APRILIA | QUASAR 180 | Technical data | APRILIA QUASAR 180 Technical data

1122 3
QUASAR 125 - 180
www.serviceaprilia.com
00/2003-09
8140724
UK
workshopmanual
FOREWORD
QUASAR 125-180
FOREWORD
0
0
Release 00/2003 - 06
GENERAL INFORMATION
1
PERIODIC MAINTENANCE
2
ENGINE
3
FUEL SYSTEM
4
ELECTRIC SYSTEM
5
CYCLE PARTS
6
0 - 1 - 00
FOREWORD
QUASAR 125-180
FOREWORD
CONTENTS
0
1
0.1 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
0.2
FOREWORD.............................................................................................................................. 0-5-00
0.3 REFERENCE MANUALS ........................................................................................................... 0-5-00
0.3.1 OWNER'S MANUALS ..................................................................................................................................... 0-5-00
0.3.2 SPARE PARTS CATALOGUE........................................................................................................................ 0-5-00
0.4
ABBREVIATIONS/SYMBOLS/CONVENTIONS .......................................................................... 0-6-00
2
3
4
5
6
7
i
9
0 - 2 - 00
Release 00/2003 - 06
FOREWORD
QUASAR 125-180
0.1
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Add the latest release pages to the manual and destroy all superseded pages (even if they belong to the release before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).
Failure to keep the manual up-to-date or to eliminate superseded pages will make the manual more difficult to consult
and creates a risk of improper servicing.
0.1.2
pag.#
LIST OF MANUAL PAGES AND UPDATE NUMBERS
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Release 00/2003 - 06
0 - 3 - 00
FOREWORD
pag.#
QUASAR 125-180
Release
pag.#
Release
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0 - 4 - 00
Release 00/2003 - 06
FOREWORD
QUASAR 125-180
0.2
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.
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.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted, are
reserved in all countries.
The mention of third parties' products is only made for information purposes, and is not binding.
Aprilia is not liable in any way for the performance or use of any such products.
For further information, see 0.3 (REFERENCE MANUALS).
First edition: September 2003
Produced and printed by:
DECA s.r.l.
via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail: deca@decagroup.it
www.decaweb.it
On behalf of:
aprilia Consumer Service s.p.a.
via Noalese, 156 - 30036 Santa Maria di Sala (VE) - Italy
Tel. +39 - 041 57 86 101
Fax +39 - 041 57 86 100
www.aprilia.com
0.3
0.3.1
REFERENCE MANUALS
OWNER'S MANUALS
Aprilia part# (description)
Model year 2003
8104713
0.3.2
UK
E
D
F
SPARE PARTS CATALOGUE
Aprilia part# (description)
Model year 2003
A 60200
Release 00/2003 - 06
UK
E
D
F
0 - 5 - 00
FOREWORD
0.4
QUASAR 125-180
ABBREVIATIONS/SYMBOLS/CONVENTIONS
#
<
>
<
>
~
∞
°C
°F
±
AC
A
Ah
API
HT
AV/DC
bar
DC
cm³
CO
CPU
DIN
DOHC
ECU
rpm
HC
ISC
ISO
Kg
Kgm
km
kph
kΩ
kPa
KS
kW
LAP
LED
LEFT
SIDE
m/s
max
mbar
mi
MIN
MPH
MS
MΩ
N.A.
N.O.M.M.
N.O.R.M.
Nm
Ω
PICK-UP
BDC
TDC
PPC
RIGHT
SIDE
SAE
TEST
T.B.E.I.
T.C.E.I.
0 - 6 - 00
= number
= is less than
= is more than
= is less than or equal to
= is more than or equal to
= approximately
= infinite
= degrees Celsius (centigrade)
= degrees Fahrenheit
= plus or minus
= Alternated Current
= Ampere
= Ampere per hour
= American Petroleum Institute
= high tension
= Anti-Vibration Double Countershaft
= pressure measurement (1 bar =100 kPa)
= Direct Current
= cubic centimeters
= carbon oxide
= Central Processing Unit
= German industrial standards
(Deutsche Industrie Norm)
= Double Overhead Camshaft
= Electronic Control Unit
= revolutions per minute
= unburnt hydrocarbons
= Idle Speed Control
= International Standardization Organization
= kilograms
= kilogram per metre (1 kgm =10 Nm)
= kilometres
= kilometres per hour
= kiloohm
= kiloPascal (1 kPa =0.01 bar)
= clutch side
(from the German "Kupplung Seite")
= kiloWatt
= litres
= racetrack lap
= Light Emitting Diode
= left side
= metres per second
= maximum
= millibar (1 mbar =0.1 kPa)
= miles
= minimum
= miles per hour
= flywheel side
= megaohm
= Not Available
= Motor Octane Number
= Research Octane Number
= Newton per metre (1 Nm =0.1 kgm)
= ohm
= pick-up
= Bottom Dead Centre
= Top Dead Centre
= Pneumatic Power Clutch
= right side
= Society of Automotive Engineers
= diagnostic check
= crowned-head Allen screw
= cheese-headed Allen screw
Release 00/2003 - 06
QUASAR 125-180
T.E.
T.P.
TSI
UPSIDEDOWN
V
W
Ø
FOREWORD
= hexagonal head
= flat head screw
= Twin Spark Ignition
= inverted fork
= Volt
= Watt
= Diameter
Release 00/2003 - 06
0 - 7 - 00
FOREWORD
QUASAR 125-180
NOTE
0 - 8 - 00
Release 00/2003 - 06
QUASAR 125-180
GENERAL INFORMATION
GENERAL INFORMATION
Release 00/2003 - 09
1
1 - 1 - 00
GENERAL INFORMATION
QUASAR 125-180
GENERAL INFORMATION
CONTENTS
0
1
2
3
1.1
CONVENTIONS USED IN THE MANUAL.................................................................................. 1-3-00
1.2
SAFETY WARNINGS ................................................................................................................ 1-3-00
1.3 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 .................................................................................................................................................... 1-5-00
1.3.6 HYDROGEN GAS AND BATTERY ELECTROLYTE ..................................................................................... 1-5-00
1.3.7 GENERAL PRECAUTIONS AND INFORMATION ......................................................................................... 1-6-00
1.3.8 BEFORE DISASSEMBLING ANY COMPONENTS........................................................................................ 1-6-00
1.3.9 DISASSEMBLING THE COMPONENTS ........................................................................................................ 1-6-00
1.3.10 REASSEMBLING THE COMPONENTS ......................................................................................................... 1-7-00
1.3.11 ELECTRICAL CONNECTORS........................................................................................................................ 1-7-00
1.3.12 TORQUE FIGURES......................................................................................................................................... 1-7-00
1.4 WARNINGS REGARDING FUEL, LUBRICANTS AND OTHER COMPONENTS.......................... 1-8-00
1.4.1 FUEL................................................................................................................................................................ 1-8-00
1.4.2 LUBRICANTS.................................................................................................................................................. 1-9-00
1.5 LOCATION OF SERIAL NUMBERS......................................................................................... 1-10-00
1.5.1 FRAME NUMBER.......................................................................................................................................... 1-10-00
1.5.2 ENGINE NUMBER......................................................................................................................................... 1-10-00
4
5
1.6
SPARE PARTS ....................................................................................................................... 1-10-00
1.7
TECHNICAL DATA ................................................................................................................. 1-11-00
1.8
LUBRICANT CHART .............................................................................................................. 1-13-00
1.9
SPECIAL TOOLS .................................................................................................................... 1-14-00
1.10 TORQUE FIGURES................................................................................................................. 1-15-00
6
7
1i
9
1 - 2 - 00
Release 00/2003 - 09
GENERAL INFORMATION
QUASAR 125-180
1.1
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" and "left" are referred to the rider seated on the vehicle in the normal riding position.
Motorcycle operation and basic maintenance are covered in the "OWNER'S MANUAL".
! Any operations preceded by the star symbol must be repeated on the opposite side of the motorcycle.
In this manual any variants are identified with these symbols:
ASD
OPT
Frame Quasar 125 HP:ZD4KY10003TXXXXXX (STARTING FROM MODEL YEAR 2003);
Frame Quasar 125 Grip:ZD4KY11003TXXXXXX (STARTING FROM MODEL YEAR 2003);
Frame Quasar 180 HP:ZD4KY00003TXXXXXX (STARTING FROM MODEL YEAR 2003);
Frame Quasar 180 Grip:ZD4KY01003TXXXXXX (STARTING FROM MODEL YEAR 2003).
automatic light switching version (Automatic Switch-on Device)
optional
VERSION:
I
Italy
GR
Greece
MAL
Malaysia
UK
United
Kingdom
NL
Holland
RCH
Chile
A
Austria
CH
Switzerland
HR
Croatia
P
Portugal
DK
Denmark
AUS
Australia
SF
Finland
J
Japan
USA
United States
of America
B
Belgium
SGP
Singapore
BR
Brazil
D
Germany
SLO
Slovenia
RSA
Republic of
South Africa
F
France
E
Spain
1.2
IL
ROK
Israele
South Korea
NZ
CDN
New Zeland
Canada
SAFETY WARNINGS
The following precautionary warnings are used throughout this manual in order to convey the following messages:
Safety warning. When you find this symbol on the vehicle or in the manual, be careful to the potential risk of personal injury.
Disregarding the instructions identified by this symbol may compromise the safety of the user, the motorcycle and third parties.
Indicates a potential hazard which may result in serious injury or even death.
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
NOTE The word "NOTE" in this manual precedes important information or instructions.
Release 00/2003 - 09
1 - 3 - 00
GENERAL INFORMATION
1.3
1.3.1
QUASAR 125-180
GENERAL SAFETY RULES
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.
Operate the engine out of doors or, if working indoors, use an exhaust emission extraction plant.
1.3.2
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. Avoid contact with bare flames, sources of
sparks or any other source which may ignite the fuel or lead to explosion.
DO NOT RELEASE FUEL INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
1.3.3
HOT COMPONENT PARTS
The engine and exhaust component parts become hot when the engine is running and will stay hot for some time after the engine
has been stopped.
Wear heat gloves before handling these components or allow for the engine and exhaust system to cool down before proceeding.
1.3.4
TRANSMISSION OIL
Use
PONTIAX HDI SAE 85W - 140 or
POTRAIMP 85W-140. 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-4 specifications.
Insufficient lubrication or the use of unsuitable lubricants may result in irreparable damage due to increased wear and
tear of the moving parts.
Do not overtighten the drain plug as this could damage the crankcase.
Used oil contains substances that are harmful to the environment, even small quantities must be disposed of in compliance with the regulations in force.
To avoid serious skin damage due to prolonged contact with oil, accurately wash your hands after handling the lubricant.
KEEP AWAY FROM CHILDREN.
1 - 4 - 00
Release 00/2003 - 09
QUASAR 125-180
1.3.5
GENERAL INFORMATION
ENGINE OIL
Use
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.
Do not overtighten the drain plug as this could damage the crankcase.
Used oil contains substances that are harmful to the environment, even small quantities must be disposed of in compliance with the regulations in force.
To avoid serious skin damage due to prolonged contact with oil, accurately wash your hands after handling the lubricant.
KEEP AWAY FROM CHILDREN.
1.3.6
HYDROGEN GAS AND BATTERY ELECTROLYTE
Battery electrolyte fluid is toxic and caustic. It contains sulphuric acid and can cause burns if spilled on the skin.
Wear close-fitting gloves and protective clothing when handling the battery electrolyte.
If any battery fluid gets on your skin, rinse the affected area with abundant fresh water.
Take special care to protect your eyes - even a small amount of battery acid can cause blindness. If battery fluid is
spilled into your eyes, flush with abundant water for fifteen minutes and contact an eye specialist immediately.
If battery fluid is swallowed accidentally, drink abundant water or milk. Seek medical advice immediately and keep drinking magnesia milk or vegetable oil in the meantime. The battery gives off explosive gases. Keep the battery well away
from any sources of ignition, such as flames, sparks, or any heat sources. Do not smoke near the battery.
Make sure the area is well-ventilated when servicing or charging the battery.
KEEP AWAY FROM CHILDREN.
Battery fluid is corrosive.
Avoid spillage. Take special care not to spill battery fluid on plastic parts.
Ensure that the electrolyte fluid you are using is suitable for your battery.
Release 00/2003 - 09
1 - 5 - 00
GENERAL INFORMATION
1.3.7
QUASAR 125-180
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; allow for the engine and exhaust system to cool down;
where possible, lift the motorcycle using adequate equipment placed on firm and level ground. Be careful of any parts of
the engine or exhaust system which may still be hot to the touch to avoid scalds or burns.
Never put any mechanical parts or other vehicle components in your mouth when you have both hands busy. None of
the motorcycle components is edible. Some components are harmful to the human body or toxic.
If not expressly indicated otherwise, for the reassembly of the units repeat the disassembly operations in reverse order.
Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly to avoid disturbing any parts
unless strictly necessary. Do not use polishing paste on matt paint.
Never use fuel instead of solvent to clean the motorcycle.
Do not use alcohol, petrol or solvents to clean the rubber and plastic parts and the seat: use only water and mild soap.
Always disconnect the battery negative (-) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid personal injury.
Read carefully 1.4 (WARNINGS REGARDING FUEL, LUBRICANTS AND OTHER COMPONENTS).
1.3.8
BEFORE DISASSEMBLING ANY COMPONENTS
- Clean off all dirt, mud, and dust and clear any foreign objects from the vehicle before disassembling any components.
- Use the model-specific special tools where specified.
1.3.9
DISASSEMBLING THE COMPONENTS
- Never use pliers or similar tools to slacken and/or tighten nuts and bolts. Always use a suitable spanner.
- Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection using a distinctive symbol or convention.
- Mark each part clearly to avoid confusion when refitting.
- Thoroughly clean and wash any components you have removed using a detergent with low flash point.
- Mated parts should always be refitted together. These parts will have seated themselves against one another in service as a
result of normal wear and should never be mixed up with other similar parts on refitting.
- Certain components are matched-pair parts and should always be replaced as a set.
- Keep the motorcycle and its components well away from heat sources.
1 - 6 - 00
Release 00/2003 - 09
QUASAR 125-180
GENERAL INFORMATION
1.3.10 REASSEMBLING THE COMPONENTS
Never reuse a circlip or snap ring. These parts must always be renewed once they have been disturbed.
When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow fitment to the shaft.
Make it a rule to check that a newly-fitted circlip or snap ring has located fully into its groove.
Never clean a bearing with compressed air.
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.
When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten evenly in subsequent steps until achieving the specified torque.
Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have a damaged
thread.
Abundantly lubricate parts subject to wear before fitting the bearings.
Make it a rule to check that all components you have fitted are correctly in place.
After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then operate the motorcycle in a private estate area or in a safe area away from traffic.
Clean all joint surfaces, oil seal edges and gaskets before assembly.
Apply a light coat of lithium grease along the edges of oil seals. Fit oil seals and bearings with the brand or serial number facing
outwards (in view).
1.3.11 ELECTRICAL CONNECTORS
Disconnect electrical connectors as follows; failure to follow the instructions can seriously damage the connectors and the wiring:
" Press down on the locking tab, where fitted.
Never separate two connectors by pulling on the wiring.
" Grasp both connectors and pull them in opposite directions until they become separated.
" Remove any dirt, rust, moisture, etc. from inside the connector blowing with compressed air.
" Ensure that the wires are securely crimped to the terminals inside each connector.
NOTE A connector will only locate properly into the matching connector when it is inserted in the correct mounting position.
" Reconnect the two connectors and ensure that they are fully engaged (where fitted, the locking tab should click audibly into
place).
