APRILIA SR MAX 125 ie Manuals

Manuals and User Guides for APRILIA SR MAX 125 ie. We have 1 APRILIA SR MAX 125 ie manual available for free PDF download: Service Station Manual

APRILIA SR MAX 125 ie Service Station Manual (280 pages)

Brand: APRILIA | Category: Motorcycle | Size: 40.95 MB

Product View
4
Index of Topics
5
General Specifications
7
Safety Rules
7
Maintenance Rules
7
Characteristics
8
Vehicle Identification
8
Dimensions and Mass
9
Overhaul Data
11
Assembly Clearances
11
Cylinder - Piston Assy.
11
Wheels and Tyres
11
Engine Coupling Categories
12
Crankcase - Crankshaft - Connecting Rod
14
Crankcase - Crankshaft Coupling/Crankshaft Half-Bearing
14
Crankshaft/Crankcase Axial Clearance
15
Cylinder Head
16
Crankshaft Category Identification
16
Head Bearings
17
Standard Valve Length
18
Standart Diameter
18
Minimum Admissable Diameter
18
Exhaust
19
Intake
19
Standard Height
21
Admissable Limits
21
Slot Packing System
22
Products
23
Models with Metal Head Gasket
23
Recommended Products Table
23
Unit of Measure - Conversion
23
Tooling
25
Specific Tools
25
Maintenance Chart
37
Scheduled Maintenance Table
37
Spark Plug
37
Hub Oil Check
38
Hub Oil Replacement
39
Air Filter
39
Engine Oil Replacement
40
Engine Oil Check
41
Engine Oil Filter
42
Oil Pressure Warning Light
42
Cooling System
43
Braking System
44
Level Check
44
Top-Up
44
Headlight Adjustment
45
Troubleshooting
47
Electrical System
51
Components Arrangement
53
Conceptual Diagrams
58
Ignition
58
Battery Recharge and Starting
59
Level Indicators and Enable Signals Section
60
Devices and Accessories
61
Lights and Turn Indicators
63
Checks and Inspections
65
Immobiliser
65
Virgin Circuit
66
Diagnostic Codes
67
Diagnostic Code - 2 Flashes
67
Diagnostic Code - 3 Flashes
68
Ignition Circuit
69
No Spark Plug
69
Stator Check
71
Voltage Regulator Check
73
Recharge System Voltage Check
73
Turn Signals System Check
74
Lights List
74
Fuses
75
Dashboard
76
Sealed Battery
77
Battery Installation
78
Connectors
82
Instrument Panel Connector
82
Tone Wheel Connector
82
Control Unit Connector
83
Antitheft Connector
83
Voltage Regulator Connector
84
Engine from Vehicle
86
Exhaust Assy. Removal
86
Removal of the Engine from the Vehicle
87
Support the Vehicle Adequality
87
Engine
93
Automatic Transmission
93
Transmission Cover
93
Air Duct
93
Removing the Driven Pulley Shaft Bearing
94
Refitting the Driven Pulley Shaft Bearing
94
Removing the Driven Pulley
95
Inspecting the Clutch Drum
95
Inspecting the Clutch
96
Removing the Clutch
97
Pin Retaining Collar
98
Removing the Driven Half-Pulley Bearing
99
Inspecting the Driven Fixed Half-Pulley
100
Inspecting the Driven Sliding Half-Pulley
101
Refitting the Driven Half-Pulley Bearing
101
Movable Driven Half-Pulley Dimensions
101
Fit the Ball Bearing with the Visible Shielding
102
Refitting the Driven Pulley
103
Inspecting the Clutch Spring
103
Refitting the Clutch
104
Drive-Belt
105
Removing the Driving Pulley
106
Inspecting the Rollers Case
107
Refitting the Driving Pulley
108
Refitting the Transmission Cover
109
End Gear
110
Removing the Hub Cover
110
Removing the Wheel Axle
110
Removing the Hub Bearings
111
Removing the Wheel Axle Bearings
111
Inspecting the Hub Shaft
113
Inspecting the Hub Cover
114
Refitting the Wheel Axle Bearing
114
Refitting the Hub Cover Bearings
116
Refitting the Hub Bearings
117
Refitting the Hub Cover
117
Flywheel Cover
118
Removing the Stator
119
Refitting the Stator
120
Refitting the Flywheel Cover
120
Flywheel and Starting
121
Removing the Starter Motor
121
Removing the Flywheel Magneto
121
Inspecting the Flywheel Components
122
Starter Gear Rim
123
Intermediate Gear
123
Refitting the Free Wheel
123
Refitting the Flywheel Magneto
124
Refitting the Starter Motor
125
Cylinder Assy. and Timing System
125
Removing the Intake Manifold
125
Removing the Rocker-Arms Cover
125
Removing the Timing System Drive
126
Removing the Cam Shaft
127
Removing the Cylinder Head
128
Removing the Valves
128
Removing the Cylinder - Piston Assy.
130
Inspecting the Small End
131
Inspecting the Wrist Pin
131
Inspecting the Piston
131
Inspecting the Piston Rings
131
Removing the Piston
132
Choosing the Gasket
132
Refitting the Piston Rings
133
Refitting the Cylinder
134
Inspecting the Cylinder Head
