APRILIA QUASAR 125 2003 Workshop Manual
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APRILIA QUASAR 125 2003 Workshop Manual

APRILIA QUASAR 125 2003 Workshop Manual

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QUASAR 125 - 180
1122 3
00/2003-09
workshopmanual

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Summary of Contents for APRILIA QUASAR 125 2003

  • Page 1 QUASAR 125 - 180 1122 3 00/2003-09 workshopmanual...
  • Page 2 FOREWORD QUASAR 125-180 FOREWORD GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE FUEL SYSTEM ELECTRIC SYSTEM CYCLE PARTS - 1 - Release 00/2003 - 06...

  • Page 3: Table Of Contents

    FOREWORD QUASAR 125-180 FOREWORD CONTENTS 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 FOREWORD..........................0-5-00 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 4: Release 00/2003-09 Update

    FOREWORD QUASAR 125-180 RELEASE 00/2003-09 UPDATE Issue date of original release (Release 00) and subsequent releases: First edition (Release 00)....... September 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 Add the latest release pages to the manual and destroy all superseded pages (even if they belong to the release before last).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 5 FOREWORD QUASAR 125-180 Release Release pag.# pag.# 4-5 -00 ......09 6-14 -00 .......09 4-6 -00 ......09 6-15 -00 .......09 5-1 -00 ......09 6-16 -00 .......09 5-2 -00 ......09 6-17 -00 .......09 5-3 -00 ......09 6-18 -00 .......09 5-4 -00 ......09 6-19 -00 .......09 5-5 -00 ......09 6-20 -00 .......09...

  • Page 6: 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 7: Abbreviations/Symbols/Conventions

    FOREWORD QUASAR 125-180 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 = degrees Fahrenheit ±...
  • Page 8 FOREWORD QUASAR 125-180 T.E. = hexagonal head T.P. = flat head screw = Twin Spark Ignition UPSIDE- DOWN = inverted fork = Volt = Watt Ø = Diameter - 7 - Release 00/2003 - 06...
  • Page 9 FOREWORD QUASAR 125-180 NOTE - 8 - Release 00/2003 - 06...
  • Page 10 GENERAL INFORMATION QUASAR 125-180 GENERAL INFORMATION - 1 - Release 00/2003 - 09...
  • Page 11 GENERAL INFORMATION QUASAR 125-180 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 ENGINE OIL ..............................

  • Page 12: Conventions Used In The Manual

    GENERAL INFORMATION QUASAR 125-180 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. - The terms "right"...

  • Page 13: General Safety Rules

    GENERAL INFORMATION QUASAR 125-180 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 indoor. Use an exhaust emission extraction plant when working indoor. Exhaust emissions contain carbon oxide, which is a poisonous gas and may lead to loss of conscience or even death.

  • Page 14: Engine Oil

    GENERAL INFORMATION QUASAR 125-180 1.3.5 ENGINE OIL SUPERMOTOROIL SAE 15W - 40 or F1 SUPERMOTOROIL 15W-40. As an alternative to recommended fluids it is possible to use high-quality fluids having equal or higher ratings with respect to A.P.I. SJ/eF specifications. Insufficient lubrication or the use of unsuitable lubricants may result in irreparable damage due to increased wear and tear of the moving parts.

  • Page 15: General Precautions And Information

    GENERAL INFORMATION QUASAR 125-180 1.3.7 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 16: Reassembling The Components

    NOTE 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 17: Warnings Regarding Fuel, Lubricants And Other Components

    GENERAL INFORMATION QUASAR 125-180 WARNINGS REGARDING FUEL, LUBRICANTS AND OTHER COMPONENTS 1.4.1 FUEL The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refuelling or in the proximity of sources of fuel vapours.

  • Page 18: Lubricants

    GENERAL INFORMATION QUASAR 125-180 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. Prolonged or repeated contact with lubricant may cause severe skin damage.

  • Page 19: 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 20: Technical Data

    GENERAL INFORMATION QUASAR 125-180 TECHNICAL DATA QUASAR 125 QUASAR 180 DIMENSIONS Length 1790 mm GRIP 1675 mm (HP) 1790 mm GRIP 1675 mm (HP) Width 970 mm (GRIP/HP) 970 mm (GRIP/HP) Max. height (to handlebars) 1060 mm (GRIP/HP) 1060 mm (GRIP/HP) Wheel base 1065 mm (GRIP/HP) 1065 mm (GRIP/HP)
  • Page 21 GENERAL INFORMATION QUASAR 125-180 QUASAR 125 QUASAR 180 WHEEL RIMS Type steel steel Front 10X5.5 10X5.5 Rear 8X8.0 8X8.0 TYRES Type tubeles tubeles Front HP 21x7-10 21x7-10 Rear HP 22x11-8 22x11-8 Front GRIP AT 21x7-10 AT 21x7-10 Rear GRIP AT 21x10-8 AT 21x10-8 Inflating pressure 20 - 25 kPa (0,20 - 0,25 bar)

  • Page 22: Lubricant Chart

    GENERAL INFORMATION QUASAR 125-180 LUBRICANT CHART LUBRICANT PRODUCT RECOMMENDED: PONTIAX HDI SAE 85W - 140 or ROTRA MP 85W-140. Transmission oil As an alternative to recommended fluids it is possible to use high-quality fluids having equal or higher ratings with respect to A.P.I. GL-5 specifications. RECOMMENDED: SUPERMOTOROIL SAE 15W - 40 or F1 SUPERMO-...

  • Page 23: Special Tools

    GENERAL INFORMATION QUASAR 125-180 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 vehi- cle are listed below.

  • Page 24: Torque Figures

    GENERAL INFORMATION QUASAR 125-180 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 torque Spanner bolt M 10 M 12 M 14 M 16 13.0 For vehicle-specific fastenings see 2.2 (FASTENERS).
  • Page 25 GENERAL INFORMATION QUASAR 125-180 NOTE - 16 - Release 00/2003 - 09...
  • Page 26 PERIODIC MAINTENANCE QUASAR 125-180 PERIODIC MAINTENANCE - 1 - Release 00/2003 - 09...
  • Page 27 PERIODIC MAINTENANCE QUASAR 125-180 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 SWITCH ................................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 28: 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 29: Fasteners

    PERIODIC MAINTENANCE QUASAR 125-180 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 Note Component Spark plug Throttle control covers Oil filter cover Flywheel retaining nut Camshaft flange nut...