1.3.12 TORQUE FIGURES
Do not forget that the tightening torques of all fasteners on wheels, brakes, wheel spindles and other suspension components are essential to ensure safe operation of the motorcycle and must be set to the indicated values.
Regularly check the tightening torques on all fasteners, and always use a torque wrench when fitting them.
Failure to observe these instructions can result in parts coming loose or off, thus jamming a wheel or creating other
problems which could affect the handling of the motorcycle, potentially resulting in serious injury or death.
Release 00/2003 - 09
1 - 7 - 00
GENERAL INFORMATION
1.4
1.4.1
QUASAR 125-180
WARNINGS REGARDING FUEL, LUBRICANTS AND OTHER COMPONENTS
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. Avoid contact with bare flames, sources of
sparks or any other source which may ignite the fuel or lead to explosion.
Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts.
In the event of accidental fuel spillage, make sure the affected area is fully dry before starting the engine. Fuel expands
from heat and when left under direct sunlight. Never fill the fuel tank up to the rim. Tighten the filler cap securely after
each refuelling.
Avoid contact with skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between different containers
using a hose.
In case of contact with the eyes, rinse abundantly with clean water and immediately seek medical attention.
If accidentally swallowed, do not induce vomiting.
Drink abundant milk or cool water and seek medical attention immediately.
DO NOT RELEASE FUEL INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only premium-grade unleaded fuel with a minimum octane rating of 95 (N.O.R.M.) and 85 (N.O.M.M.).
ENGINE OIL
Engine oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not release oil into the environment.
Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage centre.
In case any maintenance operation should be required, it is advisable to use latex gloves.
Change engine oil after running-in, namely after two weeks of usage, and then every six months, see 2.3 (PERIODIC MAINTENANCE CHART), see 1.8 (LUBRICANT CHART).
Change oil every three months if the vehicle is used in rainy or dusty areas, on uneven surfaces or on racetracks.
1 - 8 - 00
Release 00/2003 - 09
QUASAR 125-180
1.4.2
GENERAL INFORMATION
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.
Wash your hands thoroughly after handling engine oil.
Do not release into the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
When filling the vehicle with lubricant, make sure not to spill it. Immediately clean up spilled oil, as it can damage the
motorcycle paint.
Oil on the tyres can make them very slippery and dangerous to use.
In case of oil leaks, do not use the motorcycle. Identify the cause of the leak and repair it.
Release 00/2003 - 09
1 - 9 - 00
GENERAL INFORMATION
QUASAR 125-180
1.5
LOCATION OF SERIAL NUMBERS
These numbers are necessary for vehicle registration.
NOTE Altering the identification numbers of vehicle or engine is a legal
offence punishable by heavy fines and penalties. In addition, altering the
frame number (VIN) results in immediate warranty invalidation.
1.5.1
FRAME NUMBER
The motorcycle's frame number is stamped on the front part of the frame
under front mudguard support.
1.5.2
ENGINE NUMBER
The engine number is stamped on the crankcase, on the left side of the motorcycle.
1.6
SPARE PARTS
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.
1 - 10 - 00
Release 00/2003 - 09
GENERAL INFORMATION
QUASAR 125-180
1.7
TECHNICAL DATA
QUASAR 125
QUASAR 180
Length
1790 mm GRIP 1675 mm (HP)
1790 mm GRIP 1675 mm (HP)
Width
970 mm (GRIP/HP)
970 mm (GRIP/HP)
DIMENSIONS
Max. height (to handlebars)
1060 mm (GRIP/HP)
1060 mm (GRIP/HP)
Wheel base
1065 mm (GRIP/HP)
1065 mm (GRIP/HP)
Min. ground clearance
Weight ready for starting
160 mm (GRIP/HP)
160 mm (GRIP/HP)
174 Kg (GRIP) - 171 kg (HP)
174 Kg (GRIP) - 171 kg (HP)
4-stroke
4-stroke
ENGINE
Type
Number of valves
Number of cylinders
Total displacement
Bore/stroke
Compression ratio
Starting
Engine idling rpm
2
2
horizontal single cylinder
horizontal single cylinder
125 cm³
169 cm³
52,4 mm x 57,8 mm
61 mm x 57,8 mm
9,1±1:1
9,1±1:1
electric + kick starter
electric + kick starter
1800 ± 100 giri/min
1800 ± 100 giri/min
automatic, dry centrifugal
automatic, dry centrifugal
Gearbox
automatic converter transmission
automatic converter transmission
Lubrication circuit
wet casing, forced circulation via
mechanical pump
wet casing, forced circulation via
mechanical pump
air
air
Clutch
Cooling
CAPACITY
Fuel (reserve included)
8l
8l
1,5 l
1,5 l
200 cm³
200 cm³
1) engine oil change only
0,9 l
0,9 l
2) change for engine overhaul
1,2 l
1,2 l
Fuel reserve
Transmission oil
Engine oil
Seats
2
2
98 Kg (GRIP) - 98 kg (HP)
98 Kg (GRIP) - 98 kg (HP)
Converter
automatic continuous
automatic continuous
Primary
with trapezoidal belt
with trapezoidal belt
Vehicle max. load (driver + possible luggage)
TRANSMISSION
Ratios
1) minimum for continuous variable transmission
3
3
2) maximum for continuous variable transmission
0,789
0,789
Secondary
gear-type
gear-type
Final
chain-type
chain-type
premium grade unleaded petrol, number
DIN 51607, min. O.N. 95 (N.O.R.M.) and
85 (N.O.M.M.).
premium grade unleaded petrol, number
DIN 51607, min. O.N. 95 (N.O.R.M.) and
85 (N.O.M.M.).
Type
WALBRO
WALBRO
Choke
Ø 22 mm
Ø 22 mm
tube
tube
FUEL SUPPLY
Fuel
CARBURETTOR
FRAME
Type
SUSPENSIONS
Front
with independent arms
with independent arms
Rear
hydraulic monoshock absorber
hydraulic monoshock absorber
Front
Ø 110 mm mechanically driven drum
brake
Ø 110 mm mechanically driven drum
brake
Rear
Ø 130 mm mechanically driven drum
brake
Ø 130 mm mechanically driven drum
brake
BRAKES
Release 00/2003 - 09
1 - 11 - 00
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
Front GRIP
Rear GRIP
Inflating pressure
22x11-8
22x11-8
AT 21x7-10
AT 21x7-10
AT 21x10-8
AT 21x10-8
20 - 25 kPa (0,20 - 0,25 bar)
30 kPa (0,30 bar)
IGNITION
Type
Ignition advance
C.D.I.
C.D.I.
13° ± 2°
13° ± 2°
NGK CR8HSA
NGK CR8HSA
0,6 - 0,7 mm
0,6 - 0,7 mm
12 V - 9 Ah
12 V - 9 Ah
SPARK PLUG
Standard
Spark plug gap
ELECTRIC SYSTEM
Battery
Fuse
Generator (with permanent magnet)
15 A
15 A
12 V - 110 W
12 V - 110 W
12 V - 5 W
12 V - 5 W
12 V - 35/35 W
12 V - 35/35 W
BULBS
Parking light
Low/high beam
Direction indicators
Rear parking lights/Stoplight
Number plate light
1 - 12 - 00
12 V- 10 W
12 V- 10 W
12 V - 5/21 W
12 V - 5/21 W
12 V - 5 W
12 V - 5 W
Release 00/2003 - 09
GENERAL INFORMATION
QUASAR 125-180
1.8
LUBRICANT CHART
LUBRICANT
PRODUCT
Transmission oil
RECOMMENDED:
PONTIAX HDI SAE 85W - 140 or
ROTRA MP 85W-140.
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.
Engine oil
RECOMMENDED:
SUPERMOTOROIL SAE 15W - 40 or
F1 SUPERMOTOROIL 15W-40.
As an alternative to recommended oil it is possible to use high-quality oil having equal or
higher ratings with respect to A.P.I. SJ/eF specifications.
Bearings and other lubrication points
RECOMMENDED:
AUTOGREASE MP or
GREASE 30.
As an alternative to recommended fluids it is possible to use high-quality grease for bearings, temperature range -30°C...+140°C, dripping point 150°C...230°C, highly corrosion
protectant, good waterproof and oxidization-proof ability.
Battery lead protection
Use neutral grease or vaseline.
Aerosol chain lubricant
RECOMMENDED:
Release 00/2003 - 09
CHAIN SPRAY or
CHAIN LUBE.
1 - 13 - 00
GENERAL INFORMATION
1.9
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 vehicle are listed below.
If needed, order the brand-specific special tools (see Special Tools Catalogue).
Always read the instructions supplied with the special tools before use.
2
1
6
4
5
3
TOOLS
Ref.
Tool designation and application
Part number
1
Flywheel and clutch housing locking tool
8900675
2
Universal clutch assembly/disassembly tool
8900674
3
Converter locking tool
8900673
4
Ring nut spanner
8910599
5
Flywheel puller
8910600
6
Starting gear puller
8910601
1 - 14 - 00
Release 00/2003 - 09
GENERAL INFORMATION
QUASAR 125-180
1.10 TORQUE FIGURES
A
C
D
B
The table below reports the standard torque figures for metric size screws and
bolts in accordance with ISO standards.
Tightening
torque
Screw or
bolt
Spanner
M6
10
6
0.6
M8
12
15
1.5
M 10
14
30
3.0
M 12
17
55
5.5
M 14
19
85
8.5
M 16
22
130
13.0
Nm
kgm
For vehicle-specific fastenings see 2.2 (FASTENERS).
Unless otherwise specified, torque figures are intended for application to
clean, dry threads at
room temperature.
NOTE Follow the instructions below to avoid distortion and/or improper fit:
" Screw all fasteners finger-tight.
" Tighten the opposing parts to half
the prescribed torque: (A) and (B); (C)
and (D).
" Repeat sequence tightening to specified torque.
NOTE This way, the load generated by the fasteners is applied evenly across
joint surface.
Release 00/2003 - 09
1 - 15 - 00
GENERAL INFORMATION
QUASAR 125-180
NOTE
1 - 16 - 00
Release 00/2003 - 09
QUASAR 125-180
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
Release 00/2003 - 09
2
2 - 1 - 00
PERIODIC MAINTENANCE
QUASAR 125-180
PERIODIC MAINTENANCE
CONTENTS
0
1
2
2.1
PERIODIC MAINTENANCE CHART .......................................................................................... 2-3-00
2.2
FASTENERS............................................................................................................................. 2-4-00
2.3
PERIODIC MAINTENANCE CHART .......................................................................................... 2-5-00
2.4 LUBRICATION ......................................................................................................................... 2-6-00
2.4.1 SWITCH ........................................................................................................................................................... 2-6-00
2.4.2 MAIN SWITCH................................................................................................................................................. 2-7-00
2.5
BATTERY ................................................................................................................................. 2-8-00
2.6 CHECKING THE ELECTROLYTE BATTERY LEVEL ................................................................. 2-9-00
2.6.1 RECHARGING THE BATTERY ...................................................................................................................... 2-9-00
2.7
SPARK PLUG ......................................................................................................................... 2-10-00
2.8
IDLING ADJUSTMENT ........................................................................................................... 2-11-00
2.9
ADJUSTING THE THROTTLE CONTROL ............................................................................... 2-11-00
2.10 AIR CLEANER ........................................................................................................................ 2-12-00
3
2.11 FUEL VAPOURS FILTER ........................................................................................................ 2-12-00
2.11.1 ENGINE OIL .................................................................................................................................................. 2-13-00
2.11.2 CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER ................................................................. 2-14-00
2.12 CHECKING THE TRANSMISSION OIL LEVEL ....................................................................... 2-15-00
2.13 CHECKING AND ADJUSTING THE BRAKES ......................................................................... 2-16-00
4
2.14 CHECKING THE STEERING................................................................................................... 2-17-00
2.15 INSPECTING THE FRONT SUSPENSIONS ............................................................................ 2-17-00
2.16 INSPECTING THE REAR SUSPENSION ................................................................................. 2-18-00
5
2.17 WHEELS................................................................................................................................. 2-18-00
2.17.1 TYRES ........................................................................................................................................................... 2-18-00
2.18 DRIVE CHAIN......................................................................................................................... 2-19-00
2.19 MULTIFUNCTION COMPUTER .............................................................................................. 2-20-00
2.20 TOE IN ................................................................................................................................... 2-23-00
6
7
i
9
2 - 2 - 00
Release 00/2003 - 09
QUASAR 125-180
PERIODIC MAINTENANCE
Outlined in this section are the recommended procedures for the periodic maintenance of the key components of the motorcycle.
Before proceeding to maintain or inspect the motorcycle, stop the engine and remove the ignition switch key. Ensure
that the engine and exhaust system have cooled down. Wherever possible, place the motorcycle on firm and level
ground and lift it using suitable equipment. Be careful of any parts of the engine or exhaust system which may still be
hot to the touch to avoid scalds or burns.
All component parts of the vehicle are inedible. Do not bite, suck, chew or swallow any vehicle parts. If not expressly
indicated otherwise, for the reassembly of the units repeat the disassembly operations in reverse order.
2.1
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.
Release 00/2003 - 09
2 - 3 - 00
PERIODIC MAINTENANCE
2.2
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
Nm
kgm
Spark plug
20
2,0
Throttle control covers
13
1,3
Oil filter cover
15
1,5
Flywheel retaining nut
38
3,8
Camshaft flange nut
27
2,7
Mobile belt roller nut
38
3,8
Valve adjusting nut
5
0,5
Cylinder head nut
27
2,7
Primary drive gear nut
38
3,8
Head stud bolt
13
1,3
Oil bleeder
25
2,5
Right casing screw
10
1,0
Left casing screw
10
1,0
Valve cover screw
14
1,4
Converter cover screw
10
1,0
Oil cooler retaining screw
9
0,9
Starter motor screw
14
1,4
Oil pump screw
14
1,4
Stator screw
14
1,4
Engine mount screw
28
28
Nm
kgm
Upper handlebars braces
4
0,4
Steering stem nut
10
1,0
Rear shock absorber retaining nut
40
4,0
Front hub retaining nut
60
6,0
Rear hub retaining nut
95
9,5
Front wheel retaining nut
38
3,8
Rear wheel retaining nut
38
3,8
Steering stem flange nut
25
2,5
Swinging arm spindle nut
90
9,0
Chain adjusting nut
22
2,2
Handlebars lower fastener
10
1,0
Front brake lever
10
1,0
Rear brake lever
10
1,0
Rear axle (inner) retaining screw
9
0,9
Rear axle (outer) retaining screw
15
1,5
Front shield retaining screw
4
0,4
Steering arm retaining screw
30
3,0
Headlight retaining screw
16
1,6
Muffler retaining screw
25
2,5
Footpeg retaining screw
4
0,4
Front suspension screw
40
4,0
Component
Note
FRAME
Component
2 - 4 - 00
Note
Release 00/2003 - 09
PERIODIC MAINTENANCE
QUASAR 125-180
2.3
PERIODIC MAINTENANCE CHART
Components
Throttle and brake cables
Battery
Post running-in checks
(after 2 weeks)
Monthly
#
#
#
#
Drive chain
#
#
Every 10 hours of operation: #
$
Air cleaner
Stop light switch
Engine oil
Tyres pressure
Fuel indicator
%
$
Engine oil filter
Light system
#
#
%
#
#
#
#
%
Always check before use
#
&
Ignition advance
Transmission cables '
#
Brake drums/blocks
#
Always check before use
#
Drive belt
Steering tube bearing and steering clearance
#
#
#
Ties
%
Fuel filter
#
Clutch
Vehicle general operation
Valve clearance
Yearly
#
$
Spark plug
Carburettor/idle speed
Six-monthly
#
&
#
%
%
#
#
#
#
&
Greasing
Exhaust pipe / exhaust silencer
Transmission oil '
Rear belt roller pins
Fixed mobile front belt roller
Converter rollers
Bolt/screw/nut tightening
Suspensions
Fuel line
#
#
#
%
%
%
KEY
# Check, clean and lubricate, adjust, top up or change if necessary.
$ Cleaning.
