order, the return spring (1), the pedal shaft (2), the bush, the plain washer and the circlip (3). Attach the return spring (1) to the pedal spindle (2) and, using a spring pull hook, fix the other end to the pin.

  • Page 67: Removing The Primary Pulley

    Remove the start coupling (3), the spider (4), the (fixed) primary pulley (5) and the shim. IMPORTANT The shim is only present on the QUASAR 50. At the same time, remove the bush (7), the (movable) primary pulley (6) and lug holder.

  • Page 68: Checking The Primary Pulley

    ENGINE QUASAR 50-100 3.6.4 CHECKING THE PRIMARY PULLEY Check the (fixed and movable) primary pulley and the bush for signs of wear, breakage, scoring or other damage, and replace as necessary. Check that the bush slides smoothly inside the (movable) primary pulley. If not, or if the play is excessive, replace the pulley and the bush.

  • Page 69: Removing The Starting Freewheeling Clutch

    ENGINE QUASAR 50-100 3.6.5 REMOVING THE STARTING FREEWHEELING CLUTCH IMPORTANT There is no need to remove the engine from the frame. Remove the primary pulley, see 3.6.3 (REMOVING THE PRIMARY PULLEY). Extract the freewheeling clutch (1). Release and remove the two screws (2).

  • Page 70: Refitting The Starting Freewheeling Clutch

    ENGINE QUASAR 50-100 3.6.7 REFITTING THE STARTING FREEWHEELING CLUTCH Fit the bush (1) and the washer on the crankshaft. Fit the starting gear (2), lubricated with transmission oil, and the roller cage (3). Reposition the starting gear (4), lubricated with oil, the rear washer and the three front washers.

  • Page 71: Removing The Clutch And The Secondary Pulley

    ENGINE QUASAR 50-100 3.6.8 REMOVING THE CLUTCH AND THE SECONDARY PULLEY Remove the variator casing, see 3.6.1 (REMOVING THE STARTING SYSTEM). Extract the O-ring (1). Unscrew and remove the nut (2) with the special tool (flywheel and clutch bell housing retainer, code 8900675).

  • Page 72: Checking The Clutch

    ENGINE QUASAR 50-100 3.6.9 CHECKING THE CLUTCH Check the inside surface of the clutch housing. If it shows signs of rust or scoring, remove and clean with emery cloth. Also measure the inside diameter. Wear limit: 112.5 mm. Check the clutch blocks. Check the clutch blocks and if necessary reface with coarse-grained abrasive paper.

  • Page 73: Refitting The Secondary Pulley

    ENGINE QUASAR 50-100 3.6.12 REFITTING THE SECONDARY PULLEY Before fitting the pulley, clean its sliding surface, and if necessary add grease in the fixed half pulley (1) see 1.8 (LUBRICANT CHART). Wrap adhesive tape around the pulley end in order to avoid overturning the lips of the oil seals while fitting the pulley.

  • Page 74: Transmission Removal

    ENGINE QUASAR 50-100 TRANSMISSION REMOVAL IMPORTANT There is no need to remove the engine from the frame. Remove the secondary pulley, see 3.6.7 (REFITTING THE STARTING FREEWHEELING CLUTCH). Before removing the transmission cover, drain all the oil, see 2.12 (CHECKING THE TRANSMISSION OIL LEVEL).

  • Page 75: Removing The Drive Shaft

    ENGINE QUASAR 50-100 3.7.1 REMOVING THE DRIVE SHAFT Remove the transmission cover (1), see 3.7 (TRANSMISSION REMOVAL). Release and remove the screw (3) and collect the washer. Extract the complete drive shaft (12) using a mallet to tap it towards the interior of the casing.

  • Page 76: Checking The Transmission

    ENGINE QUASAR 50-100 3.7.2 CHECKING THE TRANSMISSION Check that the output shaft gears (1), the double idler gear (2) and the drive shaft (3) show no signs of wear. Replace any worn components. Check that the transmission bearings show no signs of scoring or seizing.