  • Page 30: Periodic Maintenance Chart

    PERIODIC MAINTENANCE QUASAR 125-180 PERIODIC MAINTENANCE CHART Post running-in checks Components Monthly Six-monthly Yearly (after 2 weeks) 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...

  • Page 31: Lubrication

    PERIODIC MAINTENANCE QUASAR 125-180 LUBRICATION Proper lubrication is critical to ensuring smooth operation and preserving vehicle life. NOTE 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 32: Main Switch

    PERIODIC MAINTENANCE QUASAR 125-180 2.4.2 MAIN SWITCH The main switch (1) is at the right side of the motorcycle, on the front fairing. NOTE The key turns on the main switch and enables the use of the light dip switch, when it is in the " "...

  • Page 33: Battery

    PERIODIC MAINTENANCE QUASAR 125-180 BATTERY Read carefully 1.3.6 (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 34: Checking The Electrolyte Battery Level

    PERIODIC MAINTENANCE QUASAR 125-180 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 NOTE 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 35: Spark Plug

    PERIODIC MAINTENANCE QUASAR 125-180 SPARK PLUG Read carefully 1.3 (GENERAL SAFETY RULES). Check the spark plug every six months, remove carbon deposits and replace if necessary. Removal and cleaning. Before carrying out the following operations, let the engine and the exhaust pipe cool down until they reach room temperature, in order to avoid burns.

  • Page 36: Idling Adjustment

    PERIODIC MAINTENANCE QUASAR 125-180 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 37: Air Cleaner

    PERIODIC MAINTENANCE QUASAR 125-180 2.10 AIR CLEANER Read carefully 1.3 (GENERAL SAFETY RULES). Check the condition and cleanliness of the air cleaner every month, replace, if needed. Plug the opening with a clean cloth, in order to prevent any foreign matter to get into the suction ducts.

  • Page 38: Engine Oil

    PERIODIC MAINTENANCE QUASAR 125-180 2.11.1 ENGINE OIL Carefully read 1.3 (GENERAL SAFETY RULES). Change engine oil after the first two weeks (after running-in period) and then every six months, 2.3 (PERIODIC MAINTENANCE CHART). NOTE Use only recommended oil, see 1.8 (LUBRICANT CHART). When topping up engine oil, do not exceed the "MAX"...

  • Page 39: Changing The Engine Oil And The Engine Oil Filter

    PERIODIC MAINTENANCE QUASAR 125-180 2.11.2 CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER Carefully read 1.3 (GENERAL SAFETY RULES). Clean engine oil filter every six months. " Place the vehicle on firm and level ground. Allow for the engine and the exhaust system to cool down. "...

  • Page 40: Checking The Transmission Oil Level

    PERIODIC MAINTENANCE QUASAR 125-180 2.12 CHECKING THE TRANSMISSION OIL LEVEL DO NOT RELEASE OIL INTO THE ENVIRONMENT Carefully read 1.3 (GENERAL SAFETY RULES), 1.4.2 (LUBRICANTS) and 1.8 (LUBRICANT CHART). Check the bottom part of the transmission: if any oil residue is found, then replace the oil seal, see 3.6.11 (REMOVING THE FINAL DRIVE GEARS) Run a transmission oil change every sixth months.

  • Page 41: Checking And Adjusting The Brakes

    PERIODIC MAINTENANCE QUASAR 125-180 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. Check brake efficiency before every use.

  • Page 42: Checking The Steering

    PERIODIC MAINTENANCE QUASAR 125-180 2.14 CHECKING THE STEERING Read carefully 1.3 (GENERAL SAFETY RULES). Run the first check after the first two weeks, then every six months 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 125-180 2.16 INSPECTING THE REAR SUSPENSION Read carefully 1.3 (GENERAL SAFETY RULES). Check the rear suspension every six months. 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 125-180 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 front and/or the rear sprocket.

  • Page 45: Multifunction Computer

    PERIODIC MAINTENANCE QUASAR 125-180 If the chain rollers are damaged, the pins are loose and/or the O-rings are damaged or missing, it is necessary to change the whole chain unit (both sprockets and chain). Lubricate the chain frequently, especially if there are dry or rusty parts. CLEANING AND LUBRICATION Carry out the adjustment, lubrication, cleaning and change of the chain with great care.
  • Page 46 PERIODIC MAINTENANCE QUASAR 125-180 Main components 1) "SET / RESET" push button for timer start/stop 2) Function selection "MODE" push button 3) Speed display 4) Units of measurement of the displayed speed KM/H 5) Time display 6) Function indicator 7) Battery cover 8) Contacts Accessories: - mounting support...
  • Page 47 PERIODIC MAINTENANCE QUASAR 125-180 Speed function (a) The speed function is automatically enabled upon battery installation. ODO function (b) The ODO function indicates the total distance covered by the vehicle. KM/H The counter will be automatically reset when reaching 10,000 Km. NOTE When the multifunction computer battery is removed, all stored values will be deleted.

  • Page 48: Toe In

    PERIODIC MAINTENANCE QUASAR 125-180 2.20 TOE IN Park the vehicle on an even ground with the front wheels facing ahead. Mark wheels centre to indicate the axle height. Measure the wheelbase between the two marks. Carefully move the vehicle back, turning the wheels by 180° so as to align the wheel marks with the axle height.
  • Page 49 PERIODIC MAINTENANCE QUASAR 125-180 NOTE - 24 - Release 00/2003 - 09...
  • Page 50 ENGINE QUASAR 125-180 ENGINE - 1 - Release 00/2003 - 09...
  • Page 51 ENGINE QUASAR 125-180 ENGINE CONTENTS 3.1.1 COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE INSTALLED ..........3-4-00 3.1.2 REMOVING THE ENGINE FROM THE FRAME ..................... 3-5-00 3.1.3 FITTING THE ENGINE IN THE FRAME......................3-8-00 HEAD UNIT ..........................3-9-00 3.2.1 REMOVING PROTECTION FAN........................3-9-00 3.2.2 REMOVING FLYWHEEL UPPER AND LOWER HOUSINGS ................
  • Page 52 / ENGINE QUASAR 125-180 ENGINE INDEX 3.6.15 CHECKING THE TRANSMISSION UNIT ..................... 3-41-00 3.6.16 REFITTING THE TRANSMISSION UNIT...................... 3-42-00 CRANKCASE - CRANKSHAFT ....................3-43-00 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 ....................