% Replace.
& Adjustment.
' Run monthly in case of use on muddy, wet or rough surfaces (off-road).
Service the motorcycle more frequently when you ride in the rain, on dusty or bumpy roads, or in competition trials.
Release 00/2003 - 09
2 - 5 - 00
PERIODIC MAINTENANCE
QUASAR 125-180
2.4
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).
2.4.1
SWITCH
NOTE Electrical components will only operate with the main switch at the
"
" position.
1)
HAZARD LIGHT SWITCH ( )
Press down the top (marked with the symbol) to flash all indicators at
once.
2) DIRECTION INDICATOR LIGHT SWITCH (
)
Turn the switch to the left to indicate turning to the left; to the right to
indicate turning to the right. Press the switch to turn off the indicators.
3) HORN BUTTON (
)
Press to sound the horn.
4) LIGHT DIP SWITCH (
)
Turn the light switch to " " to activate the parking and low beam lights.
Turn the switch to "
" to activate high beam.
5
4
2 - 6 - 00
3
2
1
NOTE The light dip switch is only enabled when the main switch is in the
"
" position.
5)
STARTING BUTTON ( )
Press the " " button: the starter motor will turn over the engine.
Release 00/2003 - 09
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.
1
NOTE The key turns on the main switch and enables the use of the light dip
switch, when it is in the "
" position.
The motorcycle is delivered with two keys (one spare key).
NOTE Keep the spare key separate from the motorcycle.
Position
Function
Removing the key
The engine and lights cannot be operated.
The key may be removed.
The engine may be started.
The key may not be
removed
The parking and low beam
lights are operating and the
The key may not be
high beam lights may be
removed
turned on and the engine
started.
Release 00/2003 - 09
2 - 7 - 00
PERIODIC MAINTENANCE
1
QUASAR 125-180
2.5
BATTERY
Read carefully 1.3.6 (HYDROGEN GAS AND BATTERY ELECTROLYTE).
2
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
" ", otherwise some components may be damaged.
Connect first the positive cable (+) and then the negative cable (-).
Disconnect following the reverse order.
NOTE This vehicle is provided with a maintenance-free battery and no
operation is necessary, excepting occasional checks and the recharge when
required.
If the motorcycle is not to be used for some time, disconnect the battery
terminals.
CHECKING AND CLEANING THE TERMINALS
" Remove the seat, see 6.1.1 (REMOVING THE SEAT).
" Ensure the main switch is in the " " position.
Make sure that the cable terminals (1) and the battery terminals (2) are:
- in good conditions (and not corroded or covered with deposits);
- covered with neutral grease or vaseline.
If necessary, proceed as follows:
- Disconnect the negative (-) and positive (+) leads in this order.
- Clean off corrosion deposits using a wire brush.
- Reconnect the positive (+) and negative (-) leads in the order.
- Cover the terminals of the cables and of the battery with neutral grease or
vaseline.
2 - 8 - 00
Release 00/2003 - 09
PERIODIC MAINTENANCE
QUASAR 125-180
2.6
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 "
Do not remove the battery plugs or the battery may damage.
".
" Remove the battery, see 6.1.9 (REMOVING THE BATTERY).
" Prepare an appropriate battery charger.
" Set the charger for the desired type of recharge (see table).
" Connect the battery to the battery charger.
Charge or use the battery in a well-ventilated place. Do not inhale the
gases produced by the battery under charging.
" Switch on the battery charger.
Charge rate
Ampere
rating
Time
(hours)
Normal
0.4
5
Fast
4
0.5
Reassemble the battery only 5/10 minutes after disconnecting the
recharge apparatus, since the battery continues to produce gas for a
short lapse of time.
INSTALLING THE BATTERY.
" Ensure the main switch is in the " " position.
" Remove the seat, see 6.1.1 (REMOVING THE SEAT).
NOTE The battery must be positioned in its compartment with the terminals
directed towards the right side of the vehicle.
" Place the battery in its compartment.
" Refit the battery securing elastic band (1).
On refitting, connect the positive (+) lead first, then the negative (-) lead.
1
" Connect the positive terminal (+) with its screw.
" Connect the negative terminal (-) with its screw.
" Cover the terminals of the cables and of the battery with neutral grease or
vaseline.
" Put back the red protection element (2).
" Refit the seat.
Release 00/2003 - 09
2 - 9 - 00
PERIODIC MAINTENANCE
QUASAR 125-180
2.7
1
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.
Never remove a spark plug cap while the engine is running. Shock
hazard.
" Remove the spark plug cap (1).
" Remove any trace of dirt from the spark plug base.
" Unscrew the spark plug and extract it from its seat, taking care to prevent
dust or other substances from getting inside the cylinder.
" Make sure that there are neither carbon deposits, nor corrosion marks on
the electrode and on the spark plugs ceramics; if necessary, clean with a
plug cleaner or wire brush.
Blow out with compressed air to stop residues getting into the engine itself.
If the spark plug has crackings on the insulating material, corroded electrodes
or excessive deposits, it must be changed.
Check the electrode gap with a thickness gauge.
Electrode gap should be 0.6 -0.7 mm (0.02-0.03 in). If it needs adjusting,
bend the earth electrode carefully.
Make sure the washer is in good condition. Fit the washer and screw the spark
plug finger-tight to avoid damaging the thread.
Tighten the spark plug by means of the spanner you will find in the tool kit,
giving it half a turn to compress the washer. Unscrew and tighten to the
prescribed torque.
Spark plug torque: 19 Nm (1.9 kgm).
The spark plug must be well tightened, otherwise the engine may
overheat and be seriously damaged. Replace only with spark plugs of
the type indicated in this manual.
Position the spark plug cap properly, so that it does not come off due to the
vibrations of the engine.
2 - 10 - 00
Release 00/2003 - 09
PERIODIC MAINTENANCE
QUASAR 125-180
2.8
IDLING ADJUSTMENT
1
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.
" BY SCREWING IT IN (clockwise), you increase the rpm;
" BY UNSCREWING IT (anticlockwise), you decrease the rpm.
" With the brakes engaged, accelerate and decelerate a few times to check
the operation of the throttle and to check if the idling speed is constant.
2.9
ADJUSTING THE THROTTLE CONTROL
NOTE Perform the maintenance operations more frequently if the vehicle is
1
used in rainy or dusty areas, on uneven surfaces or on racetracks.
The idle stroke of the throttle lever must be 2-6 mm.
If not, proceed as follows:
" Withdraw the protection elements (1).
" Slacken the locknut (2).
" Rotate the adjuster (3) in such a way as to restore the prescribed value.
" After the adjustment, tighten the lock nut (2) and check the idle stroke again.
" Refit the protection elements (1).
After the adjustment, make sure that the rotation of the handlebar does
not modify the engine idling rpm and that the throttle lever returns
smoothly and automatically to its original position after being released.
2
3
5
4
If necessary, turn the carburettor adjuster:
" Loosen locking nut (4).
" Turn nut (5) to adjust.
" Tighten nut (4).
Release 00/2003 - 09
2 - 11 - 00
PERIODIC MAINTENANCE
QUASAR 125-180
2.10 AIR CLEANER
1
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.
Upon reassembly, before positioning the filter case cover, make sure
that you have not left the cloth or other objects inside the filter case.
2
1
1
Make sure that the filtering element is positioned correctly, in such a
way as to prevent non-filtered air from entering.
Remember that the untimely wear of the piston rings and the cylinder
may be caused by a faulty or incorrectly positioned filtering element.
3
" Remove the rear shield, see 6.1.6 (REMOVING THE REAR SHIELD).
" Release and remove the seven screws (1).
" Remove the filter case cover (2).
" Loosen and remove the two screws (3) on the case.
" Remove the filter (4).
Change the filter with one having the same features.
4
2.11 FUEL VAPOURS FILTER
Carefully read 1.3 (GENERAL SAFETY RULES).
" Loosen and remove the two screws (1).
" Remove filter cover (2).
" Remove fuel vapours filter (3).
2
1
When cleaning the filtering element, make sure that it is not torn or
otherwise damaged. Otherwise, change the filtering element.
" Clean filter (3) outer surface using special tools for absorbing filters.
" If necessary, change the fuel vapours filter with one having the
same
features.
2
3
2 - 12 - 00
Release 00/2003 - 09
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).
1
NOTE Use only recommended oil, see 1.8 (LUBRICANT CHART).
When topping up engine oil, do not exceed the "MAX" level mark.
CHECKING THE ENGINE OIL LEVEL
" Position the vehicle on a firm and level ground.
2
Allow for the engine and the exhaust system to cool down.
" Stop the engine and let it cool down. This will allow the oil to settle into the
oil pan and cool down.
NOTE Accurate oil level measurement is only ensured when the above
procedures are observed.
" Unscrew and extract the plug/dipstick (1).
" Clean the dipstick portion in touch with oil with a clean cloth.
" Fully screw plug/dipstick inside filler opening (2).
" Remove plug/dipstick (1) again and read the oil level on the stick:
MAX = maximum level;
MIN = minimum level.
" The level is correct when the oil almost reaches the "MAX" mark on the
dipstick.
Never exceed the "MAX" mark, nor leave the oil below the "MIN" mark, in
order to avoid serious damage to the engine.
" If necessary, top up the engine oil.
TOPPING UP
" Pour a small amount of oil inside the filler opening (2) and wait for about
one minute to allow oil to uniformly settle down into the pan.
" Check engine oil level and, if necessary, top up.
" Top up with small amounts of oil until reaching the recommended level.
" Once finished, screw and tighten plug/dipstick (1).
NOTE Do not use the vehicle with a poor lubrication or with contaminated or
improper lubricants, as these factors make the moving parts wear more
rapidly and can lead to severe and irreparable damages.
Release 00/2003 - 09
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PERIODIC MAINTENANCE
QUASAR 125-180
2.11.2 CHANGING THE ENGINE OIL AND THE ENGINE OIL
FILTER
1
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.
" Stop the engine and let it cool down. This will allow the oil to settle into the
oil pan and cool down.
" Unscrew and extract the plug/dipstick (1).
" Place a container for collection under engine oil filter.
" Unscrew and remove plug (2). Save engine oil filter (3).
2
Used oil contains dangerous substances for the environment, dispose
of used oil in compliance with environment protection regulations in
force.
3
" Unscrew and remove the oil drain plug (4) and then drain off all engine oil.
" Clean oil mesh filter (3) with special detergents and refit filter (3) and plug
(2).
" Screw and tighten engine oil drain plug (4).
" Pour about 0.9 litres of oil into the filler opening.
" Screw and tighten the oil dipstick (1).
" Start the engine and let it run for several minutes. Stop the engine and let it
cool down.
" Check engine oil level, see
2.3 (PERIODIC MAINTENANCE CHART).
4
2 - 14 - 00
Release 00/2003 - 09
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PERIODIC MAINTENANCE
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. Run monthly in case of use
on muddy, wet or rough surfaces (off-road).
1
" Ride
for a few miles until reaching the normal running temperature, then
stop the engine.
" Place a graduated container no smaller than 200 cm³ (12.2 cu.in) under the
drain plug (1).
" Release the filler cap (2) as well as the drain plug (1).
" Allow the oil to completely drain out of the crankcase and measure the
quantity; if less than 200 cm³ (12.2 cu.in), refill to level with the missing
amount, see 1.8 (LUBRICANT CHART).
" Tighten the drain plug (1).
" Use a syringe or similar to inject the oil through the input hole.
NOTE To facilitate filling the crankcase, engage forward gear and turn the
wheels by hand.
" Refit and tighten the filler cap (2).
Tighten down the filler cap and drain plug carefully and check for leaks.
Check the crankcase cover gasket periodically for leaks.
Do not use the vehicle if insufficiently lubricated or if the oil is dirty or of
the wrong type, as this will increase the wear of moving parts and can
result in serious damage.
Release 00/2003 - 09
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PERIODIC MAINTENANCE
QUASAR 125-180
2.13 CHECKING AND ADJUSTING THE BRAKES
Read carefully 1.3 (GENERAL SAFETY RULES).
2
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.
If the thickness of the friction material is worn down to nearly 1 mm, replace
the blocks.
1
ADJUSTING THE FRONT BRAKES
Operate the right hand brake lever:
" Loosen the lock nuts (1).
" Adjust the brake adjuster (2).
" Loosen the lock nuts (1).
3
ADJUSTING THE REAR BRAKE
Adjust the adjuster (3) at the side of the rear brake drum.
" Adjust the left side brake adjuster (3).
ADJUSTING THE BRAKE PEDAL
There are two adjustments:
- brake pedal adjuster (5);
- rear brake adjuster (4).
4
5
6
2 - 16 - 00
The first of these adjusts all three brakes:
" Slacken the lock nut (6).
" Adjust the adjuster (5).
" Tighten the lock nut (6).
The second only adjusts the rear brake:
" Adjust the adjuster (4).
Release 00/2003 - 09
QUASAR 125-180
PERIODIC MAINTENANCE
2.14 CHECKING THE STEERING
2
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.
" Move the bottom yoke (2) in the direction of travel.
" If any play is evident, check the wear of the bush (3) and the tightness of the
nuts (4).
" Rotate the base of the headstock (2) manually in both directions.
" Check that the headstock base turns freely and evenly without noise,
otherwise replace the bearings, see 6.2.1 (REMOVING STEERING YOKE
WITH STEM).
1
3
4
2.15 INSPECTING THE FRONT SUSPENSIONS
Read carefully 1.3 (GENERAL SAFETY RULES).
Check the suspension every six months.
Check that the shock absorbers are not scratched or grooved. If they are,
replace the damaged parts.
Carry out the following checks.
With pulled front brake lever, press the handlebar repeatedly, thrusting the two
suspensions downwards.
The stroke must be gentle and there must be no trace of oil on the rods.
Check the fastening of all the components and the functionality of the front
suspension joints, see 6.2 (STEERING SYSTEM).
Release 00/2003 - 09
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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).
2.17 WHEELS
Read carefully 1.3 (GENERAL SAFETY RULES).
- Check the wheels for dents and distortions. If necessary replace them.
- Check the eccentricity of the wheels.
- Check the condition of the wheels and bearings.
- Check the balance of the wheels.
- Turn the wheel slowly several times and observe the point at which it stops.
- If the wheel is not statically balanced it will always stop at the same point. Fit
a balancing weight at the lightest (highest) point.
2.17.1 TYRES
This vehicle is fitted with tubeless tyres.
1
2 - 18 - 00
Check the tyre inflation pressures at regular intervals when the tyres are
cold, see 1.7 (TECHNICAL DATA). Checking pressure on hot tyres will
result in inaccurate measurement.
Take care to check tyres pressures before and after a long journey. An
overinflated tyre will provide a harsh ride, transmitting shock to the
handlebar and reducing riding comfort and stability when cornering.
An underinflated tyre will extend the contact patch to include a larger
portion of the tyre wall (1). This can result in cuts, the tyre moving on the
rim, or coming away from it, thus leading to the rider losing control of
the vehicle.
