Aprilia QUASAR 125 - 180 Workshop Manual - PDF DOWNLOAD

Aprilia QUASAR 125 - 180 Workshop Manual - PDF DOWNLOAD

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Aprilia QUASAR 125 - 180 Workshop Manual - PDF DOWNLOAD

Language :English
Pages :168
Downloadable : Yes
File Type : PDF

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Aprilia QUASAR 125 - 180 Workshop Manual - PDF DOWNLOAD

FOREWORD 

• This manual provides the information required for normal servicing. - The information and illustrations contained in this manual will be updated through subsequent releases, see see 0.1 (RELEASE 00/2003-09 UPDATE). - This manual is intended for use by Aprilia Dealers and their qualified mechanics.
• Certain information has been omitted intentionally, as this manual does not purport to provide a comprehensive treatise on mechanics. The persons who will use this manual must be fully conversant with the basics of mechanics and with the basic procedures of motorcycle repair. Repairing or inspecting a motorcycle when one does not possess such basic knowledge or training could result in improper servicing and make the motorcycle unsafe to ride.
• For the same reason, certain basic precautions have been omitted in the descriptions of repair and inspection procedures. Take special care to avoid damage to motorcycle components or injury to persons. Aprilia's mission is to constantly enhance the riding pleasure of final users through the on-going improvement of its products as well as of the relevant technical literature.
• All Aprilia Points of Sale and Subsidiaries worldwide are kept updated on major engineering changes and modifications to repair procedures. Such changes and modifications are then reflected in the next release of the relevant manual.
• When in doubt about an inspection or repair procedure, please contact the Aprilia Consumer Service (A.C.S.) 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

TABLE OF CONTENTS:

