APRILIA QUASAR 180 2003 Manuals

Manuals and User Guides for APRILIA QUASAR 180 2003. We have 1 APRILIA QUASAR 180 2003 manual available for free PDF download: Workshop Manual

APRILIA QUASAR 180 2003 Workshop Manual

APRILIA QUASAR 180 2003 Workshop Manual (168 pages)

Brand: APRILIA | Category: Motorcycle | Size: 4 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
- 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
- Crankcase - Crankshaft
  92
- 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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