  • Page 77: Crankcase - Crankshaft

    ENGINE QUASAR 50-100 CRANKCASE - CRANKSHAFT 3.8.1 REMOVING THE CRANKSHAFT Remove the piston, see 3.2.3 (REMOVING THE PISTON). Remove the complete oil pump, see 3.4.1 (REMOVING THE OIL PUMP). Remove the starter clutch, see 3.6.5 (REMOVING THE STARTING FREEWHEELING CLUTCH).

  • Page 78: Removing The Engine Silent Block

    ENGINE QUASAR 50-100 carefully cleaned, the big-end bearing is still stiff, does not rotate smoothly, or has an excessive play, proceed to replace it. The replacement of the big-end bearing should be carried out by a skilled technician using the special tools required for this operation.

  • Page 79: Fitting The Crankcase

    ENGINE QUASAR 50-100 3.8.5 FITTING THE CRANKCASE Apply grease to the oil seals and oil to the bearings so as to protect the crankshaft (1) against possible scoring and facilitate the fitting. Using an automatic heater, heat the right-hand crankcase to approximately 150 °C (~ 10 minutes' operation).

  • Page 80: Fitting The Crankshaft Oil Seal

    ENGINE QUASAR 50-100 3.8.6 FITTING THE CRANKSHAFT OIL SEAL On the left side of the engine, fit the oil seal (1), the circlip and the centring bush (2) taking care to smear the lip of the oil seal with grease, see 1.8 (LUBRICANT CHART).
  • Page 81 ENGINE QUASAR 50-100 NOTES - 33 - Release 00/2003 - 06...
  • Page 82 ENGINE QUASAR 50-100 NOTES - 34 - Release 00/2003 - 06...
  • Page 83 FUEL SYSTEM QUASAR 50-100 SISTEMA DI ALIMENTAZIONE FUEL SYSTEM - 1 - Release 00/2003 - 06...
  • Page 84 FUEL SYSTEM QUASAR 50-100 FUEL SYSTEM CONTENTS MAINTENANCE..........................4-3-00 DRAINING THE FUEL TANK ......................4-3-00 4.2.1 CARBURETTOR SPECIFICATIONS ........................4-5-00 REMOVING THE CARBURETTOR ....................4-6-00 REMOVING THE REED VALVE UNIT .................... 4-7-00 4.4.1 CHECKING THE REED VALVE..........................4-7-00 - 2 -...

  • Page 85: Maintenance

    FUEL SYSTEM QUASAR 50-100 MAINTENANCE Check the condition of the fuel system hoses every six months. Hoses which are dried out, cracked or cut must be replaced. Make sure the hoses are not twisted or crushed. Periodically check and clean the fuel filter.
  • Page 86 FUEL SYSTEM QUASAR 50-100 - 4 - Release 00/2003 - 06...

  • Page 87: Carburettor Specifications

    FUEL SYSTEM QUASAR 50-100 Key: 1) Carburettor 2) Spring 3) Screw 4) Elastic washer 5) Gas valve 6) Needle kit 7) Emulsion tube 8) Sump gasket 9) Maximum jet 10) Minimum hose 11) Pilot jet 12) Minimum air adjuster screw...

  • Page 88: Removing The Carburettor

    FUEL SYSTEM QUASAR 50-100 REMOVING THE CARBURETTOR Remove the airbox, see 2.10 (AIR CLEANER). IMPORTANT Close the fuel tap to avoid fuel leaks. Place a cloth below the carburettor to collect any spillage. Disconnect the fuel pipe (1). Disconnect the oil pipe (2).