The tyre may even slip off the rim under hard braking. Lastly, the vehicle
may skid in a bend. Inspect tread surface and check for wear. Badly
worn tyres adversely affect traction and handling. Enquire about correct
wear inspection procedure with your supplier. Visually inspect the
treads and replace if too worn. If the tyres are old, even if they are not
completely worn down, they can harden and lose grip. In this case,
replace the tyres. Always change a worn tyre. A tyre that becomes
punctured in the tread area should be changed when the puncture is
larger than 5 mm (0.2 in). The wheels must be balanced after each tyre
repair. Use only tyres of the size indicated by the Manufacturer, see 1.7
(TECHNICAL DATA). Never use tube tyres on tubeless tyre rims. Always
check that the caps are in place on the valves, or the tyres may deflate
suddenly. Tyre replacement and repair, and wheel servicing and
balancing are delicate operations. They should be carried out using
adequate tools and are best left to experienced mechanics. New tyres
may be coated with an oily film: drive carefully for the first several
kilometres.
Release 00/2003 - 09
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.
NOTE Perform the maintenance operations more frequently if the vehicle is
used in rainy or dusty areas, on uneven surfaces or on racetracks.
CHECKING THE SLACK
To check the slack, proceed as follows:
" Stop the engine.
" Loosen and remove screw (1).
" Remove chain tensioner (2). Take care not to damage the return spring.
" Make sure that the vertical oscillation, in an intermediate point between front
and rear sprocket in the upper part of the chain, is about 50~60 mm.
" Move the vehicle forwards, or turn the wheel, in order to be able to check
the vertical oscillation of the chain even when the wheel turns; the slack
must be constant in all the rotation phases of the wheel.
" Refit chain tensioner (2) with spring and tighten screw (1).
2
1
If in some positions the slack is higher than in others, this means that
there are crushed or seized links; in this case, replace the chain, see
6.7.1 (DISASSEMBLING THE CHAIN). To prevent the risk of seizures,
lubricate the chain frequently.
If the slack is even, but exceeding the maximum limit allowed, adjust it.
ADJUSTMENT
If after the check it is necessary to adjust the chain tension, proceed as
follows:
50 ÷ 60 mm
" Slacken the four screws (3).
" Partly slacken the two lock nuts (4) on the tensioners (5).
" Adjust the chain tension with the tensioners (5).
" After the adjustment, tighten the lock nuts (4).
" Tighten the four screws (3).
" Check that the slack is now within the maximum limit allowed.
3
CHECKING THE DRIVING CHAIN, FRONT AND REAR SPROCKET WEAR
Further, check the following parts and make sure that chain, front and rear
sprockets do not show:
- damaged rollers;
- loose pins;
- dry, rusty, crushed or seized links;
- excessive wear;
- sprocket or teeth excessively worn or damaged.
3
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4
5
5
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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.
Never wash the chain with water jets, steam jets, high-pressure water jets and
highly inflammable solvents.
" Wash the chain with naphtha or kerosene.
" After washing and drying the chain, lubricate
with spray grease, see 1.8
(LUBRICANT CHART).
" Do not use the vehicle soon after lubricating the chain, since due to the
centrifugal force the lubricant would be sprayed outwards and dirty the
surrounding areas.
" If it tends to rust quickly, intensify the maintenance intervals.
2.19 MULTIFUNCTION COMPUTER
The vehicle is equipped with an electronic device to measure the vehicle
speed, the elapsed time and to store the distance covered.
When the vehicle is unused, always keep the dial protected against
direct sun rays.
Never remove any part of the multifunction computer, battery cover
excluded.
Before using the vehicle, make sure that all the parts composing the
multifunction computer are correctly assembled.
NOTE Switch the multifunction computer on before starting the vehicle. If this
is not the case, the operation of the computer itself could be impaired. The
multifunction computer is provided with an automatic shutoff device in case
the instrument is left unused for more than 5 minutes.
NOTE When the vehicle is unused or left unattended, always remove the dial
from its mount.
2 - 20 - 00
Release 00/2003 - 09
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
5) Time display
6) Function indicator
7) Battery cover
8) Contacts
Accessories:
- mounting support
- speed sensor
- clip
- magnet
- steel ring
- rubber seal
- cable tie
- screw
- battery
6
3
MAX
MO DE
4
5
7
KM/H
T/RESET
SE
2
1
8
Setting the units of measurement
To select the desired units of measurements, press push button (1). Confirm
by pressing push button (2).
NOTE When setting the units of measurements, the instrument will also
display the reset value of the wheel diameter; press push button (1) to set this
value to 168 and store the set data by pressing push button (2).
Main functions
Before carrying out any setting or adjustment on the multifunction computer,
working from below, fit the dial on its mount on the vehicle.
Press push button (2) repeatedly so as to make the following functions appear
in the following order.
To start storing data, press push button (1) (the units of measurement
indicator is flashing). To stop data storing, press push button (1) again (the
units of measurement indicator is not flashing).
2
1
f
b
c
d
a
MAS
ODO
DST
AVS
TM
MO DE
KM/H
T/RESET
SE
e
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PERIODIC MAINTENANCE
QUASAR 125-180
f
b
c
d
a
MAS
ODO
DST
AVS
TM
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.
The counter will be automatically reset when reaching 10,000 Km.
KM/H
NOTE When the multifunction computer battery is removed, all stored values
will be deleted.
MO DE
T/RESET
SE
DST function (c)
The DST function indicates the partial distance covered by the vehicle.
The counter will be automatically reset when reaching 1,000 Km.
To manually reset counter, press push buttons (1) and (2) at the same time.
e
AVS function (d)
The AVS function indicates the trip average speed.
To reset the stored speed value, press push buttons (1) and (2) at the same
time.
TM function (e)
The TM function indicates the time vehicle is being used.
The counter will be automatically reset when reaching 12 hours.
To manually reset counter, press push buttons (1) and (2) at the same time.
MAS function (f)
The MAS function indicates the maximum speed.
To manually reset counter, push buttons (1) and (2) at the same time.
2
1
3
2 - 22 - 00
Installing battery
Using a coin, undo the battery cover (3).
Install battery (3 V) inside its compartment. Take care to position positive pole
(+) pointing upwards and negative pole (-) pointing downwards.
Once finished, close battery cover (3) again.
Release 00/2003 - 09
QUASAR 125-180
PERIODIC MAINTENANCE
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.
Measure the wheelbase between the two marks.
Calculate the difference between the reading at the back and at the front.
Toe in: 5 mm ± 10
If the value is outside the specified limits, turn both linkages to equally change
their length. Keep ball-joint locked while turning.
Tighten check nuts.
Tightening torque: 35-43 Nm
Release 00/2003 - 09
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PERIODIC MAINTENANCE
QUASAR 125-180
NOTE
2 - 24 - 00
Release 00/2003 - 09
ENGINE
QUASAR 125-180
ENGINE
Release 00/2003 - 09
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ENGINE
QUASAR 125-180
ENGINE
CONTENTS
0
1
2
3
4
5
6
7
i
9
3.1.1
3.1.2
3.1.3
COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE INSTALLED ............................................ 3-4-00
REMOVING THE ENGINE FROM THE FRAME ............................................................................................. 3-5-00
FITTING THE ENGINE IN THE FRAME.......................................................................................................... 3-8-00
3.2 HEAD UNIT .............................................................................................................................. 3-9-00
3.2.1 REMOVING PROTECTION FAN..................................................................................................................... 3-9-00
3.2.2 REMOVING FLYWHEEL UPPER AND LOWER HOUSINGS ........................................................................ 3-9-00
3.2.3 REMOVING THE INTAKE MANIFOLD ........................................................................................................... 3-9-00
3.2.4 REMOVING THE HEAD ................................................................................................................................ 3-10-00
3.2.5 REMOVING THE TENSIONER ..................................................................................................................... 3-10-00
3.2.6 REMOVING CAMSHAFT COMPLETE MOUNT ........................................................................................... 3-11-00
3.2.7 REMOVING THE ROCKER ARMS ............................................................................................................... 3-11-00
3.2.8 REFITTING THE ROCKER ARMS................................................................................................................ 3-12-00
3.2.9 REMOVING THE CAMSHAFT ...................................................................................................................... 3-13-00
3.2.10 CHECKING BEARING PARTS ..................................................................................................................... 3-13-00
3.2.11 REFITTING THE CAMSHAFT....................................................................................................................... 3-14-00
3.2.12 ADJUSTING VALVE CLEARANCE.............................................................................................................. 3-15-00
3.2.13 REMOVING THE HEAD ................................................................................................................................ 3-15-00
3.2.14 CHECKING VALVES SEALING CAPACITY ................................................................................................ 3-15-00
3.2.15 REMOVING VALVES .................................................................................................................................... 3-16-00
3.2.16 CHECKS ........................................................................................................................................................ 3-16-00
3.2.17 VALVE SPRINGS FREE LENGTH................................................................................................................ 3-16-00
3.2.18 CHECKING VALVES AND VALVE SEATS.................................................................................................. 3-17-00
3.2.19 GRINDING ..................................................................................................................................................... 3-17-00
3.2.20 CHECKING THE HEAD AND CYLINDER .................................................................................................... 3-18-00
3.2.21 REFITTING VALVES AND HEAD................................................................................................................. 3-19-00
3.2.22 REMOVING THE CYLINDER ........................................................................................................................ 3-20-00
3.2.23 REMOVING THE PISTON ............................................................................................................................. 3-20-00
3.2.24 CHECKING THE CYLINDER ........................................................................................................................ 3-20-00
3.2.25 CHECKING THE PISTON ............................................................................................................................. 3-21-00
3.2.26 CHECKING PISTON RINGS ......................................................................................................................... 3-22-00
3.2.27 CHECKING PISTON GUDGEON PIN ........................................................................................................... 3-22-00
3.2.28 REFITTING THE PISTON.............................................................................................................................. 3-23-00
3.3 ALTERNATOR ........................................................................................................................ 3-24-00
3.3.1 REMOVING THE COOLING FAN ................................................................................................................. 3-24-00
3.3.2 REMOVING THE ALTERNATOR.................................................................................................................. 3-24-00
3.3.3 CHECKING THE FLYWHEEL ....................................................................................................................... 3-24-00
3.3.4 REMOVING THE FREEWHEELING CLUTCH.............................................................................................. 3-25-00
3.3.5 CHECKING THE STARTER CLUTCH .......................................................................................................... 3-26-00
3.3.6 REFITTING THE FREEWHEELING CLUTCH .............................................................................................. 3-26-00
3.4 OIL PUMP .............................................................................................................................. 3-27-00
3.4.1 REMOVING THE OIL PUMP ......................................................................................................................... 3-27-00
3.4.2 CHECKING THE OIL PUMP ......................................................................................................................... 3-28-00
3.4.3 REFITTING THE OIL PUMP.......................................................................................................................... 3-28-00
3.5 STARTER MOTOR.................................................................................................................. 3-29-00
3.5.1 REMOVING THE STARTER MOTOR ........................................................................................................... 3-29-00
3.5.2 REFITTING THE STARTER MOTOR............................................................................................................ 3-29-00
3.6 STARTING SYSTEM............................................................................................................... 3-30-00
3.6.1 REMOVING THE STARTING SYSTEM ........................................................................................................ 3-30-00
3.6.2 REFITTING THE STARTING SYSTEM......................................................................................................... 3-31-00
3.6.3 REMOVING THE PRIMARY BELT ROLLER................................................................................................ 3-32-00
3.6.4 CHECKING THE PRIMARY BELT ROLLER ................................................................................................ 3-33-00
3.6.5 REMOVING THE CLUTCH AND THE SECONDARY BELT ROLLER ........................................................ 3-34-00
3.6.6 CHANGING THE CLUTCH BLOCKS ........................................................................................................... 3-35-00
3.6.7 CHECKING THE CLUTCH ............................................................................................................................ 3-36-00
3.6.8 CHECKING THE SECONDARY BELT ROLLER.......................................................................................... 3-36-00
3.6.9 CHECKING THE BELT ................................................................................................................................. 3-36-00
3.6.10 REFITTING THE SECONDARY BELT ROLLER.......................................................................................... 3-37-00
3.6.11 REMOVING THE FINAL DRIVE GEARS ...................................................................................................... 3-38-00
3.6.12 REMOVING THE SELECTOR SHAFT.......................................................................................................... 3-39-00
3.6.13 REMOVING THE GEAR SELECTOR SPINDLE........................................................................................... 3-40-00
3.6.14 REMOVING THE GEAR LEVER MOUNT..................................................................................................... 3-40-00
3 - 2 - 00
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/ 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
3.7 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 .................................................................................................. 3-44-00
3.7.4 REFITTING THE CRANKCASE.................................................................................................................... 3-45-00
3.7.5 REFITTING THE CRANKSHAFT OIL SEAL ................................................................................................ 3-46-00
3.8 LUBRICATION SYSTEM ........................................................................................................ 3-47-00
3.8.1 REMOVING THE ENGINE OIL COOLER..................................................................................................... 3-47-00
3.8.2 REMOVING THE ENGINE OIL LINES.......................................................................................................... 3-47-00
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ENGINE
3.1.1
QUASAR 125-180
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
BOTTOM END
- Exhaust system
RIGHT-HAND SIDE
- Fan guard
- Sprocket
- Air scoop
- Flywheel
- Stator coil
- Gearbox
LEFT-HAND SIDE
- Transmission cover
- Speed converter unit
- Clutch unit
- Drive belt
- Converter pan
- Kick-start
3 - 4 - 00
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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).
" Remove both footpegs, see 6.1.7 (REMOVING THE FOOTREST).
To clean the outer parts of the engine use a degreaser, brushes and
wipers.
Ensure that no rubber or plastic parts come in contact with detergents
and corrosive or penetrating solvents.
Should you need a steam cleaner, do not direct water, steam or highpressure air jets towards any of the following parts: wheel hubs,
handlebar controls, main warning lights, exhaust silencer, main switch.
1
" Remove
the exhaust system, see 6.1.21 (REMOVING THE EXHAUST
PIPE).
" Remove the airbox, see 2.10 (AIR CLEANER).
2
Mark cables, hoses and pipes to avoid confusing them when refitting.
" Loosen and remove screw (1) and remove clip (2).
" Disconnect the alternator connectors (3).
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QUASAR 125-180
" Disconnect the spark plug cap (4).
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).
" Loosen and remove screw (5) and remove clip (5).
" Disconnect neutral light connector (7).
" Disconnect reverse gear connectors (8).
" Disconnect pedal stop switch connector (9).
" Release wirings from ties.
6
5
7
8
9
3 - 6 - 00
Release 00/2003 - 09
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.
" Loosen and remove the bottom screw (13) between engine and frame.
"!Loosen and remove the two top screws (14).
All fixings have now been removed.
Handle with care. Be careful to avoid injury to your hands, arms and
legs.
Clear all tools from the area. Thoroughly clean the area of the floor
where the engine is to be placed.
10
10
11
" Working on the left side, loosen and remove nut (15) on vehicle right side.
Save pin (16), spacer and the two brackets.
When refitting, seat the elements properly on the pin (16).
12
13
14
16
15
Release 00/2003 - 09
3 - 7 - 00
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.
Handle with care.
Be careful to avoid injury to hands, arms and legs.
" Check
the tension of the drive chain and adjust if necessary, see 2.18
(DRIVE CHAIN)
Inspect any parts you have removed, paying special attention to these
components:
- wiring must be properly fastened with wire ties.
Wires and hoses must not be twisted and/or crushed.
- Electrical connectors must be fitted to the matching connectors;
- Hoses and pipes and couplings must be securely in place and fastened with
suitable clips;
- The throttle cables must slide smoothly inside their housings and must not
bind when handlebars are turned.
" Restore engine oil level, see
2.11.1 (ENGINE OIL) and, if necessary, top up
transmission oil see 2.12 (CHECKING THE TRANSMISSION OIL LEVEL).