  • Page 53: Components That Can Be Removed With The Engine Installed

    ENGINE QUASAR 125-180 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 - Chain tensioner FRONT END - Tappet cover - Camshaft - Engine oil cooler...

  • Page 54: Removing The Engine From The Frame

    ENGINE QUASAR 125-180 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 shields, see 6.1.5 (REMOVING THE FRONT SHIELD) and see 6.1.6 (REMOVING THE REAR SHIELD).
  • Page 55 ENGINE QUASAR 125-180 " Disconnect the spark plug cap (4). 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. " Remove carburettor, see 4.3 (REMOVING THE CARBURETTOR). "...
  • Page 56 ENGINE QUASAR 125-180 " Remove chain, see 6.7.1 (DISASSEMBLING THE CHAIN). " Loosen and remove the five screws (10) and remove bottom panel (11). " Drain off all engine oil, see 2.11.1 (ENGINE OIL). " Remove engine oil lines, see 3.8.2 (REMOVING THE ENGINE OIL LINES). "! Loosen and remove the rear screw (12) between engine and frame.

  • Page 57: Fitting The Engine In The Frame

    ENGINE QUASAR 125-180 3.1.3 FITTING THE ENGINE IN THE FRAME Read carefully 1.3 (GENERAL SAFETY RULES). NOTE To refit the engine in the frame, reverse the removal procedure, see 3.1.2 (REMOVING THE ENGINE FROM THE FRAME). Before proceeding, however, you will have to perform the operations detailed below.

  • Page 58: Head Unit

    ENGINE QUASAR 125-180 HEAD UNIT 3.2.1 REMOVING PROTECTION FAN NOTE Engine can be left assembled on frame. " Remove right footrest, 6.1.7 (REMOVING THE FOOTREST). " Loosen and remove the four screws (1- 2). " Remove flywheel housing (3) 3.2.2 REMOVING FLYWHEEL UPPER AND LOWER HOUSINGS NOTE Engine can be left assembled on frame.

  • Page 59: Removing The Head

    ENGINE QUASAR 125-180 3.2.4 REMOVING THE HEAD NOTE Engine can be left assembled on frame. " Drain off all engine oil, see 2.11.1 (ENGINE OIL). " Put a cloth under the head. " Remove clip (1) and disconnect pipe (2). "...

  • Page 60: Removing Camshaft Complete Mount

    ENGINE QUASAR 125-180 3.2.6 REMOVING CAMSHAFT COMPLETE MOUNT NOTE Engine can be left assembled on frame. " Remove head cover, see 3.2.1 (REMOVING PROTECTION FAN). " Loosen and remove the four screws (1). Screws (1) tightening torque: 9 Nm (0.9 kgm). "...

  • Page 61: Refitting The Rocker Arms

    ENGINE QUASAR 125-180 3.2.8 REFITTING THE ROCKER ARMS " Position plate (1) 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.

  • Page 62: Removing The Camshaft

    ENGINE QUASAR 125-180 3.2.9 REMOVING THE CAMSHAFT NOTE Engine can be left assembled on frame. " Remove chain tensioner, see 3.2.5 (REMOVING THE TENSIONER). " Remove the complete camshaft mount, see 3.2.6 (REMOVING CAMSHAFT COMPLETE MOUNT). " Remove chain (1) from camshaft (2) ring gear. "...

  • Page 63: Refitting The Camshaft

    ENGINE QUASAR 125-180 3.2.11 REFITTING THE CAMSHAFT " Remove flywheel housing, see 3.2.2 (REMOVING FLYWHEEL UPPER AND LOWER HOUSINGS). " Move piston to bottom dead centre, by taking care that the flywheel notch (T) is opposite (180°) to the pan fin. "...

  • Page 64: Adjusting Valve Clearance

    ENGINE QUASAR 125-180 3.2.12 ADJUSTING VALVE CLEARANCE Turn engine by hand and re-align the reference marks on toothed gear and camshaft mount, then proceed to valve clearance adjustment. Using a feeler gauge, measure the gap between rocker arm and valve stem. Perform this operation on both valves.

  • Page 65: Removing Valves

    ENGINE QUASAR 125-180 3.2.15 REMOVING VALVES " Remove the head, see 3.2.13 (REMOVING THE HEAD). " Use the special tool to compress valve springs. To avoid valve wrong positioning after disassembly, mark intake and exhaust valves. " Remove intake valve guide oil seal. "...

  • Page 66: Checking Valves And Valve Seats

    ENGINE QUASAR 125-180 3.2.18 CHECKING VALVES AND VALVE SEATS Valves must show no signs of burning, grooves or deformation. Clean off any carbon deposits. Check valve seats on valve head. NOTE Measurements must be taken at valve stems working area ("N") end, radially and in different positions.

  • Page 67: Checking The Head And Cylinder

    ENGINE QUASAR 125-180 3.2.20 CHECKING THE HEAD AND CYLINDER Using a rounded soft scraper, remove any carbon deposits from the head. Take care not to damage the spark plug thread and to avoid aluminium parts. Remove any deposits from the cylinder head combustion chamber. Then measure head flatness.

  • Page 68: Refitting Valves And Head

    ENGINE QUASAR 125-180 3.2.21 REFITTING VALVES AND HEAD " Fit plate and oil seal. " Lubricate valve stems and install them into valve guides. " Fit exhaust valve oil seal, springs, upper seals and collets. " Fit valves using the special tool. Make sure that collets are perfectly assembled;...