  • Page 89: Removing The Reed Valve Unit

    FUEL SYSTEM QUASAR 50-100 REMOVING THE REED VALVE UNIT Remove the deflector, see 6.1.10 (REMOVING THE DEFLECTOR). Remove the four screws (1). Torque wrench setting for screws (1): 8 Nm (0.8 kgm). Remove, in the following order, the intake manifold (2), the reed valve (3)
  • Page 90 FUEL SYSTEM QUASAR 50-100 NOTES - 8 - Release 00/2003 - 06...
  • Page 91 ELECTRIC SYSTEM QUASAR 50-100 ELECTRIC SYSTEM - 1 - Release 00/2003 - 06...
  • Page 92 ELECTRIC SYSTEM QUASAR 50-100 ELECTRIC SYSTEM CONTENTS FOREWORD........................... 5-3-00 5.1.1 CABLE COLOURS..............................5-3-00 5.1.2 ELECTRICAL CONNECTORS..........................5-3-00 ELECTRICAL COMPONENTS ......................5-4-00 TROUBLESHOOTING........................5-5-00 5.3.1 CHECKING CHECKING THE CHARGE VOLTAGE ............................. 5-5-00 5.3.2 RECTIFIER ................................5-5-00 FUEL INJECTION SYSTEM......................5-6-00 5.4.1 HIGH TENSION COIL............................

  • Page 93: Foreword

    ELECTRIC SYSTEM QUASAR 50-100 FOREWORD Please read the following information before reading this section. IMPORTANT For ease of reference, the same numbering is used in the specific wiring diagrams and in the general schematics. 5.1.1 CABLE COLOURS Orange Light blue...

  • Page 94: Electrical Components

    ELECTRIC SYSTEM QUASAR 50-100 ELECTRICAL COMPONENTS Key: 1) Front direction indicators 2) Rear direction indicators 3) Tail light 4) Headlight 5) Left-hand commutator 6) Handlebar cover 7) Hazard lights relay 8) Voltage stabiliser 9) Rectifier 10) Engine Control Unit 11) Battery...

  • Page 95: Troubleshooting

    ELECTRIC SYSTEM QUASAR 50-100 TROUBLESHOOTING 5.3.1 CHECKING CHECKING THE CHARGE VOLTAGE After having completely charged the battery, see 2.5 (BATTERY). Connect a multimeter between the positive (+) and negative (-) battery terminals. After starting the engine, disconnect the fuse and connect an ammeter to the ends of the wires.

  • Page 96: Fuel Injection System

    ELECTRIC SYSTEM QUASAR 50-100 FUEL INJECTION SYSTEM Key: 1) Engine Control Unit (ECU) 2) HT coil 3) Spark plug 4) Main switch 5) Generator 5.4.1 HIGH TENSION COIL Read carefully 1.3 (GENERAL SAFETY RULES). Remove the cylinder guard, see 6.1.9 (REMOVING THE AIR SCOOP GUARD).

  • Page 97: Bulbs

    ELECTRIC SYSTEM QUASAR 50-100 BULBS Read carefully 1.3 (GENERAL SAFETY RULES). Risk of fire. Keep fuel and other flammable substances away from the electrical components. Before changing a bulb, move the main switch to position " " and wait a few minutes, so that the bulb cools down. Change the bulb wearing clean gloves or using a clean and dry cloth.

  • Page 98: Changing The Headlight Bulbs

    ELECTRIC SYSTEM QUASAR 50-100 5.5.2 CHANGING THE HEADLIGHT BULBS Read carefully 5.5 (BULBS). The headlight contains: one low/high beam bulb (1). one parking light bulb (2); Remove the lamp unit from the front fairing, see 6.1.20 (REMOVING THE HEADLIGHT). LOW/HIGH BEAM BULB (HALOGEN).

  • Page 99: Changing The Rear Light Bulb

    ELECTRIC SYSTEM QUASAR 50-100 5.5.3 CHANGING THE REAR LIGHT BULB Read carefully 5.5 (BULBS). To change the bulbs, proceed as follows: Release and remove the two screws (1). Remove the lens (2). Extract the damaged bulb and replace it with a new one of the same type.