Aprilia QUASAR 125 - 180 Workshop Manual - PDF DOWNLOAD

QUASAR 125 - 180 1
0 1 Release 00/2003-09 UPDATE 4
0 1 1 Manual updates 4
0 1 2 List of manual pages and update numbers 4
0 2 FOREWORD 6
0 3 REFERENCE MANUALS 6
0 3 1 OWNER'S MANUALS 6
0 3 2 SPARE PARTS CATALOGUE 6
0 4 Abbreviations/symbols/conventions 7
1 1 Conventions used in the manual 12
1 2 SAFETY WARNINGS 12
1 3 GENERAL SAFETY RULES 13
1 3 1 CARBON OXIDE 13
1 3 2 FUEL 13
1 3 3 Hot component parts 13
1 3 4 TRANSMISSION OIL 13
1 3 5 ENGINE OIL 14
1 3 6 HYDROGEN GAS AND BATTERY ELECTROLYTE 14
1 3 7 General precautions and information 15
1 3 8 Before disassembling any components 15
1 3 9 Disassembling the components 15
1 3 10 Reassembling the components 16
1 3 11 Electrical connectors 16
1 3 12 Torque figures 16
1 4 WARNINGS REGARDING FUEL, LUBRICANTS AND OTHER COMPONENTS 17
1 4 1 Fuel 17
1 4 2 LUBRICANTS 18
1 5 Location of serial numbers 19
1 5 1 Frame number 19
1 5 2 Engine number 19
1 6 Spare parts 19
1 7 TECHNICAL DATA 20
1 8 LUBRICANT CHART 22
1 9 Special tools 23
1 10 Torque figures 24
2 1 Periodic maintenance chart 28
2 2 FASTENERS 29
2 3 PERIODIC MAINTENANCE CHART 30
2 4 LUBRICATION 31
2 4 1 SWITCH 31
2 4 2 MAIN SWITCH 32
2 5 BATTERY 33
2 6 CHECKING THE ELECTROLYTE BATTERY LEVEL 34
2 6 1 RECHARGING THE BATTERY 34
2 7 SPARK PLUG 35
2 8 IDLING ADJUSTMENT 36
2 9 ADJUSTING THE throttle CONTROL 36
2 10 AIR CLEANER 37
2 11 FUEL VAPOURS FILTER 37
2 11 1 ENGINE OIL 38
2 11 2 CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER 39
2 12 CHECKING THE TRANSMISSION OIL LEVEL 40
2 13 CHECKING AND ADJUSTING THE BRAKES 41
2 14 CHECKING THE STEERING 42
2 15 INSPECTING THE FRONT SUSPENSIONS 42
2 16 INSPECTING THE REAR SUSPENSION 43
2 17 Wheels 43
2 17 1 TYRES 43
2 18 DRIVE CHAIN 44
2 19 MULTIFUNCTION COMPUTER 45
2 20 TOE IN 48
3 0 1 COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE INSTALLED 53
3 1 2 REMOVING THE ENGINE FROM THE FRAME 54
3 1 3 FITTING THE ENGINE IN THE FRAME 57
3 2 HEAD UNIT 58
3 2 1 REMOVING PROTECTION FAN 58
3 2 2 REMOVING FLYWHEEL UPPER AND LOWER HOUSINGS 58
3 2 3 REMOVING THE INTAKE MANIFOLD 58
3 2 4 REMOVING THE HEAD 59
3 2 5 REMOVING THE TENSIONER 59
3 2 6 REMOVING CAMSHAFT COMPLETE MOUNT 60
3 2 7 REMOVING THE ROCKER ARMS 60
3 2 8 REFITTING THE ROCKER ARMS 61
3 2 9 REMOVING THE CAMSHAFT 62
3 2 10 CHECKING BEARING PARTS 62
3 2 11 REFITTING THE CAMSHAFT 63
3 2 12 ADJUSTING VALVE CLEARANCE 64
3 2 13 REMOVING THE HEAD 64
3 2 14 CHECKING VALVES SEALING CAPACITY 64
3 2 15 REMOVING VALVES 65
3 2 16 CHECKS 65
3 2 17 VALVE SPRINGS FREE LENGTH 65
3 2 18 CHECKING VALVES AND VALVE SEATS 66
3 2 19 GRINDING 66
3 2 20 CHECKING THE HEAD AND CYLINDER 67
3 2 21 REFITTING VALVES AND HEAD 68
3 2 22 REMOVING THE CYLINDER 69
3 2 23 REMOVING THE PISTON 69
3 2 24 CHECKING THE CYLINDER 69
3 2 25 CHECKING THE PISTON 70
3 2 26 CHECKING PISTON RINGS 71
3 2 27 CHECKING PISTON GUDGEON PIN 71
3 2 28 REFITTING THE PISTON 72
3 3 ALTERNATOR 73
3 3 1 REMOVING THE COOLING FAN 73
3 3 2 REMOVING THE ALTERNATOR 73
3 3 3 CHECKING THE FLYWHEEL 73
3 3 4 REMOVING THE FREEWHEELING CLUTCH 74
3 3 5 CHECKING THE STARTER CLUTCH 75
3 3 6 REFITTING THE FREEWHEELING CLUTCH 75
3 4 OIL PUMP 76
3 4 1 REMOVING THE OIL PUMP 76
3 4 2 CHECKING THE OIL PUMP 77
3 4 3 REFITTING THE OIL PUMP 77
3 5 STARTER MOTOR 78
3 5 1 REMOVING THE STARTER MOTOR 78
3 5 2 REFITTING THE STARTER MOTOR 78
3 6 STARTING SYSTEM 79
3 6 1 REMOVING THE STARTING SYSTEM 79
3 6 2 REFITTING THE STARTING SYSTEM 80
3 6 3 REMOVING THE PRIMARY BELT ROLLER 81
3 6 4 CHECKING THE PRIMARY BELT ROLLER 82
3 6 5 REMOVING THE CLUTCH AND THE SECONDARY BELT ROLLER 83