  • Page 69: Removing The Cylinder

    ENGINE QUASAR 125-180 3.2.22 REMOVING THE CYLINDER " Remove the head, see 3.2.13 (REMOVING THE HEAD). " Remove seal (1). " Remove upper sliding shoe (2). " Remove cylinder (3). " Remove seal (4). 3.2.23 REMOVING THE PISTON " Remove the cylinder, see 3.2.22 (REMOVING THE CYLINDER). Before removing gudgeon pin circlips, block off casing opening with a clean cloth to prevent them from falling into the engine.

  • Page 70: Checking The Piston

    ENGINE QUASAR 125-180 3.2.25 CHECKING THE PISTON Remove piston rings taking care not to over-enlarge them. Then, using a rounded scraper, remove any carbon deposits from piston crown. To clean piston rings seats, use a waste piston ring. Do not use silundum emery cloth to clean piston crowns or seats asa too high amount of metal would be removed and the silundum particles settling inside the piston will lead to an early wear of cylinder bore and thus to piston corrosion.

  • Page 71: Checking Piston Rings

    ENGINE QUASAR 125-180 3.2.26 CHECKING PISTON RINGS Measure piston rings side clearance with a feeler gauge. Side clearance: 0.12 mm Check piston rings carefully. Distance between the two ends shall be 0.5 mm. To check, use a feeler gauge and insert the piston ring horizontally inside the cylinder.

  • Page 72: Refitting The Piston

    ENGINE QUASAR 125-180 3.2.28 REFITTING THE PISTON " Refit piston rings as shown in the figure and taking care not to damage them. NOTE Piston rings are correctly assembled when the reference mark is facing up. After assembling, piston rings can move freely into their seats. Centre ring shall be fitted with the tooth facing down.

  • Page 73: Alternator

    ENGINE QUASAR 125-180 ALTERNATOR 3.3.1 REMOVING THE COOLING FAN NOTE Engine can be left assembled on frame. " Remove the fan guard, see 3.2.1 (REMOVING PROTECTION FAN). " Loosen and remove the four screws (1). Save the washers. " Remove cooling fan (2). 3.3.2 REMOVING THE ALTERNATOR "...

  • Page 74: Removing The Freewheeling Clutch

    ENGINE QUASAR 125-180 3.3.4 REMOVING THE FREEWHEELING CLUTCH " Remove the alternator, see 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"...

  • Page 75: Checking The Starter Clutch

    ENGINE QUASAR 125-180 3.3.5 CHECKING THE STARTER CLUTCH Check the starter clutch. Push needle roller bearings along the arrows direction and check that they can move freely inside their seat and go back to their original position. If necessary, change them. Check gear teeth, freewheeling clutch (1) outer and inner surface and roller bearing for wear.

  • Page 76: Oil Pump

    ENGINE QUASAR 125-180 OIL PUMP 3.4.1 REMOVING THE OIL PUMP " Drain off all engine oil, 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). "...

  • Page 77: Checking The Oil Pump

    ENGINE QUASAR 125-180 3.4.2 CHECKING THE OIL PUMP Carefully check the oil pump. Even if really seldom, excessive wear or malfunctioning can modify pump calibrating values. In case pump does not seem to work properly, check the pump drive gear for wear and, if necessary, change it.

  • Page 78: Starter Motor

    ENGINE QUASAR 125-180 STARTER MOTOR 3.5.1 REMOVING THE STARTER MOTOR NOTE Engine can be left assembled on frame. In case of starter motor (1) faulty operation, before removing this part, check electrical connections and, if necessary, restore them. " Loosen and remove the screw (2). "...

  • Page 79: Starting System

    ENGINE QUASAR 125-180 STARTING SYSTEM 3.6.1 REMOVING THE STARTING SYSTEM NOTE Engine can be left assembled on frame. " Remove left footrest, 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). "...

  • Page 80: Refitting The Starting System

    ENGINE QUASAR 125-180 3.6.2 REFITTING THE STARTING SYSTEM " Refit the return spring (1) first, and then the starter shaft (2). NOTE Make sure that the reference mark (3) on the starter shaft (2) is facing the sliding gear (4) axis. "...

  • Page 81: Removing The Primary Belt Roller

    ENGINE QUASAR 125-180 3.6.3 REMOVING THE PRIMARY BELT ROLLER NOTE Engine can be left assembled on frame. " Remove the converter casing, see 3.6.1 (REMOVING THE STARTING SYSTEM). " Loosen and remove the belt roller nut (1) using the special tool (converter locking spanner part no.

  • Page 82: Checking The Primary Belt Roller

    ENGINE QUASAR 125-180 3.6.4 CHECKING THE PRIMARY BELT ROLLER Check the primary (fixed and mobile) belt roller and the bushing for wear, cracks, scores or other damages. Change, if necessary. Check that bushing runs smoothly and without jams inside the primary (mobile) belt roller.

  • Page 83: Removing The Clutch And The Secondary Belt Roller

    ENGINE QUASAR 125-180 3.6.5 REMOVING THE CLUTCH AND THE SECONDARY BELT ROLLER " Remove the converter casing, see 3.6.1 (REMOVING THE STARTING SYSTEM). " Loosen and remove nut (1) with the special tool (clutch housing and flywheel locking tool part no. 8900675). The clutch nut is strongly tightened;...

  • Page 84: Changing The Clutch Blocks

    ENGINE QUASAR 125-180 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. "...

  • Page 85: Checking The Clutch

    ENGINE QUASAR 125-180 3.6.7 CHECKING THE CLUTCH Check clutch inner surface. In case of scoring or rust, remove and clean with emery cloth. Then measure inner diameter. Wear limit: 125.5 mm. Check clutch blocks. If necessary grind with rough emery cloth and, once finished, thoroughly clean the unit.

  • Page 86: Refitting The Secondary Belt Roller

    ENGINE QUASAR 125-180 3.6.10 REFITTING THE SECONDARY BELT ROLLER Before fitting the belt roller, thoroughly clean the sliding surface and, if necessary, apply some grease inside the fixed split belt roller (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.