  • Page 100: Adjusting The Headlight Beam

    ELECTRIC SYSTEM QUASAR 50-100 5.5.5 ADJUSTING THE HEADLIGHT BEAM To rapidly check the correct direction of the beam, place the vehicle on flat ground, 10 m away from a wall. Turn on the low beam, sit on the vehicle and make sure that the beam projected on the wall is slightly under the horizontal line of the headlight (about 9/10th of the total height).

  • Page 101: Wiring Diagram

    ELECTRIC SYSTEM QUASAR 50-100 WIRING DIAGRAM N/Bi Gr/scr Bi/R Bi/R Bi/N Bi/N Bi/N Bi/B Bi/R Bi/R Gr/scr M/Bi Bi/B B/Bi B/Bi M/Bi M/Bi M/scr Gr/scr V/scr V/scr Gr/scr Gr/scr M/scr M/scr V/scr V/scr R/Bi B/Bi - 11 - Release 00/2003 - 06...
  • Page 102 ELECTRIC SYSTEM QUASAR 50-100 Key: 1) Multiple connectors 2) High beam warning light 3) Hazard warning light 4) Mixing oil level warning light 5) Mixing oil level warning light 6) Keyswitch with parking light switch 7) Hazard flasher with buzzer...
  • Page 103 ELECTRIC SYSTEM QUASAR 50-100 NOTES - 13 - Release 00/2003 - 06...
  • Page 104 ELECTRIC SYSTEM QUASAR 50-100 NOTES - 14 - Release 00/2003 - 06...
  • Page 105 CYCLE PARTS QUASAR 50-100 CYCLE PARTS - 1 - Release 00/2003 - 06...
  • Page 106 CYCLE PARTS QUASAR 50-100 CYCLE PARTS CONTENTS BODYWORK ..........................6-3-00 6.1.1 REMOVING THE SEAT............................6-5-00 6.1.2 REMOVING THE HANDLEBAR COVER......................6-5-00 6.1.3 REMOVING THE HANDLEBAR..........................6-5-00 6.1.4 REMOVING THE FRONT FAIRING ........................6-7-00 6.1.5 REMOVING THE REAR FAIRING ........................6-8-00 6.1.6...

  • Page 107: Bodywork

    CYCLE PARTS QUASAR 50-100 BODYWORK 1) Left-hand front shock absorber 2) Headlight 3) Handlebar cover 4) Left-hand rearview mirror 5) Front fairing 6) Mixer oil tank filler cap 7) Battery 8) Fuse 9) Seat 10) Rear shock absorber 11) Left footpeg...
  • Page 108 CYCLE PARTS QUASAR 50-100 1) Rear fairing 2) Tail light 3) Fuel tank 4) Fuel filler cap 5) Right-hand rearview mirror 6) Warning horn 7) Front right shock absorber 8) Fuel tap 9) Front + rear brake pedal (100 cc only)

  • Page 109: Removing The Seat

    CYCLE PARTS QUASAR 50-100 6.1.1 REMOVING THE SEAT Disengage the seat with the lever (1). Remove the seat (2). 6.1.2 REMOVING THE HANDLEBAR COVER Unscrew the two screws (1). Remove the handlebar cover (2). Disconnect the handlebar cover connectors. Mark all wires with their original positions to avoid confusing them when refitting.
  • Page 110 CYCLE PARTS QUASAR 50-100 Remove the rear brake cable (2) from its seat. Loosen the two locking washers (3) completely. Tighten the two adjusters (4) all the way in. Remove the front brake cables (5). Remove the two screws (6).

  • Page 111: Removing The Front Fairing

    CYCLE PARTS QUASAR 50-100 Release and remove the four screws (9). Remove the two clamps (10). Remove the handlebar. 6.1.4 REMOVING THE FRONT FAIRING Remove the handlebar see 6.1.3 (REMOVING THE HANDLEBAR). Unscrew and remove the three screws (1) and collect the washers and nuts.