135
Inspecting the Timing System Components
135
Inspecting the Valve Sealings
135
Inspecting the Valves
136
Residual Stroke Check
136
Refitting the Valves
139
Inspecting the Cam Shaft
139
Refitting the Head and Timing System Components
140
Refitting the Rocker-Arms Cover
142
Refitting the Intake Manifold
142
Crankcase - Crankshaft
142
Splitting the Crankcase Halves
142
Crankcase Opening
143
Inspecting the Crankshaft Components
144
Inspecting the Crankshaft Alignment
144
Inspecting the Crankcase Halves
145
Inspecting the Crankshaft Plain Bearings
146
Coupling Chart
146
Refitting the Crankcase Halves
146
Studs
148
Lubrication
149
Oil Pressure Check
150
Crankshaft Oil Seals Removal
151
Crankshaft Oil Seals Refitting
151
Oil Pump
152
Oil Pump Removal
153
Oil Pump Inspection
153
Oil Pump Refitting
154
Removing the Oil Sump
155
Inspecting the By-Pass Valve
156
Refitting the Oil Sump
156
Injection
158
MIU Injection System
159
Transparency
159
Precautions
161
Troubleshooting Hints
161
Terminals Setup
163
Terminal Layout
163
EMS Circuit Diagram
164
Troubleshooting Procedure
165
Engine Does Not Start
165
Starting Difficulties
165
Engine Stops at Idle
166
Engine Does Not Rev down
166
Exhaust Backfires in Deceleration
167
Engine Revs Irregularly
167
Poor Performance at Full Throttle
167
Engine Knocking
168
Fuel Supply System
168
Removing the Butterfly Valve
169
Refitting the Butterfly Valve
171
Pump Supply Circuit
171
Injection Loads
172
Electrical Data
172
Circuit Leak Test
176
Fuel Filter Check
177
Inspecting the Injector Circuit
178
Inspecting the Injector Hydraulics
183
Components Location
184
Tachometer
185
HT Coil
187
Coolant Temperature Sensor
192
Zeroing the Throttle
193
Lambda Probe
194
Signal Control
194
Front Suspensions
201
Removing the Front Wheel
201
Front Wheel Hub Overhaul
201
Refitting the Front Wheel
204
Handlebar Removal
205
Handlebar Refitting
205
Front Fork Removal
205
Overhaul
206
Component Check
208
Front Fork Refitting
210
Steering Column Removal
213
Steering Column Refitting
214
Steering Bearing Removal
217
Steering Fifth Wheel Track Removal
217
Steering Bearing Refitting
218
Steering Fifth Wheel Track Fitting
218
Rear Suspensions
221
Removing the Rear Wheel
221
Refitting the Rear Wheel
223
Swing-Arm Removal
223
Swing-Arm Overhaul
225
Swing-Arm Refitting
228
Shock Absorbers
228
Shock Absorber Removal
229
Shock Absorber Refitting
229
Centre-Stand Removal
229
Centre-Stand Fitting
229
Side Stand Fitting
230
Rear Brake Calliper Removal
232
Rear Brake Calliper Overhaul
232
Rear Brake Calliper Refitting
233
Front Brake Calliper Removal
234
Front Brake Calliper Overhaul
234
Front Brake Calliper Refitting
235
Rear Brake Disc Removal
236
Rear Brake Disc Refitting
236
Rear Brake Disc Inspection
236
Front Brake Disc Removal
238
Front Brake Disc Refitting
238
Front Brake Disc Inspection
238
Front Brake Pads Removal
239
Front Brake Pads Refitting
240
Rear Brake Pads
240
Rear Brake Pads Removal
241
Rear Brake Pads Refitting
241
Fill - Bleeding the Braking System
242
Rear - Combined
242
Front
243
Front Brake Pump Removal
243
Cooling System Circuit Diagram
246
Technical Specifications
246
System Bleed
247
Chassis
250
Seat
250
Rear Handlebar Cover
250
Instrument Panel
251
Front Handlebar Cover
251
Headlight Assy.
252
Frame Central Cover
252
Legshield
254
Side Fairing
254
Front Lower Frame
254
Front Upper Frame
255
Front Turn Indicators
256
Front Shield
256
Knee-Guard
257
Lower Shield Back Plate
259
Removing the Ignition Key-Switch When on *Off*
260
Front Wheel Housing
260
Taillight Assy.
261
Footrest
261
Passenger Footrest
261
Right and Left Footrest
262
Rider Footrest
262
Side Fairings
263
License Plate Holder
264
Rear Mudguard
265
Helmet Bay
266
Spoiler
267
Front Mudguard
268
Fuel Tank
268
Rear Central Cover
269
Radiator Fan
270
Expansion Tank
270
Handles and Top Side Fairings
271
Flyscreen
272
Pilot Lights Kit
272
Battery
273
Pre-Delivery
275
Aesthetic Inspection
275
Tightening Torques Inspection
275
Levels Check
276
Road Test
276
Static Test
277
Functional Inspection
277
Index
278

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APRILIA SR MAX 125 ie Manuals

APRILIA SR MAX 125 ie Service Station Manual (280 pages)

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