  • Page 87: Removing The Final Drive Gears

    ENGINE QUASAR 125-180 3.6.11 REMOVING THE FINAL DRIVE GEARS " Drain off all transmission oil, see 2.12 (CHECKING THE TRANSMISSION OIL LEVEL). " Remove clutch, see 3.6.5 (REMOVING THE CLUTCH AND THE SECONDARY BELT ROLLER). NOTE Block off the final drive casing with a cloth to collect any oil leaks. "...

  • Page 88: Removing The Selector Shaft

    ENGINE QUASAR 125-180 " Remove shaft (6) with toothed 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).

  • Page 89: Removing The Gear Selector Spindle

    ENGINE QUASAR 125-180 3.6.13 REMOVING THE GEAR SELECTOR SPINDLE NOTE Engine can be left assembled 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). "...

  • Page 90: Checking The Transmission Unit

    ENGINE QUASAR 125-180 3.6.15 CHECKING THE TRANSMISSION UNIT Check that the following gears: - reverse gear shaft (1) - forward gear shaft (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.

  • Page 91: Refitting The Transmission Unit

    ENGINE QUASAR 125-180 3.6.16 REFITTING THE TRANSMISSION UNIT The following operations apply to the right casing. " Fit toothed gear (2) onto shaft (1) using snap ring. " Install the complete shaft (1) inside casing. " To fit selector (3) to shaft (1), engage the selector arm tooth (4) with the selector (3) slot.

  • Page 92: Crankcase - Crankshaft

    ENGINE QUASAR 125-180 CRANKCASE - CRANKSHAFT 3.7.1 REMOVING THE CRANKSHAFT " Remove piston, see 3.2.23 (REMOVING THE PISTON). " Remove the complete oil pump, see 3.4.1 (REMOVING THE OIL PUMP). " Remove the starting system, see 3.6.1 (REMOVING THE STARTING SYSTEM).

  • Page 93: Checking The Crankcase, The Crankshaft And The Connecting Rod

    ENGINE QUASAR 125-180 3.7.2 CHECKING THE CRANKCASE, THE CRANKSHAFT AND THE CONNECTING ROD - Thoroughly check crankshaft main bearings. Turn them and, in case of jamming, change both crankshaft and bearings. - Check bearing seats on crankshaft for wear or scoring. - Check connecting rod.

  • Page 94: Refitting The Crankcase

    ENGINE QUASAR 125-180 3.7.4 REFITTING THE CRANKCASE Grease oil seals and oil bearings to prevent crankshaft (1) from being scored and to make assembly operation easier. " Heat the left casing with an automatic heater up to about 150°C (~ 10 minutes).

  • Page 95: Refitting The Crankshaft Oil Seal

    ENGINE QUASAR 125-180 3.7.5 REFITTING THE CRANKSHAFT OIL SEAL " Working on engine left side, refit the oil seal (1) first, 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.

  • Page 96: Lubrication System

    ENGINE QUASAR 125-180 LUBRICATION SYSTEM 3.8.1 REMOVING THE ENGINE OIL COOLER " Put a container under the oil cooler. " Loosen and remove the four screws (1). " Keep pipes (2) up and remove them. Save the two O-rings. "! Loosen and remove the two screws (3).
  • Page 97 ENGINE QUASAR 125-180 NOTES - 48 - Release 00/2003 - 09...
  • Page 98 FUEL SYSTEM QUASAR 125-180 FUEL SYSTEM - 1 - Release 00/2003 - 09...
  • Page 99 FUEL SYSTEM QUASAR 125-180 FUEL SYSTEM CONTENTS MAINTENANCE........................4-3-00 DRAINING THE FUEL TANK ....................4-3-00 4.2.1 CARBURETTOR ............................. 4-4-00 4.2.2 CARBURETTOR FEATURES ......................... 4-4-00 REMOVING THE CARBURETTOR .................... 4-5-00 - 2 - Release 00/2003 - 09...

  • Page 100: Maintenance

    FUEL SYSTEM QUASAR 125-180 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. DRAINING THE FUEL TANK Read carefully 1.3 (GENERAL SAFETY RULES).

  • Page 101: Carburettor

    FUEL SYSTEM QUASAR 125-180 4.2.1 CARBURETTOR Key: 1) Starter valve 2) Circlip 3) Choke 4) Maximum flow #110 5) Maximum flow #35 6) Float 7) Filter 8) Needle valve 9) Cable guide 10) Fitting 4.2.2 CARBURETTOR FEATURES COMPONENTS FEATURES Intake manifold ø...

  • Page 102: Removing The Carburettor

    FUEL SYSTEM QUASAR 125-180 REMOVING THE CARBURETTOR NOTE Close the fuel tap to avoid fuel leaks. Place a cloth below the carburettor to collect any spillage. " Disconnect fuel (1) and vacuum (2) lines from tap (3). " Disconnect vacuum line (2) from manifold (4). "...
  • Page 103 FUEL SYSTEM QUASAR 125-180 NOTES - 6 - Release 00/2003 - 09...
  • Page 104 ELECTRIC SYSTEM QUASAR 125-180 ELECTRIC SYSTEM - 1 - Release 00/2003 - 09...
  • Page 105 ELECTRIC SYSTEM QUASAR 125-180 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 STARTER MOTOR - BATTERY RECHARGE - GENERATOR..............5-5-00 5.3.2 CHECKING THE CHARGE VOLTAGE......................5-6-00 5.3.3 RECTIFIER ..............................5-6-00 IGNITION SYSTEM ........................

  • Page 106: Foreword

    ELECTRIC SYSTEM QUASAR 125-180 FOREWORD Please read the following information before reading this section. NOTE 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 Blue White Yellow...

  • Page 107: Electrical Components

    ELECTRIC SYSTEM QUASAR 125-180 ELECTRICAL COMPONENTS Key: 17) Stoplight switch 1) Front direction indicators 18) Starter motor 2) Rear direction indicators 19) Spark plug 3) Tail light 20) Fuel sensor 4) Headlight 21) Sensors control unit 5) Left-hand switch 22) Automatic starter 6) Dashboard 23) Earth 7) Hazard lights relay...

  • Page 108: Troubleshooting

    ELECTRIC SYSTEM QUASAR 125-180 TROUBLESHOOTING 5.3.1 STARTER MOTOR - BATTERY RECHARGE - GENERATOR Start logic Lights Brakes consent 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 - 5 -...