  • Page 112: Removing The Rear Fairing

    CYCLE PARTS QUASAR 50-100 Disconnect the headlight connectors (6). Disconnect the main switch connector (7). Remove the front fairing. 6.1.5 REMOVING THE REAR FAIRING Remove the battery, see 6.1.7 (REMOVING THE BATTERY). Unhook the elastic band (1). Remove the tool kit (2).

  • Page 113: Removing The Footpegs

    CYCLE PARTS QUASAR 50-100 Unscrew and remove the three screws (6) and collect the washers and nuts. Disconnect the direction indicator connectors (7). Disconnect the tail light connectors (8). Remove the rear fairing. 6.1.6 REMOVING THE FOOTPEGS Unscrew and remove the three screws (1) and collect the washers and nuts.

  • Page 114: Removing The Battery

    CYCLE PARTS QUASAR 50-100 6.1.7 REMOVING THE BATTERY Set the main switch to " ". Remove the seat, see 6.1.1 (REMOVING THE SEAT). Unhook the elastic band (1). Release and remove the negative (-) terminal screw (2). Slide the negative lead (3) aside.

  • Page 115: Removing The Air Scoop Guard

    CYCLE PARTS QUASAR 50-100 6.1.9 REMOVING THE AIR SCOOP GUARD IMPORTANT There is no need to remove the engine from the frame. Disconnect the spark plug cap (1). Remove the fan guard, see 6.1.8 (REMOVING THE FAN GUARD). Remove the cylinder air scoop guard (2).

  • Page 116: Removing The Fuel Tank

    CYCLE PARTS QUASAR 50-100 6.1.12 REMOVING THE FUEL TANK Remove the front fairing, see 6.1.4 (REMOVING THE FRONT FAIRING). Close the fuel tap (1). Release the hose clip (2). Remove the tap-carburettor hose (3). Unscrew and remove the screw (4).

  • Page 117: Removing The Mixer Oil Tank

    CYCLE PARTS QUASAR 50-100 6.1.13 REMOVING THE MIXER OIL TANK Remove the rear fairing, see 6.1.5 (REMOVING THE REAR FAIRING). Prepare a container of at least 1.5 litres. Empty out the oil tank with a pump. Release the clip (1).

  • Page 118: Removing The Switchgear

    CYCLE PARTS QUASAR 50-100 6.1.15 REMOVING THE SWITCHGEAR Read carefully 1.3 (GENERAL SAFETY RULES). Set the main switch to " ". Release and remove the two screws (1) and housing halves (2-3). Disconnect the two connectors (4). Remove the two housing halves (2-3).

  • Page 119: Removing The Main Switch

    CYCLE PARTS QUASAR 50-100 6.1.19 REMOVING THE MAIN SWITCH Remove the ignition key. Remove the front fairing, see 6.1.4 (REMOVING THE FRONT FAIRING). Straighten out the retaining shims (1). Remove the retainer (1). Withdraw the main switch (2) from outside the fairing.

  • Page 120: Removing The Front Direction Indicators

    CYCLE PARTS QUASAR 50-100 6.1.21 REMOVING THE FRONT DIRECTION INDICATORS Disconnect the two connectors (1). Unscrew and remove the screw (2). Remove the direction indicator. IMPORTANT Repeat the process for the other indicator if needed. 6.1.22 REMOVING THE WARNING HORN Disconnect the two connectors (1).

  • Page 121: Removing The Tail Light

    CYCLE PARTS QUASAR 50-100 6.1.23 REMOVING THE TAIL LIGHT Set the main switch to " ". Disconnect the connector (1). Release and remove the two nuts (2) and collect the washers. Remove the tail light (3). 6.1.24 REMOVING THE REAR DIRECTION INDICATORS Disconnect the two connectors.