FOREWORD
Engine parts shall be disassembled working on a bench. The operations that
can be carried out with the engine assembled on frame will be accompanied
by a note.
The manufacturer declines all responsibility for any damages originated
by engine disassembly and reassembly operations carried out with
unsuitable tools.
3 - 8 - 00
Release 00/2003 - 09
ENGINE
QUASAR 125-180
3.2
HEAD UNIT
3
3.2.1
REMOVING PROTECTION FAN
2
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
1
NOTE Engine can be left assembled on frame.
" Remove
flywheel housing, see 3.2.2 (REMOVING FLYWHEEL UPPER
AND LOWER HOUSINGS).
" Remove intake manifold, see 3.2.3 (REMOVING THE INTAKE
MANIFOLD).
" Loosen and remove screws (1-2).
" Loosen and remove screw (3).
" Remove upper (4) and lower (5) housing.
1
2
3
4
5
3.2.3
REMOVING THE INTAKE MANIFOLD
NOTE Engine can be left assembled on frame.
1
" Remove carburettor, see 4.3 (REMOVING THE CARBURETTOR).
" Loosen and remove the two screws (1).
" Remove the intake manifold (2) and save the O-ring.
NOTE Change the O-ring at every reassembly.
2
Release 00/2003 - 09
3 - 9 - 00
ENGINE
QUASAR 125-180
3.2.4
2
1
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).
" Loosen and remove the four screws (3).
" Remove head cover (4).
NOTE Change the seal at every reassembly.
4
3
3
3.2.5
REMOVING THE TENSIONER
NOTE Engine can be left assembled on frame.
" Remove
2
1
flywheel upper housing, see 3.2.2 (REMOVING FLYWHEEL
UPPER AND LOWER HOUSINGS).
" Loosen and remove the two screws (1).
" Remove chain tensioner (2).
NOTE Change the seal at every reassembly.
3 - 10 - 00
Release 00/2003 - 09
ENGINE
QUASAR 125-180
3.2.6
REMOVING CAMSHAFT COMPLETE MOUNT
1
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).
" Remove camshaft complete mount (2).
2
NOTE At reassembly, position the mount with the two "E-X" letters facing the
exhaust pipe.
1
3.2.7
REMOVING THE ROCKER ARMS
3
NOTE Engine can be left assembled on frame.
" Remove
camshaft complete mount, see 3.2.9 (REMOVING THE
CAMSHAFT).
" Position camshaft complete mount on a resting surface.
" Remove the two shafts (1-2) and save the two rocker arms (3) and plate (4).
1
NOTE While removing, check the position of the two shafts (1-2) not to
mismatch them at reassembly.
Release 00/2003 - 09
4
2
3 - 11 - 00
ENGINE
QUASAR 125-180
3.2.8
2
REFITTING THE ROCKER ARMS
" Position plate (1) and the two rocker arms (2) onto mount (3).
" Install the two shafts (4-5).
1
4
NOTE Make sure that the two shafts (4-5) are correctly positioned.
" Refit
the complete camshaft mount and tighten the four screws (6)
crossways.
" Refit head cover and tighten the four screws (7) crossways.
3
2
5
6
6
7
3 - 12 - 00
7
Release 00/2003 - 09
ENGINE
QUASAR 125-180
3.2.9
REMOVING THE CAMSHAFT
1
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.
" Remove camshaft (2).
2
3.2.10 CHECKING BEARING PARTS
3
Rotate bearings (1-2) by hand. They must run smoothly, must not jam at any
positions and/or be quiet.
No axial play shall be present.
Change the camshaft if bearings are noisy, run hard or have play.
4
CAMS
Check cams (3) for wear. If excessively worn, scored or scratched, change the
camshaft.
TOOTHED GEAR
Check gear (4) teeth for wear. If excessively worn, change the camshaft.
ROCKER ARMS
Check the amount of wear on the rocker arm surface in touch with the cams. If
excessively worn, change the camshaft.
Release 00/2003 - 09
1
2
3 - 13 - 00
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.
" Turn camshaft so as to fully close both valves.
" Drive chain onto toothed gear by taking care that, after being installed onto
camshaft, the reference marks (1) are parallel with the head edge.
" Remove tensioner top screw (2) and remove the spring from the inside.
" Push on the stop tooth to move back rocker arm.
" Change seal and refit mount. Tighten the two screws (3).
" Fit spring and tensioner screw, then manually turn crankshaft by 3 or 4 turns
and check once more timing reference marks correct positioning.
Before turning crankshaft by hand, check that spark plug is not into its
location.
1
" Proceed
to valve adjustment, see 3.2.12 (ADJUSTING VALVE
CLEARANCE).
" Refit the complete camshaft mount and, working crossways, tighten the four
screws (4).
" Refit head cover and, working crossways, tighten the four screws (5).
2
3
4
4
5
3 - 14 - 00
5
Release 00/2003 - 09
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. Clearance must be: 0.08 mm (0.003 in).
3.2.13 REMOVING THE HEAD
2
" Remove camshaft, see 3.2.9 (REMOVING THE CAMSHAFT).
" Loosen and remove the two screws (1).
" Remove head (2).
3.2.14 CHECKING VALVES SEALING CAPACITY
To perform this test, fill intake and exhaust ducts with fuel.
In case of leaks, proceed to grinding, see 3.2.19 (GRINDING).
Release 00/2003 - 09
1
3 - 15 - 00
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.
" Remove exhaust valve guide oil seal.
" Thoroughly clean mating surfaces. Do not damage them.
" Thoroughly clean the combustion chamber. Remove any carbon deposits.
Take care not to score valve seats while cleaning these parts.
3.2.16 CHECKS
Check the combustion chamber for cracks or damage.
Using a scale, check that cylinder head bottom surface is perfectly flat. Take
measurements as shown in the figure, see 3.2.20 (CHECKING THE HEAD
AND CYLINDER).
3.2.17 VALVE SPRINGS FREE LENGTH
Measure springs length:
-inner spring 31.2 mm (1.228 in)
-outer spring 34.1 mm (1.342 in)
3 - 16 - 00
Release 00/2003 - 09
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.
SI
NO
NOTE Measurements must be taken at valve stems working area ("N") end,
radially and in different positions.
Check valve seats for cracks or damage.
Check valve stem "S" diameter and valve guide "G" inner diameter.
Measurements must be taken at working area end.
Calculate the gap between stem and guide. Allowed limit: intake 0.08 mm
(0.003 in) exhaust 0.10 mm (0.004 in).
NOTE If excessively worn, change head and valves.
N
S
S
V
V
G
3.2.19 GRINDING
To ensure optimum sealing, proceed to valve grinding. Use fine lapping
compound with extreme care. While carrying out this operation, keep the head
with valve axes in horizontal position in order to avoid any lapping compound
residues from entering between valve guide and stem (see figure).
To avoid any scores on the mating surface, stop turning the valve when
the lapping compound is over. Thoroughly wash head and valve using a
product compatible with the lapping compound used.
Release 00/2003 - 09
3 - 17 - 00
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. If necessary, restore head flatness - 0.05 mm
limit - as follows:
- rest a metal scale on cylinder head and check flatness with a feeler gauge.
If the value is outside the specified limits, restore flatness using 400-600
soaked emery cloth and working following a "8" movement.
Repeat the same check on the cylinder.
Check that cylinder wall is not seized, worn or scored.
3 - 18 - 00
Release 00/2003 - 09
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; spring underneath,
which is compressed, could suddenly slip off its seat and injure the
operator.
" Using a plastic or a wood hammer, gently tap on valve stems to settle collets
into their seats. Make sure that valve is free to move inside its working area.
Carry out this operation with great care since parts could be damaged
and the operator injured.
" Refit head to engine. Change head gasket.
" Tighten the two screws (1).
" Refit camshaft, see 3.2.11 (REFITTING THE CAMSHAFT).
1
Release 00/2003 - 09
3 - 19 - 00
ENGINE
QUASAR 125-180
3.2.22 REMOVING THE CYLINDER
1
" Remove the head, see 3.2.13 (REMOVING THE HEAD).
" Remove seal (1).
" Remove upper sliding shoe (2).
" Remove cylinder (3).
" Remove seal (4).
2
4
3
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.
" Remove gudgeon pin (2) circlip (1).
" Remove gudgeon pin (2).
" Remove piston (3).
1
2
3
3.2.24 CHECKING THE CYLINDER
Check that cylinder inner walls are not seized or excessively worn. Measure
cylinder inner diameter using a bore gauge.
Wear limit 0.10 mm (0.004 in) beyond cylinder nominal size (see Coupling
table).
Measure the diameter at three different positions along the cylinder height
and, at each position, take the reading along the circumference.
3 - 20 - 00
Release 00/2003 - 09
QUASAR 125-180
ENGINE
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.
Thoroughly inspect piston skirt. If hard carbon deposits are present, soak the
whole piston in a suitable liquid, such as that used to clean carburettors.
Hard carbon detergents are very dangerous; their vapours can cause
severe diseases and the contact with skin or eyes causes immediate
severe injuries. Always use the recommended protective equipment,
such as goggles and gloves and thoroughly follow the instructions and
the warnings written on the detergent container.
After cleaning, some light scores could still be present on the piston skirt. Do
not care.
In case of deep scores, change the piston.
Measure the piston diameter at 5 mm from piston lower edge using a
micrometer gauge, as shown.
Piston-cylinder coupling shall not be above 0.10 mm.
Release 00/2003 - 09
3 - 21 - 00
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. To do so, position the piston ring squarely with the cylinder using the
bare piston.
Position piston ring inside its original location on cylinder upper side.
3.2.27 CHECKING PISTON GUDGEON PIN
Carefully inspect gudgeon pin: it must be perfectly smooth, without scorings,
steps or blueish stains due to overheating. In case of scores or steps, or if
blueish/greyish stains are present, change the gudgeon pin. In case the
gudgeon pin colour is slightly matt, do not change it.
Measure gudgeon pin outer diameter (D).
Gudgeon pin outer diameter:
14.960 mm.
Check gudgeon pin seat diameter.
Gudgeon pin seat diameter:
15.04 mm.
Check gudgeon pin seat diameter inside the connecting rod.
Connecting rod inner diameter:
15.06 mm.
3 - 22 - 00
Release 00/2003 - 09
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.
" Fit piston (1) with the "IN" mark on intake valve side.
" Install gudgeon pin and fit the new gudgeon pin circlips (2).
1
Position gudgeon pin circlip opening along the cylinder axis.
NOTE When fitting the gudgeon pin-piston assembly, block off the casing
opening with a clean cloth to prevent gudgeon pin circlips from falling inside
the engine.
" Fit cylinder (3) with engine block gasket (4).
" Refit head, see 3.2.21 (REFITTING VALVES AND HEAD).
2
4
Release 00/2003 - 09
3
3 - 23 - 00
ENGINE
QUASAR 125-180
3.3
1
3.3.1
ALTERNATOR
REMOVING THE COOLING FAN
NOTE Engine can be left assembled on frame.
2
" 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
" Remove the cooling fan, see 3.3.1 (REMOVING THE COOLING FAN).
" Remove the flywheel nut (1) with washer.
" Using the special "Flywheel puller" (part no. 8910600), remove the flywheel
1
and save the key.
2
The flywheel nut is strongly tightened; proceed with extreme care not to
hurt your hands.
" Disconnect connectors (3 - 4) from wiring.
1
Take care not to damage seal and cable.
" Loosen and remove the two screws (5). Save the plate.
" Loosen and remove the two screws (6).
" Loosen and remove the two screws (7).
" Remove the stator (8).
3
3.3.3
CHECKING THE FLYWHEEL
Proceed to a mechanical check of all flywheel components. Check key seat
and keyway on crankshaft for wear. Change those parts which are excessively
worn.
4
5
5
6
7
8
3 - 24 - 00
Release 00/2003 - 09
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
1
2
spanner" (part no. 8910599). Save the spacer.
" Remove the freewheeling clutch (5) with the toothed gear (6) and the roller
bearing (7).
1
1
3
4
7
6
Release 00/2003 - 09
5
3 - 25 - 00
ENGINE
QUASAR 125-180
3.3.5
2
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. If excessivley worn, change them.
Check roller bearing (2) for wear.
1
3.3.6
1
REFITTING THE FREEWHEELING CLUTCH
" Fit the roller bearing (1) and the toothed gear (2) on the freewheeling clutch
(3).
" Fit the complete freeweheeling clutch on the crankshaft.
" Position shim and tighten locking ring nut (4).
" Fit starter motor gear (5).
" Change gasket and fit casing (6). Tighten the seven screws (7).
" Refit the alternator, see 3.3.2 (REMOVING THE ALTERNATOR).
2
3
5
4
7
6
7
3 - 26 - 00
7
Release 00/2003 - 09
ENGINE
QUASAR 125-180
3.4
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).
" Loosen and remove the two screws (1). Save the plate (2).
" Loosen and remove nut (3).
" Remove the toothed gear (4). Save the chain.
" Loosen the two screws (5).
" Remove the oil pump (6).
1
2
4
3
5
6
Release 00/2003 - 09
3 - 27 - 00
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.
3.4.3
REFITTING THE OIL PUMP
" Fit pump (1) and tighten the two screws (2).
" Fit the toothed gear (2) with chain and tighten nut (4).
" Fit plate (5) and tighten the two screws (6).
" Refit the starter clutch, see 3.6.5 (REMOVING THE
2
CLUTCH AND THE
SECONDARY BELT ROLLER).
" Fill engine oil, see 2.11.2 (CHANGING THE ENGINE OIL AND THE
ENGINE OIL FILTER).
1
3
4
6
5
3 - 28 - 00
Release 00/2003 - 09
ENGINE
QUASAR 125-180
3.5
3.5.1
STARTER MOTOR
REMOVING THE STARTER MOTOR
2
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).
" Disconnect connector (3).
" Loosen and remove the two screws (4).
3
4
1
3.5.2
REFITTING THE STARTER MOTOR
" Make sure that the O-ring (1) is correctly seated, apply a thin layer of special
grease for oil seals, see 1.8 (LUBRICANT CHART). Refit the starter motor
(2).
" Position and tighten the two screws (3).
" Reconnect connector (4) and tighten screw (5).
2
1
4
3
5
4
Release 00/2003 - 09
3 - 29 - 00
ENGINE
QUASAR 125-180
3.6
STARTING SYSTEM
2
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).
" Loosen and remove the eight screws (5).
" Remove the casing (6).
" Remove the converter, see 3.6.3 (REMOVING THE PRIMARY
1
BELT
ROLLER).
4
Spring (7) is pre-loaded.
" Using a pair of pincers, release the lever (7) return spring.
" Remove the starter shaft (8).
" Remove the sliding gear (9).
3
5
5
5
5
6
9
5
7
8
3 - 30 - 00
Release 00/2003 - 09
ENGINE
QUASAR 125-180
3.6.2
REFITTING THE STARTING SYSTEM
6
" Refit the return spring (1) first, and then the starter shaft (2).
1
NOTE Make sure that the reference mark (3) on the starter shaft (2) is facing
the sliding gear (4) axis.
" Hook-up the return spring (1) to the starter shaft (2) and, using a stretching
hook, secure the other spring end on the shaft.
NOTE When refitting the spring (1), take care not to over-stretch it while
hooking.
5
4
3
2
If over-stretched, the spring could yield.
8
8
8
Danger.
Refit the sliding gear (4) first and then the spring. Slightly move the starter
shaft (2) so as to make gear fitting easier.
NOTE Make sure that the reference mark (5) on the sliding gear is facing the
crankshaft (6) axis.
NOTE Grease the spring and the toothed part with the recommended grease,
see 1.8 (LUBRICANT CHART).