  • Page 109: Checking The Charge Voltage

    ELECTRIC SYSTEM QUASAR 125-180 5.3.2 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 110: Ignition System

    ELECTRIC SYSTEM QUASAR 125-180 IGNITION SYSTEM Key: 28)Voltage regulator 29)Coil 30)Spark plug 31)Pick-Up sensor 32)Generator 34)C.D.I. - 7 - Release 00/2003 - 09...

  • Page 111: High Tension Coil

    ELECTRIC SYSTEM QUASAR 125-180 5.4.1 HIGH TENSION COIL Read carefully 1.3 (GENERAL SAFETY RULES). " Remove the cylinder guard, see 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.

  • Page 112: Checking The Generator Idle Operation

    ELECTRIC SYSTEM QUASAR 125-180 CHECKING THE GENERATOR IDLE OPERATION " Disconnect regulator cables connector. " Start engine and reach 3000 rpm, with the gear in neutral. " Using a portable tester, measure voltage along the cables (alternate current a.c.). Standard idle voltage: above the values specified in the diagram. 30 V 40 V CHECKING THE ALTERNATOR CONTINUITY...

  • Page 113: Automatic Starter

    ELECTRIC SYSTEM QUASAR 125-180 AUTOMATIC 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). Ω R=31 ± 10% - 10 - Release 00/2003 - 09...

  • Page 114: Checking The C.d.i. Control Unit

    ELECTRIC SYSTEM QUASAR 125-180 CHECKING THE C.D.I. CONTROL UNIT " The ignition control unit is of the capacitive discharge type, with digitally- controlled ignition advance based on engine rpm. The control unit is equipped with two connectors. A - Starting enabling B - Earth 1)Coil control 2)Earth...

  • Page 115: Fuel Level Sensor

    ELECTRIC SYSTEM QUASAR 125-180 5.10 FUEL LEVEL SENSOR " Disconnect the two-way connector (8) from the fuel level sensor (45). " Check pointer " With a 5.6 Ω resistance, connect the 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.

  • Page 116: Switches

    ELECTRIC SYSTEM QUASAR 125-180 5.11 SWITCHES " Using a portable tester, check switches continuity. Please, refer to the special diagram. In case of faults, change the part. 1) Horn button ( Cables 2) Dip switch ( Cables G/N G/R V/N "...
  • Page 117 ELECTRIC SYSTEM QUASAR 125-180 6) Front Stop switch Cables 7) Rear Stop switch Cables V/R V/G 8) Pedal stop switch Cables - 14 - Release 00/2003 - 09...

  • Page 118: Starting Circuit

    ELECTRIC SYSTEM QUASAR 125-180 5.12 STARTING CIRCUIT 5.12.1 WIRING DIAGRAM To rectifier To inition relay V/Bi V/Bi 3)Neutral repeater light 7)Key-operated switch 12)Left 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 "...

  • Page 119: Troubleshooting

    ELECTRIC SYSTEM QUASAR 125-180 5.12.2 TROUBLESHOOTING THE STARTER MOTOR DOES NOT RUN " Check the ignition relay. " Check battery (CHECKING THE BATTERY). " Check the 15A fuse. " Check starter motor cables connectors. " Check the ignition relay (CHECKING THE IGNITION RELAY). "...
  • Page 120 ELECTRIC SYSTEM QUASAR 125-180 CHECKING THE RESISTORS " Disconnect the two-way connector positioned close to resistors. " Measure resistance on yellow and black cables. Standard values: 4.5 Ω ± 10 %. CHECKING THE START BUTTON " " " Disconnect button connector. "...

  • Page 121: Bulbs

    ELECTRIC SYSTEM QUASAR 125-180 5.13 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.
  • Page 122 ELECTRIC SYSTEM QUASAR 125-180 5.13.1 CHANGING THE DIRECTION INDICATOR BULBS V/SCR To rectifier V/SCR M/Bi M/SCR M/SCR Horn button V/SCR Parts: 5)Hazard repeater light 7)Key-operated switch 8)Hazard flasher with buzzer 9)Flasher with buzzer 10)Horn 17)Right rear direction indicator 20)Left rear direction indicator 37)Left front direction indicator 41)Right front direction indicator Read carefully 5.13 (BULBS).

  • Page 123: Changing The Headlight Bulbs

    ELECTRIC SYSTEM QUASAR 125-180 5.13.2 CHANGING THE HEADLIGHT BULBS Read carefully 5.13 (BULBS). The headlight contains: - a high / low beam bulb; - a parking light bulb. " Disconnect connector (1). "! Loosen and remove screw (2). Save washer. "...

  • Page 124: Changing The Tail Light Bulb

    ELECTRIC SYSTEM QUASAR 125-180 5.13.3 CHANGING THE TAIL LIGHT BULB Read carefully 5.13 (BULBS). To change the bulb, 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. STOP LIGHTS To rectifier To inition relay...

  • Page 125: Changing The Handlebar Cover Lights

    ELECTRIC SYSTEM QUASAR 125-180 HIGH-LOW BEAM - PARKING LIGHTS Key-operated ana - aba B/Bi B/Bi B/Bi Parts: 2)High beam repeater light 4)Parking light repeater light 7)Key-operated switch with parking light switch 11)Left dip switch 18)Rear twin-light bulb 21)Number plate light 28)Voltage regulator 39)Front parking light bulb 40)Front twin-light bulb...

