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QUASAR 125 2003
APRILIA QUASAR 125 2003 Manuals
Manuals and User Guides for APRILIA QUASAR 125 2003. We have
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APRILIA QUASAR 125 2003 manual available for free PDF download: Workshop Manual
APRILIA QUASAR 125 2003 Workshop Manual (168 pages)
Brand:
APRILIA
| Category:
Motorcycle
| Size: 4.29 MB
Table of Contents
Foreword
3
Table of Contents
3
Manual Updates
4
List of Manual Pages and Update Numbers
4
Release 00/2003-09 Update
4
Foreword
6
Reference Manuals
6
Owner's Manuals
6
Spare Parts Catalogue
6
Abbreviations/Symbols/Conventions
7
General Information
11
Conventions Used in the Manual
12
Safety Warnings
12
General Safety Rules
13
Carbon Oxide
13
Fuel
13
Hot Component Parts
13
Transmission Oil
13
Engine Oil
14
Hydrogen Gas and Battery Electrolyte
14
General Precautions and Information
15
Before Disassembling any Components
15
Disassembling the Components
15
Reassembling the Components
16
Electrical Connectors
16
Torque Figures
16
1.3.5 Engine Oil
14
Warnings Regarding Fuel, Lubricants and Other Components
17
Fuel
17
Lubricants
18
Location of Serial Numbers
19
Frame Number
19
Engine Number
19
Spare Parts
19
Technical Data
20
Lubricant Chart
22
Special Tools
23
Torque Figures
24
Periodic Maintenance
27
Periodic Maintenance Chart
28
Fasteners
29
Periodic Maintenance Chart
30
Switch
31
Lubrication
31
Main Switch
32
Battery
33
Checking the Electrolyte Battery Level
34
Recharging the Battery
34
Spark Plug
35
Adjusting the Throttle Control
36
Idling Adjustment
36
Air Cleaner
37
Fuel Vapours Filter
37
Engine Oil
38
Changing the Engine Oil and the Engine Oil Filter
39
Checking the Transmission Oil Level
40
Checking and Adjusting the Brakes
41
Checking the Steering
42
Inspecting the Front Suspensions
42
Inspecting the Rear Suspension
43
Wheels
43
Tyres
43
Drive Chain
44
Multifunction Computer
45
Toe in
48
Engine
51
Components that Can be Removed with the Engine Installed
53
Removing the Engine from the Frame
54
Fitting the Engine in the Frame
57
Head Unit
58
Removing Protection Fan
58
Removing Flywheel Upper and Lower Housings
58
Removing the Intake Manifold
58
Removing the Head
59
Removing the Tensioner
59
Removing Camshaft Complete Mount
60
Removing the Rocker Arms
60
Refitting the Rocker Arms
61
Removing the Camshaft
62
Checking Bearing Parts
62
Refitting the Camshaft
63
Adjusting Valve Clearance
64
Removing the Head
64
Checking Valves Sealing Capacity
64
Removing Valves
65
Checks
65
Valve Springs Free Length
65
Checking Valves and Valve Seats
66
Grinding
66
Checking the Head and Cylinder
67
Refitting Valves and Head
68
Removing the Cylinder
69
Removing the Piston
69
Checking the Cylinder
69
Checking the Piston
70
Checking Piston Rings
71
Checking Piston Gudgeon Pin
71
Refitting the Piston
72
Alternator
73
Removing the Cooling Fan
73
Removing the Alternator
73
Checking the Flywheel
73
Removing the Freewheeling Clutch
74
Checking the Starter Clutch
75
Refitting the Freewheeling Clutch
75
Oil Pump
76
Removing the Oil Pump
76
Checking the Oil Pump
77
Refitting the Oil Pump
77
Starter Motor
78
Removing the Starter Motor
78
Refitting the Starter Motor
78
Starting System
79
Removing the Starting System
79
Refitting the Starting System
80
Removing the Primary Belt Roller
81
Checking the Primary Belt Roller
82
Removing the Clutch and the Secondary Belt Roller
83
Changing the Clutch Blocks
84
Checking the Clutch
85
Checking the Secondary Belt Roller
85
Checking the Belt
85
Refitting the Secondary Belt Roller
86
Removing the Final Drive Gears
87
Removing the Selector Shaft
88
Removing the Gear Selector Spindle
89
Removing the Gear Lever Mount
89
Checking the Transmission Unit
90
Refitting the Transmission Unit
91
Crankcase - Crankshaft
92
Removing the Crankshaft
92
Checking the Crankcase, the Crankshaft and the Connecting Rod
93
Removing Engine Rubber Bushing
93
Refitting the Crankcase
94
Refitting the Crankshaft Oil Seal
95
Lubrication System
96
Removing the Engine Oil Cooler
96
Removing the Engine Oil Lines
96
Fuel System
99
Draining the Fuel Tank
100
Carburettor
101
Maintenance
100
Carburettor Features
101
Removing the Carburettor
102
Electric System
105
Foreword
106
Cable Colours
106
Electrical Connectors
106
Electrical Components
107
Troubleshooting
108
Starter Motor - Battery Recharge - Generator
108
Checking the Charge Voltage
109
Rectifier
109
Ignition System
110
High Tension Coil
111
Checking the Alternator Continuity
112
Checking the Generator Idle Operation
112
Checking the Ignition Coil
112
Checking the Pick-Up Sensor
112
Automatic Starter
113
Checking the C.D.I. Control Unit
114
Check Data
114
Fuel Level Sensor
115
Switches
116
Starting Circuit
118
Wiring Diagram
118
Troubleshooting
119
Check Data
119
Bulbs
121
Changing the Headlight Bulbs
123
Changing the Tail Light Bulb
124
Changing the Handlebar Cover Lights
125
Adjusting the Headlight Beam
126
Changing the Fuses
126
Wiring Diagram
127
Cycle Parts
131
Bodywork
132
Removing the Seat
134
Removing the Dashboard
134
Removing the Headlight
135
Removing the Handlebars
136
Removing the Front Shield
138
Removing the Rear Shield
139
Removing the Footrest
140
Removing the Air Filter Case
140
Removing the Battery
141
Removing the Fuel Tank
142
Removing the Control Unit
143
Removing the Electrical Controls
143
Removing the Rear Brake Lever
144
Removing the Right Control
144
Removing the Brake Pedal
144
Removing the Main Switch
145
Removing the Front Direction Indicators
145
Removing the Horn
145
Removing the Tail Light
146
Removing the Rear Direction Indicators
146
Removing the Exhaust Pipe
147
Removing the Wheels
148
Removing the Front Subframe
148
Removing the Footrest Mount
148
Removing the Frame
149
Steering System
149
Removing Steering Yoke with Stem
149
Removing the Steering Arm
150
Removing the Ball Joint
150
Removing the Front Shock Absorber
151
Removing Suspension Arm
151
6.2.3 Removing the Ball Joint
151
Swinging Arm
151
Removing the Rear Shock Absorber
151
Removing the Swinging Arm
152
Front Brakes
153
Removing the Brake
153
Disassembling the Brake Drum
153
Checking the Parts
154
Rear Brake
155
Removing the Brake
155
Chain
156
Disassembling the Chain
156
Refitting the Chain
156
The Engine Does Not Start
160
Poor Performance at Idle and Low Speed
161
Poor Performance at High Speed
162
Excessive Noise Level
163
Excessive Fumes
163
Low Power
164
Poor Vehicle Maneuverability
165
Checking the Parts
156
6.4.2 Disassembling the Brake Drum
154
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