  • Page 122: Removing The Exhaust

    CYCLE PARTS QUASAR 50-100 6.1.25 REMOVING THE EXHAUST Remove the rear fairing, see 6.1.5 (REMOVING THE REAR FAIRING). Remove the right footpeg, see 6.1.6 (REMOVING THE FOOTPEGS). Release and remove the two screws (1). Remove the plate (2). Release and remove the two screws (3).

  • Page 123: Removing The Wheels

    CYCLE PARTS QUASAR 50-100 6.1.26 REMOVING THE WHEELS Place a support under the front of the frame to remove one or both of the front wheels or under the rear axle to remove one or both of the rear wheels.

  • Page 124: Steering System

    CYCLE PARTS QUASAR 50-100 STEERING SYSTEM 6.2.1 REMOVING THE BASE WITH HEADSTOCK Remove the front fairing, see 6.1.4 (REMOVING THE FRONT FAIRING). Release and remove the two nuts (1) and collect the clamp (2) and bush (3). Remove the two split pins (4).

  • Page 125: Removing The Steering Lever

    CYCLE PARTS QUASAR 50-100 6.2.2 REMOVING THE STEERING LEVER Extract the spilt pin (1). Release and remove the nut (2). Extract the spilt pin (3). Release and remove the nut (4). Remove the steering lever (5). IMPORTANT Repeat the process to remove the other lever if needed.

  • Page 126: Removing The Front Shock Absorber

    CYCLE PARTS QUASAR 50-100 6.2.4 REMOVING THE FRONT SHOCK ABSORBER Place a support under the front of the frame. Unscrew and remove the two screws (1) and collect the washers and nuts. Remove the shock absorber (2). 6.2.5 REMOVING THE SUSPENSION ARM Remove the shock absorber, see 6.2.4 (REMOVING THE FRONT SHOCK...

  • Page 127: Removing The Fork

    CYCLE PARTS QUASAR 50-100 6.3.2 REMOVING THE FORK Remove the chain, see 6.6.1 (BREAKING THE CHAIN). Release and remove the two nuts (1). Release and remove the two screws (2). Remove the guard (3). Release and remove the two nuts (4).

  • Page 128: Front Brakes

    CYCLE PARTS QUASAR 50-100 FRONT BRAKES 6.4.1 REMOVING THE BRAKE IMPORTANT The following procedure can be applied to either brake. Place a support under the front of the frame. Disconnect the two brake cables (1-2). Remove the hub cap (3).

  • Page 129: Removing The Brake Drum

    CYCLE PARTS QUASAR 50-100 6.4.2 REMOVING THE BRAKE DRUM Remove the complete wheel, see 6.4.1 (REMOVING THE BRAKE). Remove the following components from the outer side of the wheel in order: - the spacer (1); - the oil seal (2);...

  • Page 130: Rear Brake

    CYCLE PARTS QUASAR 50-100 REAR BRAKE 6.5.1 REMOVING THE BRAKE Place a support under the rear of the frame. Disconnect the brake cables and remove the guard, see 6.3.2 (REMOVING THE FORK). Remove the left-hand hub cap (1). Extract the spilt pin.

  • Page 131: Checking The Components

    CYCLE PARTS QUASAR 50-100 6.5.2 CHECKING THE COMPONENTS BRAKE DRUM Inspect the sliding surface for scoring and/or scratching. Eliminate minor scoring with wet sand paper (grain size 1). Replace the drum (1) if badly scored. SEALS Check the condition of the seals. Replace any damaged or worn seals.

  • Page 132: Chain

    CYCLE PARTS QUASAR 50-100 CHAIN 6.6.1 BREAKING THE CHAIN Read carefully 1.3 (GENERAL SAFETY RULES). Slacken the chain, see 2.18 (DRIVE CHAIN). Turn the rear wheels to identify the master link. Extract the clip (1) and remove the plate beneath it.
  • Page 133 CYCLE PARTS QUASAR 50-100 NOTES - 29 - Release 00/2003 - 06...
  • Page 134 CYCLE PARTS QUASAR 50-100 NOTES - 30 - Release 00/2003 - 06...

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