  • Page 126: Adjusting The Headlight Beam

    ELECTRIC SYSTEM QUASAR 125-180 5.13.5 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 127: Wiring Diagram

    ELECTRIC SYSTEM QUASAR 125-180 5.14 WIRING DIAGRAM N/Bi Bi/N Bi/N B/Bi B/Bi V/Bi Bi/B Bi/B B/Bi B/Bi Bi/N Bi/N B/Bi M/Bi B/Bi B/Bi 15 A M/Bi M/Bi R/Bi M/scr Gr/scr V/scr V/scr Gr/scr V/scr Bi/Ar V/Bi V/Bi V/Bi - 24 - Release 00/2003 - 09...
  • Page 128 ELECTRIC SYSTEM QUASAR 125-180 Key: 1) Multiple connectors 2) Parking light repeater light 3) Neutral repeater light 4) High beam repeater light 5) Hazard repeater light 6) Fuel level instrument 7) Key-operated switch with parking light switch 8) Hazard flasher with buzzer 9) Flasher with buzzer 10) Horn 11) Left dip switch...
  • Page 129 ELECTRIC SYSTEM QUASAR 125-180 NOTES - 26 - Release 00/2003 - 09...
  • Page 130 CYCLE PARTS QUASAR 125-180 CYCLE PARTS - 1 - Release 00/2003 - 09...
  • Page 131 CYCLE PARTS QUASAR 125-180 CYCLE PARTS CONTENTS BODYWORK ..........................6-3-00 6.1.1 REMOVING THE SEAT........................... 6-5-00 6.1.2 REMOVING THE DASHBOARD ........................6-5-00 6.1.3 REMOVING THE HEADLIGHT ........................6-6-00 6.1.4 REMOVING THE HANDLEBARS ........................6-7-00 6.1.5 REMOVING THE FRONT SHIELD........................6-9-00 6.1.6 REMOVING THE REAR SHIELD ........................

  • Page 132: Bodywork

    CYCLE PARTS QUASAR 125-180 BODYWORK 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 - 3 - Release 00/2003 - 09...
  • Page 133 CYCLE PARTS QUASAR 125-180 1) Tail light 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 - 4 -...

  • Page 134: Removing The Seat

    CYCLE PARTS QUASAR 125-180 6.1.1 REMOVING 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.

  • Page 135: Removing The Headlight

    CYCLE PARTS QUASAR 125-180 6.1.3 REMOVING THE HEADLIGHT " Disconnect connector (1). "! Loosen and remove the two screws (2). " Remove the complete headlight with subframe (3). - 6 - Release 00/2003 - 09...

  • Page 136: Removing The Handlebars

    CYCLE PARTS QUASAR 125-180 6.1.4 REMOVING THE HANDLEBARS " Remove the dashboard, see 6.1.2 (REMOVING THE DASHBOARD). " Remove headlight, see 6.1.3 (REMOVING THE HEADLIGHT). " Loosen adjusting nut (1). " Remove rear brake cable (2) from its seat. " Fully loosen the two locking washers (3).
  • Page 137 CYCLE PARTS QUASAR 125-180 " Loosen and remove the two screws (9). " Remove mount (10). " Loosen and remove the four screws (11). " Remove the two braces (12). " Remove handlebars. - 8 - Release 00/2003 - 09...

  • Page 138: Removing The Front Shield

    CYCLE PARTS QUASAR 125-180 6.1.5 REMOVING THE FRONT SHIELD " Remove handlebars see 6.1.3 (REMOVING 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. "...

  • Page 139: Removing The Rear Shield

    CYCLE PARTS QUASAR 125-180 " Remove the front shield (6). 6.1.6 REMOVING THE REAR SHIELD " 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).

  • Page 140: Removing The Footrest

    CYCLE PARTS QUASAR 125-180 6.1.7 REMOVING THE FOOTREST " Loosen and remove the five screws (1). Save washers and nuts. " Loosen and remove the five screws (2). Save washers and nuts. " Loosen the four screws (3). Save washers and nuts. "...

  • Page 141: Removing The Battery

    CYCLE PARTS QUASAR 125-180 6.1.9 REMOVING THE BATTERY " Turn main switch to " ". " Remove the seat, see 6.1.1 (REMOVING THE SEAT). " Release the elastic strip. " Loosen and remove screw (1) on negative terminal (-). " Move negative cable (2) aside.

  • Page 142: Removing The Fuel Tank

    CYCLE PARTS QUASAR 125-180 6.1.10 REMOVING THE FUEL TANK " Remove the front 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). "...

  • Page 143: Removing The Control Unit

    CYCLE PARTS QUASAR 125-180 6.1.11 REMOVING THE CONTROL UNIT Carefully read see 1.3 (GENERAL SAFETY RULES). " Turn main switch to " ". " Disconnect 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).

  • Page 144: Removing The Rear Brake Lever

    CYCLE PARTS QUASAR 125-180 6.1.13 REMOVING THE REAR BRAKE LEVER " Disconnect brake cable, see 6.1.4 (REMOVING THE HANDLEBARS). " Remove switch, see 6.1.12 (REMOVING ELECTRICAL CONTROLS). " Remove twistgrip (1). " Loosen and remove screw (2). " Remove brake lever. 6.1.14 REMOVING THE RIGHT CONTROL "...

  • Page 145: Removing The Main Switch

    CYCLE PARTS QUASAR 125-180 6.1.16 REMOVING THE MAIN SWITCH " Remove ignition key. " Remove the dashboard, see 6.1.2 (REMOVING THE DASHBOARD). " Straighten retainer (1) reeds. " Remove retainer (1). " Remove main switch (2) from outside the dashboard. 6.1.17 REMOVING THE FRONT DIRECTION INDICATORS "...

  • Page 146: Removing The Tail Light

    CYCLE PARTS QUASAR 125-180 6.1.19 REMOVING THE TAIL LIGHT " Turn main switch to " ". " Disconnect connector (1). " Loosen and remove the two nuts (2). Save washers. " Remove tail light (3). 6.1.20 REMOVING THE REAR DIRECTION INDICATORS "...

  • Page 147: Removing The Exhaust Pipe

    CYCLE PARTS QUASAR 125-180 6.1.21 REMOVING THE EXHAUST PIPE " Remove the rear shield, see 6.1.6 (REMOVING 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). "...

  • Page 148: Removing The Wheels

    CYCLE PARTS QUASAR 125-180 6.1.22 REMOVING THE WHEELS " To remove one or both front wheels, raise the front part of frame with a suitable stand, while to remove one or both rear wheels, place the stand under the rear axle. "...