" Refit the converter, see 3.6.3 (REMOVING THE PRIMARY BELT ROLLER).
" Refit the casing (7).
" Position and tighten the eight screws (8).
" Fit the kick-start pedal (9) and tighten the screw (10).
" Refit the filter (11) and tighten the clip (12).
" Refit the left footrest, see 6.1.7 (REMOVING THE FOOTREST).
8
7
8
9
10
11
12
Release 00/2003 - 09
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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. 8900673).
" Remove the tapered washer (2).
NOTE At reassembly, make sure that washer (2) is correctly positioned.
" Remove primary (fixed) belt roller (3).
" Remove bushing (4), primary (mobile) belt roller (5) and block holder at the
same time.
Do not disassemble belt roller from block holder as the six inner blocks
could fall to the ground.
" Separate belt roller from block holder and remove the six inner blocks.
NOTE At reassembly, change the seal.
1
3
2
5
4
3 - 32 - 00
Release 00/2003 - 09
QUASAR 125-180
3.6.4
ENGINE
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. If it runs hard or in case of excessive play, change both
belt roller and bushing.
Check block outer diameter: it shall not be below the max. wear limit. If
necessary, change them.
Change blocks in case their cylindrical side is faceted.
Wear limit: 14.6 mm.
Check block holder and the 3 driving blocks for wear. If excessively worn,
change them.
Release 00/2003 - 09
3 - 33 - 00
ENGINE
QUASAR 125-180
3.6.5
1
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; proceed with extreme care not to
hurt your hands.
" Slide out belt and remove clutch housing (2).
" Remove the secondary belt roller unit (3).
" Compress the unit with the special tool (universal
3
tool to disassemble/
assemble clutch units part no. 8900674) and remove the clutch nut (4).
The spring is compressed.
" Remove the clutch blocks mount (5) first, then the counter spring (6), the
spring seat (7) and the complete secondary belt roller (8).
" Remove the two stop teeth (9) and separate the fixed secondary belt roller
(10) from the mobile one (11).
2
4
7
8
5
6
11
10
9
3 - 34 - 00
Release 00/2003 - 09
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.
" Remove the three blocks (4).
1
2
3
4
Release 00/2003 - 09
3 - 35 - 00
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.
Clean clutch blocks with a jet of compressed air. If vitrified, remove the
deposits with emery cloth.
NOTE Once vitrified deposits have been removed, blow with compressed air
to thoroughly clean the blocks from grinding residues.
If necessary, change clutch blocks, see 3.6.6 (CHANGING THE CLUTCH
BLOCKS).
1
2
3.6.8
CHECKING THE SECONDARY BELT ROLLER
Check that the secondary belt roller is not worn and that it runs smoothly and
without jams. If it runs hard or if excessively worn, change the belt roller.
Check the groove, the stop teeth, the two O-rings (1) and the two oil seals (2).
If damaged or worn, change them.
Measure (secondary belt roller) counter spring free length. If outside the
specified limits, change the spring.
Free length: 164.0 mm.
2
3.6.9
CHECKING THE BELT
Check that the belt is free from cuts, cracks, excessive wear and oil. If not so,
change it.
Measure the head width at different positions of the belt. If outside the
specified limits, change the belt.
Standard width: 19.0 mm.
3 - 36 - 00
Release 00/2003 - 09
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).
5
1
Apply a stripe of adhesive tape around the belt roller end to avoid oil
seal lips overturning while fitting the belt roller.
Fit the two stop teeth (3) and apply some grease inside the mobile belt roller
(2) groove.
Before assembling, grease also the O-rings (4) on the mobile secondary belt
roller.
Fit the spring (5) seat and check that belt roller and return spring run smoothly.
3
4
Remove any exceeding grease.
2
Release 00/2003 - 09
3 - 37 - 00
ENGINE
QUASAR 125-180
3.6.11 REMOVING THE FINAL DRIVE GEARS
2
" Drain off all transmission oil, see 2.12 (CHECKING THE TRANSMISSION
1
OIL LEVEL).
clutch, see 3.6.5 (REMOVING THE CLUTCH AND THE
SECONDARY BELT ROLLER).
" Remove
NOTE Block off the final drive casing with a cloth to collect any oil leaks.
" Loosen and remove the seven screws (1).
" Remove the right casing (2).
" Working on the left casing, remove the following parts in the given order:
1
- reverse gear shaft (3)
- forward gear shaft (4)
- clutch shaft (5)
1
4
5
The following operations apply to the right casing.
" Remove from shaft (6) the following parts in the given order:
- the snap ring
- the fixed washer(7)
- the toothed gear (8)
- the fixed washer (9)
- the snap ring (10).
" Loosen and remove nut (11). Save the washer.
" Remove the rear sprocket (12).
" Remove the selector belt roller (13).
3
8
10
7
9
6
12
11
6
3 - 38 - 00
13
Release 00/2003 - 09
ENGINE
QUASAR 125-180
" Remove shaft (6) with toothed gear (14).
" Remove the circlip (15).
" Remove the toothed gear (14) from shaft (6).
14
6
15
14
6
3.6.12 REMOVING THE SELECTOR SHAFT
" Remove the final drive gears, see
1
3.6.11 (REMOVING THE FINAL DRIVE
GEARS).
2
" Loosen and remove nut (1).
" Remove arm (2).
" Loosen and remove screw (3).
" Remove the complete selector shaft (4).
3
4
Release 00/2003 - 09
3 - 39 - 00
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).
" Remove the gear selector spindle (2) and the spring (3).
1
1
3
2
3.6.14 REMOVING THE GEAR LEVER MOUNT
NOTE Engine can be left assembled on frame.
" Remove the lever.
" Loosen and remove mount (1).
1
3 - 40 - 00
Release 00/2003 - 09
ENGINE
QUASAR 125-180
3.6.15 CHECKING THE TRANSMISSION UNIT
2
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. Change those parts which are excessively worn.
Check bearings for scores and seizure. If necessary, change them.
3
1
Check that gear selector can run smoothly and, in case of malfunctioning,
change it.
4
5
6
7
8
Release 00/2003 - 09
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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.
" Fit the following parts onto shaft (1) in the given order:
- snap ring (5)
- fixed washer (6)
- toothed gear (7)
- fixed washer (8)
- snap ring.
2
1
1
The following operations apply to the left casing.
" Fit the clutch shaft (9) first and then the oil seal.
" Then fit the forward gear (10) and the reverse gear (11).
" Join the two pans. Change the gasket.
" Tighten screws (12) working crossways.
3
4
7
5
8
6
10
9
11
12
12
3 - 42 - 00
12
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ENGINE
QUASAR 125-180
3.7
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
2
SYSTEM).
" Remove the oil pump gear and the drive chain, see
3.4.1 (REMOVING THE
OIL PUMP).
" Loosen and remove screw (1).
" Gently tap with a rubber hammer on the right casing (2) to separate it from
crankshaft (3).
" Loosen and remove screw (4) on lower chain sliding shoe (5).
" Remove lower chain sliding shoe (5).
" Using special tool ("Gear puller" part no. 8910601), remove kick-start pedal
gear (6).
" Gently tap with a rubber hammer on the crankshaft (3) from outside the left
casing and remove the complete crankshaft (3).
1
4
5
6
6
3
Release 00/2003 - 09
3 - 43 - 00
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. It shall not be bent, and must perfectly run at right
angles with the crankshaft.
3.7.3
1
REMOVING ENGINE RUBBER BUSHING
NOTE The following operations refer to the removal of a single rubber
bushing, but apply to the four of them.
" Heat the casing with an automatic heater up to about 150°C (~ 10 minutes).
" Using an hydraulic press, remove rubber bushing (1) working from the
outside to the inside and pressing all around the rubber bushing.
3 - 44 - 00
Release 00/2003 - 09
ENGINE
QUASAR 125-180
3.7.4
REFITTING THE CRANKCASE
1
2
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).
" To fit crankshaft (1) to left casing (2), install valve drive chain.
" Heat up right casing, as previously described for the left one, and fit it to
crankshaft.
" Tighten retaining screw (3).
To carry out the following operations, work on engine left side.
" Install kick-start pedal gear (4), with the chamfered edge facing downwards,
onto crankshaft.
" Refit lower chain sliding shoe (5) and secure it in place with screw (6).
" Refit kick-start pedal system, see 3.6.2 (REFITTING THE STARTING
SYSTEM).
To carry out the following operations, work on engine right side.
" Refit gear and pump drive chain, see 3.4.3 (REFITTING THE OIL PUMP).
" Refit the electric starting system, see 3.6.2 (REFITTING THE STARTING
SYSTEM).
" Refit the piston, see 3.2.28 (REFITTING THE PISTON).
Once finished, check for crankshaft (1) correct positioning. It shall be free to
turn without any jamming.
3
NOTE If needed, restore axial play with a mallet.
6
Do not use any metal mallet, but a rubber or plastic mallet. Never tap
directly on the crankshaft.
5
Release 00/2003 - 09
4
3 - 45 - 00
ENGINE
QUASAR 125-180
3.7.5
2
1
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.
" Once finished, make sure that the oil seal (1) lip is properly seated inside the
casing (3), as shown in the figure.
" Working on engine right side, fit the oil seal as described above.
3
1
1
3
3 - 46 - 00
Release 00/2003 - 09
ENGINE
QUASAR 125-180
3.8
LUBRICATION SYSTEM
3.8.1
1
REMOVING THE ENGINE OIL COOLER
1
" 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).
" Remove the oil cooler (4).
2
3
4
3.8.2
1
REMOVING THE ENGINE OIL LINES
" Drain
all oil out of the circuit, see 2.11.2 (CHANGING THE ENGINE OIL
AND THE ENGINE OIL FILTER).
" Put a container under the engine oil pipe.
" Loosen and remove screw (1). Save the two washers.
" Loosen and remove the two screws (2).
" Remove engine oil pipe (3). Save the O-rings.
If necessary, repeat the same procedure on the other pipe.
2
3
Release 00/2003 - 09
3 - 47 - 00
ENGINE
QUASAR 125-180
NOTES
3 - 48 - 00
Release 00/2003 - 09
FUEL SYSTEM
QUASAR 125-180
FUEL SYSTEM
Release 00/2003 - 09
4
4 - 1 - 00
FUEL SYSTEM
QUASAR 125-180
FUEL SYSTEM
CONTENTS
4.1
0
MAINTENANCE........................................................................................................................ 4-3-00
4.2 DRAINING THE FUEL TANK .................................................................................................... 4-3-00
4.2.1 CARBURETTOR ............................................................................................................................................. 4-4-00
4.2.2 CARBURETTOR FEATURES ......................................................................................................................... 4-4-00
4.3
REMOVING THE CARBURETTOR ............................................................................................ 4-5-00
1
2
3
4
5
6
7
i
9
4 - 2 - 00
Release 00/2003 - 09
FUEL SYSTEM
QUASAR 125-180
4.1
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.
4.2
DRAINING THE FUEL TANK
Read carefully 1.3 (GENERAL SAFETY RULES).
Risk of fire. Allow for the engine and exhaust silencer to cool down
completely. Fuel vapours are harmful to human health. Ensure that the
room is well ventilated before proceeding. Do not inhale fuel vapours.
Do not smoke or use bare flames near fuel vapours.
DO NOT RELEASE FUEL INTO THE ENVIRONMENT.
" The engine should be off and completely cold.
" Prepare a container of more than adequate capacity to contain the amount
of fuel in the tank. Place the container on the floor on the right-hand side of
the motorcycle.
" Remove the fuel tank filler cap (1).
" Use a manual pump or similar system to drain the fuel tank.
1
3
After draining the tank, close the fuel filler cap (1).
To drain the carburettor completely, proceed as follows:
" Place the free end of the hose (2) into a container.
" Working on the left-hand side of the vehicle front, open the fuel drain by
releasing the drain screw (3) below the tank.
" When all the fuel in the carburettor has drained out, fully tighten down the
drain screw (3).
2
Tighten the drain screw (3) to avoid fuel leaks from the carburettor when
refilling.
Release 00/2003 - 09
4 - 3 - 00
FUEL SYSTEM
4.2.1
QUASAR 125-180
CARBURETTOR
2
10
9
1
3
8
4
5
7
6
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
Intake manifold
FEATURES
ø 22.2 (23.0 x 21.0)
Throttle valve
ø 24.0
Intake hole
ø 38.0
Maximum flow
# 110
Maximum air flow
# 90
Taper needle
MGM 3/3
Nozzle
ø 2.6
Minimum flow
# 35
Minimum air flow
# 90
Fuel level
29.5
Air screw
2 1/2 turn
Float
6g
4 - 4 - 00
Release 00/2003 - 09
FUEL SYSTEM
QUASAR 125-180
4.3
REMOVING THE CARBURETTOR
NOTE Close the fuel tap to avoid fuel leaks.
3
1
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).
" Loosen clip and disconnect air hose (5).
" Loosen clip (6) and remove carburettor (7) from manifold (4).
2
Plug the intake hose (4) with a clean cloth.
" Loosen the two nuts (8).
" Slide out cable (9).
" Remove the carburettor (7).
" Loosen and remove the two screws (10) and remove the automatic starter
4
(11) from carburettor (7).
2
5
8
7
6
4
9
11
10
Release 00/2003 - 09
4 - 5 - 00
FUEL SYSTEM
QUASAR 125-180
NOTES
4 - 6 - 00
Release 00/2003 - 09
ELECTRIC SYSTEM
QUASAR 125-180
ELECTRIC SYSTEM
Release 00/2003 - 09
5
5 - 1 - 00
ELECTRIC SYSTEM
QUASAR 125-180
ELECTRIC SYSTEM
CONTENTS
0
1
2
3
5.1 FOREWORD.............................................................................................................................. 5-3-00
5.1.1 CABLE COLOURS.......................................................................................................................................... 5-3-00
5.1.2 ELECTRICAL CONNECTORS........................................................................................................................ 5-3-00
5.2
ELECTRICAL COMPONENTS ................................................................................................... 5-4-00
5.3 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
5.4 IGNITION SYSTEM .................................................................................................................. 5-7-00
5.4.1 HIGH TENSION COIL...................................................................................................................................... 5-8-00
5.5
CHECKING THE GENERATOR IDLE OPERATION ................................................................... 5-9-00
5.6
CHECKING THE ALTERNATOR CONTINUITY......................................................................... 5-9-00
5.7 CHECKING THE IGNITION COIL ............................................................................................. 5-9-00
5.7.1 CHECKING THE PICK-UP SENSOR.............................................................................................................. 5-9-00
5.8
AUTOMATIC STARTER.......................................................................................................... 5-10-00
5.9 CHECKING THE C.D.I. CONTROL UNIT ................................................................................ 5-11-00
5.9.1 CHECK DATA ............................................................................................................................................... 5-11-00
5.10 FUEL LEVEL SENSOR............................................................................................................ 5-12-00
5.11 SWITCHES ............................................................................................................................. 5-13-00
4
5
6
5.12 STARTING CIRCUIT .............................................................................................................. 5-15-00
5.12.1 WIRING DIAGRAM........................................................................................................................................ 5-15-00
5.12.2 TROUBLESHOOTING................................................................................................................................... 5-16-00
5.12.3 CHECK DATA ............................................................................................................................................... 5-16-00
5.13 BULBS ................................................................................................................................... 5-18-00
5.13.2 CHANGING THE HEADLIGHT BULBS ........................................................................................................ 5-20-00
5.13.3 CHANGING THE TAIL LIGHT BULB............................................................................................................ 5-21-00
5.13.4 CHANGING THE HANDLEBAR COVER LIGHTS........................................................................................ 5-22-00
5.13.5 ADJUSTING THE HEADLIGHT BEAM......................................................................................................... 5-23-00
5.13.6 CHANGING THE FUSES .............................................................................................................................. 5-23-00
5.14 WIRING DIAGRAM ................................................................................................................. 5-24-00
7
i
9
5 - 2 - 00
Release 00/2003 - 09
QUASAR 125-180
5.1
ELECTRIC SYSTEM
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
Ar
Az
B
Bi
g
Gr
M
N
R
Ro
V
Vi
CABLE COLOURS
Orange
Light blue
Blue
White
Yellow
Grey
Brown
Black
Red
Pink
Green
Purple
5.1.2
ELECTRICAL CONNECTORS
Disconnect the electrical connectors as follows:
" Press down on the locking tab, where fitted.