3 6 6 CHANGING THE CLUTCH BLOCKS 84
3 6 7 CHECKING THE CLUTCH 85
3 6 8 CHECKING THE SECONDARY BELT ROLLER 85
3 6 9 CHECKING THE BELT 85
3 6 10 REFITTING THE SECONDARY BELT ROLLER 86
3 6 11 REMOVING THE FINAL DRIVE GEARS 87
3 6 12 REMOVING THE SELECTOR SHAFT 88
3 6 13 REMOVING THE GEAR SELECTOR SPINDLE 89
3 6 14 REMOVING THE GEAR LEVER MOUNT 89
3 6 15 CHECKING THE TRANSMISSION UNIT 90
3 6 16 REFITTING THE TRANSMISSION UNIT 91
3 7 CRANKCASE - CRANKSHAFT 92
3 7 1 REMOVING THE CRANKSHAFT 92
3 7 2 CHECKING THE CRANKCASE, THE CRANKSHAFT AND THE CONNECTING ROD 93
3 7 3 REMOVING ENGINE RUBBER BUSHING 93
3 7 4 REFITTING THE CRANKCASE 94
3 7 5 REFITTING THE CRANKSHAFT OIL SEAL 95
3 8 LUBRICATION SYSTEM 96
3 8 1 REMOVING THE ENGINE OIL COOLER 96
3 8 2 REMOVING THE ENGINE OIL LINES 96
4 1 MAINTENANCE 100
4 2 DRAINING THE FUEL TANK 100
4 2 1 Carburettor 101
4 2 2 CarBURETTOR FEATURES 101
4 3 REMOVING THE CARBURETTOR 102
5 1 Foreword 106
5 1 1 CABLE COLOURS 106
5 1 2 Electrical connectors 106
5 2 ELECTRICAL COMPONENTS 107
5 3 TROUBLESHOOTING 108
5 3 1 STARTER MOTOR - BATTERY RECHARGE - GENERATOR 108
5 3 2 CHECKING THE CHARGE VOLTAGE 109
5 3 3 RECTIFIER 109
5 4 IGNITION SYSTEM 110
5 4 1 HIGH TENSION COIL 111
5 5 CHECKING THE GENERATOR IDLE OPERATION 112
5 6 CHECKING THE ALTERNATOR CONTINUITY 112
5 7 CHECKING THE IGNITION COIL 112
5 7 1 checking the pick-up sensor 112
5 8 AUTOMATIC STARTER 113
5 9 CHECKING THE C D I CONTROL UNIT 114
5 9 1 Check data 114
5 10 FUEL LEVEL SENSOR 115
5 11 SWITCHES 116
5 12 STARTING CIRCUIT 118
5 12 1 WIRING DIAGRAM 118
5 12 2 TROUBLESHOOTING 119
5 12 3 CHECK DATA 119
5 13 BULBS 121
5 13 2 CHANGING THE HEADLIGHT BULBS 123
5 13 3 CHANGING THE TAIL LIGHT BULB 124
5 13 4 CHANGING THE HANDLEBAR COVER LIGHTS 125
5 13 5 ADJUSTING THE HEADLIGHT BEAM 126
5 13 6 CHANGING THE FUSES 126
5 14 Wiring diagram 127
6 1 BODYWORK 132
6 1 1 REMOVING THE SEAT 134
6 1 2 REMOVING THE DASHBOARD 134
6 1 3 REMOVING THE HEADLIGHT 135
6 1 4 REMOVING THE HANDLEBARS 136
6 1 5 REMOVING THE FRONT SHIELD 138
6 1 6 REMOVING THE REAR SHIELD 139
6 1 7 REMOVING THE FOOTREST 140
6 1 8 REMOVING THE AIR FILTER CASE 140
6 1 9 REMOVING THE BATTERY 141
6 1 10 REMOVING THE FUEL TANK 142
6 1 11 REMOVING THE CONTROL UNIT 143
6 1 12 REMOVING THE ELECTRICAL CONTROLS 143
6 1 13 REMOVING THE REAR BRAKE LEVER 144
6 1 14 REMOVING THE RIGHT CONTROL 144
6 1 15 REMOVING THE BRAKE PEDAL 144
6 1 16 REMOVING THE MAIN SWITCH 145
6 1 17 REMOVING THE FRONT DIRECTION INDICATORS 145
6 1 18 REMOVING THE HORN 145
6 1 19 REMOVING THE TAIL LIGHT 146
6 1 20 REMOVING THE REAR DIRECTION INDICATORS 146
6 1 21 REMOVING THE EXHAUST PIPE 147
6 1 22 REMOVING THE WHEELS 148
6 1 23 REMOVING THE FRONT SUBFRAME 148
6 1 24 REMOVING THE FOOTREST MOUNT 148
6 1 25 REMOVING THE FRAME 149
6 2 STEERING SYSTEM 149
6 2 1 REMOVING STEERING YOKE WITH STEM 149
6 2 2 REMOVING THE STEERING ARM 150
6 2 3 REMOVING THE BALL JOINT 150
6 2 4 REMOVING THE FRONT SHOCK ABSORBER 151
6 2 5 REMOVING SUSPENSION ARM 151
6 3 SWINGING ARM 151
6 3 1 REMOVING THE REAR SHOCK ABSORBER 151
6 3 2 REMOVING THE SWINGING ARM 152
6 4 FRONT BRAKES 153
6 4 1 REMOVING THE BRAKE 153
6 4 2 DISASSEMBLING THE BRAKE DRUM 153
6 4 3 CHECKING THE PARTS 154
6 5 REAR BRAKE 155
6 5 1 REMOVING THE BRAKE 155
6 6 CHECKING THE PARTS 156
6 7 CHAIN 156
6 7 1 DISASSEMBLING THE CHAIN 156
6 7 2 REFITTING THE CHAIN 156
7 1 The engine does not start 160
7 2 Poor performance at idle and low speed 161
7 3 Poor performance at high speed 162
7 4 Excessive noise leveL 163
7 5 Excessive fumes 163
7 6 Low power 164
7 7 Poor vehicle maneuverability 165

S.M 21/3/2025