  • Page 149: Removing The Frame

    CYCLE PARTS QUASAR 125-180 6.1.25 REMOVING THE FRAME " Remove engine, see see 3.1.2 (REMOVING THE ENGINE FROM THE FRAME). " Remove horn, see 6.1.18 (REMOVING THE HORN). " Remove the steering unit, see 6.2 (STEERING SYSTEM). " Remove the rear swinging arm, see 6.3 (SWINGING ARM). "...

  • Page 150: Removing The Steering Arm

    CYCLE PARTS QUASAR 125-180 6.2.2 REMOVING THE STEERING ARM " Remove split pin (1). " Loosen and remove nut (2). " Remove split pin (3). " Loosen and remove nut (4). " Remove steering arm (5). NOTE If necessary, repeat the above procedure to remove the other steering arm.

  • Page 151: Removing The Front Shock Absorber

    CYCLE PARTS QUASAR 125-180 6.2.4 REMOVING THE FRONT SHOCK ABSORBER " Raise frame front part on a suitable stand. " Loosen and remove the two screws (1). Save washers and nuts. " Remove front shock absorber (2). 6.2.5 REMOVING SUSPENSION ARM "...

  • Page 152: Removing The Swinging Arm

    CYCLE PARTS QUASAR 125-180 6.3.2 REMOVING THE SWINGING ARM " Remove chain, see 6.7.1 (DISASSEMBLING THE 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).

  • Page 153: Front Brakes

    CYCLE PARTS QUASAR 125-180 FRONT BRAKES 6.4.1 REMOVING THE BRAKE NOTE The following operations apply to both brakes. " Raise frame front part on a suitable stand. " Remove split pin. " Loosen and remove nut (1). Save washer. " Remove wheel with brake drum.

  • Page 154: Checking The Parts

    CYCLE PARTS QUASAR 125-180 6.4.3 CHECKING THE PARTS BRAKE DRUM " Check sliding surface: it shall be free from scoring and /or cracks. In case of minor scores, grind surface with soaked emery cloth (grain 1). " In case of deep scores, change hub (1). BEARINGS "...

  • Page 155: Rear Brake

    CYCLE PARTS QUASAR 125-180 REAR BRAKE 6.5.1 REMOVING THE BRAKE " Raise frame rear part on a suitable stand. " Disconnect brake cables, see 6.3.2 (REMOVING THE SWINGING ARM). " Remove split pin. " Loosen and remove nut (1). Save washer. "...

  • Page 156: Checking The Parts

    CYCLE PARTS QUASAR 125-180 CHECKING THE PARTS BRAKE DRUM " Check sliding surface: it shall be free from scoring and /or cracks. In case of minor scores, grind surface with soaked emery cloth (grain 1). In case of deep scores, change drum (1). SEALS "...
  • Page 157 CYCLE PARTS QUASAR 125-180 NOTES - 28 - Release 00/2003 - 09...
  • Page 158 TROUBLESHOOTING QUASAR 125-180 TROUBLESHOOTING - 1 - Release 00/2003 - 09...
  • Page 159 TROUBLESHOOTING QUASAR 125-180 TROUBLESHOOTING CONTENTS THE ENGINE DOES NOT START ..................... 7-3-00 POOR PERFORMANCE AT IDLE AND LOW SPEED..............7-4-00 POOR PERFORMANCE AT HIGH SPEED ..................7-5-00 EXCESSIVE NOISE LEVEL....................... 7-6-00 EXCESSIVE FUMES ......................... 7-6-00 LOW POWER ..........................7-7-00 POOR VEHICLE MANEUVERABILITY ..................7-8-00 - 2 - Release 00/2003 - 09...

  • Page 160: The Engine Does Not Start

    TROUBLESHOOTING QUASAR 125-180 THE ENGINE DOES NOT START Possible causes Check fuel delivery to carburettor - No fuel - Clogged floater needle - Obstructed fuel tank cap breather hole - Obstructed fuel pipe or fuel filter - Faulty spark plug Check spark plugs - Fouled spark plug Missing or weak spark...

  • Page 161: Poor Performance At Idle And Low Speed

    TROUBLESHOOTING QUASAR 125-180 POOR PERFORMANCE AT IDLE AND LOW SPEED Possible causes Check engine timing - Faulty CDI unit or pick-up sensor Check carburettor and air screw adjustment - Wrong air screw adjustment Check for leaks at the intake manifold - Damaged O-ring - Loose or disconnected ignition system wires Check spark plugs...

  • Page 162: Poor Performance At High Speed

    TROUBLESHOOTING QUASAR 125-180 POOR PERFORMANCE AT HIGH SPEED Possible causes Check engine timing - Faulty CDI unit or ignition coil - No fuel Check fuel delivery to carburettor - Obstructed fuel line Blocked fuel flow - Obstructed fuel filter - Obstructed fuel tank cap breather hole Remove carburettor and check jets - Clean jets Obstructed...

  • Page 163: Excessive Noise Level

    TROUBLESHOOTING QUASAR 125-180 EXCESSIVE NOISE LEVEL Possible causes - Worn valve adjustment Excessive noise level - 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 EXCESSIVE FUMES Possible causes...

  • Page 164: Low Power

    TROUBLESHOOTING QUASAR 125-180 LOW POWER Possible causes Raise wheels from ground and turn them by - Locked brake - Adjust it hand - Drive chain is too tensioned - Damaged axle bearing They do not turn freely - Punctured tyre Check tyres inflation pressure - Wrong inflation pressure Poor inflation pressure...

  • Page 165: Poor Vehicle Maneuverability

    TROUBLESHOOTING QUASAR 125-180 POOR VEHICLE MANEUVERABILITY Possible causes - Damaged steering bearing Hard steering - Damaged steering stem bushing - Bent steering stem - Bent rim One of the wheels vibrates - Wheel hub assembled in a wrong position - Excessive play at the wheel bearing - Damaged suspension - Bent frame - Excessive wear at the swinging arm bush...
  • Page 166 TROUBLESHOOTING QUASAR 125-180 NOTE - 9 - Release 00/2003 - 09...
  • Page 167 TROUBLESHOOTING QUASAR 125-180 NOTE - 10 - Release 00/2003 - 09...
  • Page 168 G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com...

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Quasar 180 2003

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