Never separate two connectors by pulling on the wiring.
" Grasp
both connectors and pull them in opposite directions until they
become separated.
" Remove any dirt, rust, moisture, etc. from inside the connector blowing with
compressed air.
" Ensure that the wires are securely crimped to the terminals inside each
connector.
NOTE A connector will only locate properly into the matching connector when
it is inserted in the correct mounting position.
" Reconnect
the two connectors and ensure that they are fully engaged
(where fitted, the locking tab should click audibly into place).
Release 00/2003 - 09
5 - 3 - 00
ELECTRIC SYSTEM
5.2
QUASAR 125-180
ELECTRICAL COMPONENTS
25
24
16
7
4
9
10
21
12
8
23
18
17
5
19
13
6
11
14
2
20
1
3
22
Key:
1) Front direction indicators
2) Rear direction indicators
3) Tail light
4) Headlight
5) Left-hand switch
6) Dashboard
7) Hazard lights relay
8) Voltage stabiliser
9) Rectifier
10) Engine Control Unit
11) Battery
12) Warning horn
13) Starting relay
14) Fuse
15) Number plate light
16) Coil
5 - 4 - 00
15
17)
18)
19)
20)
21)
22)
23)
24)
25)
Stoplight switch
Starter motor
Spark plug
Fuel sensor
Sensors control unit
Automatic starter
Earth
Neutral sensor
Reverse gear sensor
Release 00/2003 - 09
ELECTRIC SYSTEM
QUASAR 125-180
5.3
5.3.1
TROUBLESHOOTING
STARTER MOTOR - BATTERY RECHARGE - GENERATOR
11
7
G/V
N
V
Lights
1
Start logic
Brakes consent
V/R
G
G/V
R
M
24
R
15A
N
R
27
N
25
N
32
N
31
R
Bi
V
G
V
G
Bi
B/N
26
28
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
Release 00/2003 - 09
5 - 5 - 00
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.
" Using a revolution counter, accelerate and measure the charge voltage and
current.
13.0 ~ 15.0 V / 1.0 A below 5000 rpm.
If the measured value is incorrect, check the rectifier, see 5.3.3 (RECTIFIER).
5.3.3
RECTIFIER
" Disconnect the four-way connector (1) (coloured green).
" Set a multimeter to the x 1 M. range and measure the resistance of each
terminal from the rectifier side (inner male terminals).
Connect meter (+) to:
Connect meter (-) to:
2
-
White
White
-
Yellow
∞
Red
Green
Yellow
Red
Green
∞
∞
-
∞
5M
1,8 M
∞
-
∞
∞
4,64 M
∞
-
This test method provides an approximate measure of resistance. Where
possible, fit a substitute rectifier known to be in good working order to
test the charge system.
If the reading found deviates from the specified value, change the rectifier.
5 - 6 - 00
Release 00/2003 - 09
ELECTRIC SYSTEM
QUASAR 125-180
IGNITION SYSTEM
Bi
V
G
V
N/G
V
B/V
V
G
Bi
N/G
B/Bi
5.4
31
32
29
28
34
30
Key:
28)Voltage regulator
29)Coil
30)Spark plug
31)Pick-Up sensor
32)Generator
34)C.D.I.
Release 00/2003 - 09
5 - 7 - 00
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.
1
2
Do not touch the metal parts. Electrical shock hazard. Hold the spark
plug only by its cap (2).
" Turn the key to " " and press the start button "
" Check that the electrodes spark.
" If this does not happen, replace the coil (4).
" (3).
3
4
5 - 8 - 00
Release 00/2003 - 09
ELECTRIC SYSTEM
QUASAR 125-180
5.5
CHECKING THE GENERATOR IDLE OPERATION
8V
" 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
G
Bi
a.c.).
Standard idle voltage: above the values specified in the diagram.
30 V
40 V
V
5.6
CHECKING THE ALTERNATOR CONTINUITY
R2
0,5Ω
With the engine off:
" Disconnect the regulator cables connector.
" Using a portable tester, check the continuity between stator cables.
" Check also stator mount isolation.
R1, R2, R3 resistance standard value: 0.1-1 Ω
Resistance between stator cables and mount standard value: ∞
G
Bi
R1
0,7Ω
R3
0,8Ω
V
5.7
CHECKING THE IGNITION COIL
" Carry
out this test with a portable tester. Check primary and secondary
windings continuity. The reading, expressed in ohm, shall not be perfect but,
if the windings are not damaged, the following ohm resistance values shall
be measured.
Coil winding resistance
Primary
0.2 ohm ± 10%
Secondary
3 Kohm ± 10%
Disconnect spark plug cap before any reading.
5.7.1
CHECKING THE PICK-UP SENSOR
" Disconnect the pick-up sensor connector.
" Using a portable tester (1000 ohm range), measure the resistance between
the blue/green and blue/white terminals resistance between 148 ohm ± 10%
(at 20 °C).
" If the resistance value is infinite or below the recommended value, change
the pick-up sensor.
Release 00/2003 - 09
5 - 9 - 00
ELECTRIC SYSTEM
QUASAR 125-180
5.8
AUTOMATIC STARTER
G
G/R
R
M
N
V
G
V
N
G
G
7
V
33
23
28
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).
R=31Ω ± 10%
5 - 10 - 00
Release 00/2003 - 09
QUASAR 125-180
5.9
ELECTRIC SYSTEM
CHECKING THE C.D.I. CONTROL UNIT
" The ignition control unit
is of the capacitive discharge type, with digitallycontrolled ignition advance based on engine rpm. The control unit is
equipped with two connectors.
A - Starting enabling
B - Earth
1)Coil control
2)Earth
3)Pick-up sensor input
4)Gear shift logic
5.9.1
CHECK DATA
Checking the ignition relay
To check relay correct operation, proceed as follows:
" Feed the two terminals with 12 V.
" Using a tester, set on the resistance meter function, check the continuity
between the two terminals.
Correct value of the powered relay: 0 Ω
Correct value of the unpowered relay: ∞
If the values are outside the specified limits, change the relay.
Release 00/2003 - 09
5 - 11 - 00
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
8
of connector (8) (wiring side). Check that pointer (6) goes on 4/4 with a ± 5°
tolerance.
" Repeat this operation using a 100 Ω resistance and check that pointer (6)
goes to 0 (zero) with a ± 5° tolerance.
Between cables
45
6
Resistance
Correct reading
White/Black (B/N) Black (N)
5.6 Ω
4/4 ± 5°
White/Black (B/N) Black (N)
84.1 Ω
0 ± 5°
6)Fuel level instrument
7)Key-operated switch
45)Fuel level sensor
7
B/N
5 - 12 - 00
N
M
N
R
Release 00/2003 - 09
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
Rs
RO
)
N
!
2)
Dip switch (
Cables
Rs
)
G/N G/R V/N
G
4
3
"
2
#
3)
Direction indicators
Rs
Cables M/
Bi
Gr V
Gr V
scr scr Gr scr scr
$
1
3
%
&
4)
Start button
Cables
Rs
B/Bi
N
'
5)
Ignition switch
Cables
Rs
Ar
V
(
)
*
OPEN
5
Release 00/2003 - 09
5 - 13 - 00
ELECTRIC SYSTEM
QUASAR 125-180
6)
Front Stop switch
Cables
Rs
V/G
M
ON
7)
Rear Stop switch
Cables
Rs
V/R V/G
ON
6-7
8)
Pedal stop switch
Cables
Rs
V/G
M
ON
8
5 - 14 - 00
Release 00/2003 - 09
ELECTRIC SYSTEM
QUASAR 125-180
5.12 STARTING CIRCUIT
5.12.1 WIRING DIAGRAM
To rectifier
R
M
13
14
15
To inition relay
Gr
N
N
3
16
Bi/B
12
N
N
M
M
M
7
V/Bi
V/Bi
N
N
Ar
M
34
22
Key
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
"
" only after one of the two brake levers has been pulled.
Release 00/2003 - 09
5 - 15 - 00
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).
" Check start button “ “ (CHECKING THE START BUTTON).
" Check stop switches (CHECKING THE STOP SWITCHES).
THE STARTER MOTOR RUNS BUT THE ENGINE DOES NOT RUN
" Check starter motor, freewheeling clutch and freewheeling clutch gear.
THE STARTER MOTOR RUNS WITHOUT HAVING MADE
OPERATION
" Check starter motor cables connectors.
" Check the ignition relay (CHECKING THE IGNITION RELAY).
ANY
5.12.3 CHECK DATA
CHECKING THE IGNITION RELAY
" Disconnect all cables from relay (1).
" Using a tester, set on resistance meter function, measure the continuity
between power terminals (screws M5). Correct value: infinite resistance.
" Feed (connector) control cables with a 12 V battery.
" Using a tester, set on resistance meter function, measure the continuity
between power terminals. Correct value: 0 Ω.
CHECKING THE STARTER MOTOR
" Disconnect spark plug cap, turn ignition switch to ON and start the engine
with the resistance meter connected to the starter motor system.
" Standard values: 45 A in a steady state ± 15 %.
" Using a tester, set on resistance meter function,
check the resistance
between starter motor positive and negative terminals. Standard value: 0.3
Ω ± 10 %.
5 - 16 - 00
Release 00/2003 - 09
QUASAR 125-180
ELECTRIC SYSTEM
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.
" Using a tester, set on resistance meter function, check the continuity
between the contacts in the pressed and released positions based on the
existing connections (MAIN WIRING DIAGRAM).
THE STOP LIGHT IS ALWAYS ON
" Check connections on tail light.
" Check front STOP switch (CHECKING THE FRONT AND REAR STOP
SWITCH).
" Check the rear STOP switch (CHECKING THE FRONT AND REAR STOP
SWITCH).
THE STOP LIGHT DOES NOT COME ON
" Check bulb and bulb holder.
" Check stop light circuit cables connectors.
" Check main power supply circuit.
" Check the front STOP switch (CHECKING THE FRONT AND REAR STOP
SWITCH).
" Check the rear STOP switch (CHECKING THE FRONT AND REAR STOP
SWITCH).
Release 00/2003 - 09
5 - 17 - 00
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. Change the bulb wearing
clean gloves or using a clean and dry cloth. Do not leave fingerprints on
the bulb, since these may cause its overheating and consequent
breakage. If you touch the bulb with bare hands, remove any fingerprint
with alcohol, in order to avoid any damage.
DO NOT FORCE THE ELECTRIC CABLES.
NOTE Before changing a bulb, check the fuse, see 5.13.6 (CHANGING THE
FUSES).
5 - 18 - 00
Release 00/2003 - 09
ELECTRIC SYSTEM
QUASAR 125-180
9
To rectifier
R
M
M
M
M/Bi
key operated
direction
indicators
5.13.1 CHANGING THE DIRECTION INDICATOR BULBS
41
V/SCR
N
17
V/SCR
N
N
7
M/SCR
8
10
20
N
Ro
37
N
M/SCR
Horn button
Gr
M
V/SCR
M
Gr
5
Hazard
switch
N
N
Gr
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).
" Remove the protection screen (1) from the indicator mount by pushing on its
sides with a screwdriver.
Make sure not to damage the protection screen, while removing it.
" Extract the damaged bulb and replace it with a new one of the same type.
NOTE When refitting, assemble the protection screen (1) carefully to its
mount.
1
Release 00/2003 - 09
5 - 19 - 00
ELECTRIC SYSTEM
QUASAR 125-180
5.13.2 CHANGING THE HEADLIGHT BULBS
1
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.
" Loosen and remove the two screws (3).
" Remove the headlight body (4) from the two shells (5).
HALOGEN HIGH / LOW BEAM BULB.
" To remove the bulb holder (6), turn it counter-clockwise.
" Remove bulb and change it with one of the same rating.
2
5
3
4
PARKING LIGHT
" Grasp the bulb holder (7) and pull to extract.
" Withdraw the bulb and replace it with one of the same type.
7
6
5 - 20 - 00
Release 00/2003 - 09
ELECTRIC SYSTEM
QUASAR 125-180
5.13.3 CHANGING THE TAIL LIGHT BULB
1
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.
2
STOP LIGHTS
18
To inition relay
(for inition logic)
G/R
14
V/G
13
V/G
12
V/G
M
7
N
M
M
M
R
V/G
To rectifier
Parking ligth
to key-operated
switch
Parts:
7)Key-operated switch
12)Left Stop switch
13)Right Stop switch
14)Integral braking Stop switch
18)Rear twin-light bulb
Release 00/2003 - 09
5 - 21 - 00
ELECTRIC SYSTEM
QUASAR 125-180
HIGH-LOW BEAM - PARKING LIGHTS
Key-operated
ana - aba
B
7
B/Bi
21
43
39
18
G/R
G/R
G/R
G/R
G/R
G/R
G
B/Bi
11
2
40
4
N
N
N
N
N
N
B/Bi
28
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
43)Odometer light
5.13.4 CHANGING THE HANDLEBAR COVER LIGHTS
4
2
3
The handlebar cover contains:
1) High beam warning light (blue)
2) Hazard light (red)
3) Parking/low beam warning light (green)
4) Neutral light (green)
To change the bulbs, proceed as follows:
1
NOTE Remove the handlebar cover, see
DASHBOARD).
6.1.2 (REMOVING THE
" Disconnect the two connectors for the warning light being replaced.
" Unscrew the nut (5).
" Remove the warning light from the handlebar cover.
5
5 - 22 - 00
Release 00/2003 - 09
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).
To adjust the headlight beam:
" Loosen the two screws (1) on headlight (2) and mounts.
" Adjust headlight beam angle.
" Tighten the two screws (1).
1
2
5.13.6 CHANGING THE FUSES
1
Read carefully 1.3 (GENERAL SAFETY RULES).
Do not repair faulty fuses.
Never use fuses different from the recommended ones.
The use of unsuitable fuses may cause damages to the electric system
or, in case of short circuit, even a fire.
NOTE If a fuse blows frequently, there probably is a short circuit or an
overload in the electric system.
2
If an electric component does not work or works irregularly, or if the vehicle
fails to start, it is necessary to check the fuse.
For the check, proceed as follows:
" Remove the seat, see 6.1.1 (REMOVING THE SEAT).
" Disconnect the battery cables, see 6.1.9 (REMOVING THE BATTERY).
" Extract the fuse (1) from the fuse carrier (2).
NOTE When you find a blown fuse, determine and rectify the cause before
fitting a new fuse.
" Replace the damaged fuse with a new one having the same amperage.
Release 00/2003 - 09
5 - 23 - 00
ELECTRIC SYSTEM
QUASAR 125-180
5.14 WIRING DIAGRAM
44
42
40
1
R
N
45
1
1
V/scr
N
1
B
B/Bi
N
G/R
V/scr
N
B
B/Bi
N
G/R
N
M/scr
B/Bi
N
B
N
M/scr
36
B/Bi
N
B
1
35
G/R
N
43
39
41
38
37
N/Bi
N
Bi/N
N
Bi/N
N
N
Bi/B
N
B/Bi
N
N
B/Bi
M
Gr
M
Az
M
N
Bi/N
M
N
Bi/N
G
G/R
V
N
R
M
Az
G/R
V
N
R
M
4
5
46
C
?
7
G
Bi
V
ON
OFF
1
32
G
Bi
V
+
1
31
B/V
B/Bi
3
V
G
2
33
N
N
B/Bi
G/R
6
Bi/B
N
1
B/Bi
G/R
V/G
M
1
34
N/G
V
B/V
V/Bi
Ar
1
1
30
M
M/Bi
B
L
10
M
Ro
28
V
G
Bi
R
26
R
G/R
G/N
G
B/Bi
M/Bi
M/scr
V/scr
Ro
Gr
M/Bi
Gr/scr
V/scr
Ro
Gr
Gr/scr
V/scr
N
N
G/N
V/R
V/R
V/G
N
1
1
1
M
25
V/R
G/R
N
11
27
G/R
B
B/Bi
G/N
R
15 A
R/Bi
24
N
9
29
N/G
V
B
L
8
M
Gr
12
V/G
M
1
N
V/R
23
G
13
V/G
M
N
N
V/G
1
1
1
M
M
Gr
Bi/Ar
14
Gr
N
V/G
M
Gr
N
V/Bi
N
V/Bi
N
15
22
Gr
N
Ar
16
V/Bi
N
1
N
V/scr
N
N
V/G
G/R
M/scr
N
N
G/R
N
1
1
1
V/scr
N
N
Az
V/scr
M/scr
N
N
Az
17
18
20
21
19
5 - 24 - 00
Release 00/2003 - 09
QUASAR 125-180
ELECTRIC SYSTEM
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
12) Left Stop switch
13) Right Stop switch
14) Integral braking Stop switch
15) Neutral light switch
16) Reverse gear switch
17) Right rear direction indicator
18) Rear twin-light bulb
19) Tail light
20) Left rear direction indicator
21) Number plate light
22) Gear shift logic control unit
23) Resistor
24) Starting relay
25) Starter motor
26) Fuse
27) Battery
28) Voltage regulator
29) Coil
30) Spark plug
31) Pick-up sensor
32) Generator
33) Automatic starter
34) C.D.I.
35) Right (supplementary) front headlight connector
36) Left (supplementary) front headlight connector
37) Left front direction indicator
38) Headlight
39) Front parking light bulb
40) Front twin-light bulb
41) Right front direction indicator
42) Odometer sensor
43) Odometer light
44) Odometer
45) Fuel level sensor
46) Dashboard
Release 00/2003 - 09
5 - 25 - 00
ELECTRIC SYSTEM
QUASAR 125-180
NOTES
5 - 26 - 00
Release 00/2003 - 09
CYCLE PARTS
QUASAR 125-180
CYCLE PARTS
Release 00/2003 - 09
6
6 - 1 - 00
CYCLE PARTS
QUASAR 125-180
CYCLE PARTS
CONTENTS
0
1
2
3
4
5
6
7
6.1 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 .................................................................................................................. 6-10-00
6.1.7 REMOVING THE FOOTREST....................................................................................................................... 6-11-00
6.1.8 REMOVING THE AIR FILTER CASE............................................................................................................ 6-11-00
6.1.9 REMOVING THE BATTERY ........................................................................................................................ 6-12-00
6.1.10 REMOVING THE FUEL TANK ...................................................................................................................... 6-13-00
6.1.11 REMOVING THE CONTROL UNIT ............................................................................................................... 6-14-00
6.1.12 REMOVING THE ELECTRICAL CONTROLS .............................................................................................. 6-14-00
6.1.13 REMOVING THE REAR BRAKE LEVER ..................................................................................................... 6-15-00
6.1.14 REMOVING THE RIGHT CONTROL ............................................................................................................ 6-15-00
6.1.15 REMOVING THE BRAKE PEDAL ................................................................................................................ 6-15-00
6.1.16 REMOVING THE MAIN SWITCH .................................................................................................................. 6-16-00
6.1.17 REMOVING THE FRONT DIRECTION INDICATORS.................................................................................. 6-16-00
6.1.18 REMOVING THE HORN................................................................................................................................ 6-16-00
6.1.19 REMOVING THE TAIL LIGHT....................................................................................................................... 6-17-00
6.1.20 REMOVING THE REAR DIRECTION INDICATORS .................................................................................... 6-17-00
6.1.21 REMOVING THE EXHAUST PIPE ................................................................................................................ 6-18-00
6.1.22 REMOVING THE WHEELS ........................................................................................................................... 6-19-00
6.1.23 REMOVING THE FRONT SUBFRAME......................................................................................................... 6-19-00
6.1.24 REMOVING THE FOOTREST MOUNT......................................................................................................... 6-19-00
6.1.25 REMOVING THE FRAME.............................................................................................................................. 6-20-00
6.2 STEERING SYSTEM............................................................................................................... 6-20-00
6.2.1 REMOVING STEERING YOKE WITH STEM................................................................................................ 6-20-00
6.2.2 REMOVING THE STEERING ARM............................................................................................................... 6-21-00
6.2.3 REMOVING THE BALL JOINT ..................................................................................................................... 6-21-00
6.2.4 REMOVING THE FRONT SHOCK ABSORBER .......................................................................................... 6-22-00
6.2.5 REMOVING SUSPENSION ARM.................................................................................................................. 6-22-00
6.3 SWINGING ARM..................................................................................................................... 6-22-00
6.3.1 REMOVING THE REAR SHOCK ABSORBER............................................................................................. 6-22-00
6.3.2 REMOVING THE SWINGING ARM............................................................................................................... 6-23-00
6.4 FRONT BRAKES .................................................................................................................... 6-24-00
6.4.1 REMOVING THE BRAKE.............................................................................................................................. 6-24-00
6.4.2 DISASSEMBLING THE BRAKE DRUM ....................................................................................................... 6-24-00
6.4.3 CHECKING THE PARTS............................................................................................................................... 6-25-00
6.5 REAR BRAKE ......................................................................................................................... 6-26-00
6.5.1 REMOVING THE BRAKE.............................................................................................................................. 6-26-00
i
6.6
CHECKING THE PARTS......................................................................................................... 6-27-00
6.7 CHAIN .................................................................................................................................... 6-27-00
6.7.1 DISASSEMBLING THE CHAIN..................................................................................................................... 6-27-00
6.7.2 REFITTING THE CHAIN................................................................................................................................ 6-27-00
9
6 - 2 - 00
Release 00/2003 - 09
CYCLE PARTS
QUASAR 125-180
6.1
BODYWORK
10
1
11
2
3
8
4
5
7
6
9
KEY
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
Release 00/2003 - 09
6 - 3 - 00
CYCLE PARTS
QUASAR 125-180
4
8
9
6
3
13
1
7
5
12
10
11
2
KEY
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
6 - 4 - 00
Release 00/2003 - 09
CYCLE PARTS
QUASAR 125-180
6.1.1
REMOVING THE SEAT
" Use lever (1) to unhook the seat.
" Remove the seat (2).
1
2
6.1.2
REMOVING THE DASHBOARD
1
" Loosen the two screws (1).
" Remove the dashboard (2).
" Disconnect the dashboard connectors.
Mark cables to avoid their wrong positioning at reassembly.
2
Release 00/2003 - 09
6 - 5 - 00
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).
1
2
3
6 - 6 - 00
Release 00/2003 - 09
CYCLE PARTS
QUASAR 125-180
6.1.4
REMOVING THE HANDLEBARS
1
" 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).
" Fully tighten the two adjusters (4).
" Remove front brake cables (5).
" Loosen the two screws (6).
" Remove cover (7).
" Remove throttle cable (8) from its seat.
" Disconnect switch, stop light and direction indicators connectors.
Mark cables to avoid their wrong positioning at reassembly.
2
3
4
5
7
6
8
Release 00/2003 - 09
6 - 7 - 00
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.
10
9
11
12
12
11
6 - 8 - 00
Release 00/2003 - 09
CYCLE PARTS
QUASAR 125-180
6.1.5
REMOVING THE FRONT SHIELD
1
" 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.
" Loosen and remove the two screws (5).
" Loosen and remove fuel tank cap.
Block off tank opening to avoid any foreign matter from entering.
2
3
3
4
5
Release 00/2003 - 09
6 - 9 - 00
CYCLE PARTS
QUASAR 125-180
" Remove the front shield (6).
6
6.1.6
2
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).
"!Loosen and remove the five screws (4). Save nuts and washers.
" Disconnect direction indicator connectors (5).
" Remove the rear shield (6).
1
3
4
4
5
6
6 - 10 - 00
Release 00/2003 - 09
CYCLE PARTS
QUASAR 125-180
6.1.7
REMOVING THE FOOTREST
1
" 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.
" Remove the footrest.
NOTE If necessary, repeat the above procedure to remove the other footrest.
1
2
2
3
3
6.1.8
REMOVING THE AIR FILTER CASE
" Remove the rear shield, see 6.1.6 (REMOVING THE REAR SHIELD).
" Remove pipe (1).
" Remove breather from its seat.
" Loosen and remove the two screws (2). Save the two washers.
" Loosen clip (3).
" Remove filter case.
Block off intake manifold with a clean cloth to prevent any foreign matter
from entering the intake ducts. At reassembly, make sure that the cloth
or any other object is not inside the filter case, then refit filter case
cover.
1
2
3
Release 00/2003 - 09
6 - 11 - 00
CYCLE PARTS
QUASAR 125-180
6.1.9
5
1
2
6
3
4
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.
" Raise the red protective gaiter (3).
" Loosen and remove screw (4) on positive terminal (+).
" Move positive terminal (5) aside.
Do not overpull electric cables.
" Wear
latex gloves and grasp battery (6). Raise it to remove it from its
compartment.
Store the removed battery in a safe place and out of the children's reach.
At reassembly connect the cable on positive terminal (+) first and then
that on the negative terminal (-).
NOTE Change the rubber battery profile if damaged.
6 - 12 - 00
Release 00/2003 - 09
CYCLE PARTS
QUASAR 125-180
6.1.10 REMOVING THE FUEL TANK
4
" 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).
" Disconnect fuel level sensor connector (5).
" Loosen and remove tank front screw (6). Save washer.
" Loosen and remove tank rear screw (7).
" Remove fuel tank with tap.
3
1
2
5
6
7
Release 00/2003 - 09
6 - 13 - 00
CYCLE PARTS
QUASAR 125-180
6.1.11 REMOVING THE CONTROL UNIT
1
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.
2
6.1.12 REMOVING THE ELECTRICAL CONTROLS
Carefully read see 1.3 (GENERAL SAFETY RULES).
" Turn main switch to " ".
" Disconnect the three electrical connectors (1).
" Loosen and remove the two screws (2).
" Remove the two shells.
1
2
6 - 14 - 00
Release 00/2003 - 09
CYCLE PARTS
QUASAR 125-180
6.1.13 REMOVING THE REAR BRAKE LEVER
" Disconnect brake cable, see 6.1.4 (REMOVING THE HANDLEBARS).
" Remove the switch, see 6.1.12 (REMOVING THE ELECTRICAL
CONTROLS).
" Remove twistgrip (1).
" Loosen and remove screw (2).
" Remove brake lever.
1
2
6.1.14 REMOVING THE RIGHT CONTROL
" Disconnect brake and throttle cables and the stop switch wiring, see 6.1.4
3
(REMOVING THE HANDLEBARS).
" Remove twistgrip (1).
" Loosen and remove screw (2).
" Take out right control (3).
1
2
4
5
6.1.15 REMOVING THE BRAKE PEDAL
" Remove right footrest, see 6.1.7 (REMOVING THE FOOTREST).
" Remove spring pin (1). Save washer (2).
" Release spring (3).
" Release brake cable (4).
" Remove brake pedal (5).
" Save spring (3).
3
1
Release 00/2003 - 09
2
6 - 15 - 00
CYCLE PARTS
QUASAR 125-180
6.1.16 REMOVING THE MAIN SWITCH
2
" 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.
1
6.1.17 REMOVING THE FRONT DIRECTION INDICATORS
3
1
" Disconnect the two connectors (1).
" Loosen and remove screw (2).
" Remove direction indicator (3).
NOTE If necessary, repeat the above procedure to remove the other direction
indicator.
2
6.1.18 REMOVING THE HORN
" Disconnect the two electrical connectors (1).
" Loosen and remove screw (2).
" Remove horn (3).
1
3
2
6 - 16 - 00
Release 00/2003 - 09
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).
2
3
1
6.1.20 REMOVING THE REAR DIRECTION INDICATORS
2
" Disconnect the two electrical connectors (1).
" Loosen and remove nut (2). Save screw.
" Remove direction indicator (3).
NOTE If necessary, repeat the above operations to remove the other
direction indicator.
1
Release 00/2003 - 09
3
6 - 17 - 00
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).
" Loosen and remove screw (3). Save washer.
" Push down brake pedal.
" Turn the exhaust pipe (4) slightly and remove it from behind.
NOTE At reassembly, change the gasket between exhaust pipe and engine.
1
2
3
4
6 - 18 - 00
Release 00/2003 - 09
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.
" Loosen and remove the four screws (1). Save washers.
" Remove wheel (2).
2
1
1
6.1.23 REMOVING THE FRONT SUBFRAME
2
" Loosen and remove the four screws (1).
" Remove visor (2).
"!Loosen and remove the two screws (3).
" Remove front subframe (4).
1
1
3
4
6.1.24 REMOVING THE FOOTREST MOUNT
1
2
" Remove footrest, see 6.1.7 (REMOVING THE FOOTREST).
" Loosen and remove the four screws (1).
" Remove the footrest mount (2).
NOTE If necessary, repeat the above procedure to remove the other footrest
mount.
1
Release 00/2003 - 09
6 - 19 - 00
CYCLE PARTS
QUASAR 125-180
6.1.25 REMOVING THE FRAME
2
2
3
1
" 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).
" Remove the front subframe, see 6.1.23 (REMOVING THE FRONT
SUBFRAME).
" Remove both footrest mounts, see 6.1.24 (REMOVING THE FOOTREST
MOUNT).
" Disconnect number plate holder light connector (1).
" Loosen and remove the four screws (2).
" Remove the number plate holder (3).
" Remove electrical parts from frame and release all cable clips.
6.2
3
2
6.2.1
STEERING SYSTEM
REMOVING STEERING YOKE WITH STEM
" Remove the front shield, see 6.1.5 (REMOVING THE FRONT SHIELD).
" Loosen and remove the two nuts (1). Save plate (2), cable ring (3), clamp
and bushing.
" Take out the two split pins (4).
" Loosen and remove the two nuts (5).
" Remove the two arms (6) from steering yoke.
" Remove split pin (7).
" Loosen and remove nut (8).
" Remove steering yoke with stem.
1
6
5
4
6
1
7
6 - 20 - 00
Release 00/2003 - 09
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).
1
NOTE If necessary, repeat the above procedure to remove the other steering
arm.
2
5
4
3
6.2.3
REMOVING THE BALL JOINT
1
" Remove the brake, see 6.4.1 (REMOVING THE BRAKE).
" Remove split pin (1).
" Loosen and remove nut (2).
" Remove steering arm, see 6.2.2 (REMOVING THE STEERING ARM).
" Remove the ball joint (3).
2
3
Release 00/2003 - 09
6 - 21 - 00
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).
1
2
6.2.5
REMOVING SUSPENSION ARM
" Remove front shock absorber, see 6.2.4 (REMOVING THE FRONT SHOCK
ABSORBER).
" Remove ball joint, see 6.2.3 (REMOVING THE BALL JOINT).
" Loosen and remove screw (1). Save nut.
" Loosen and remove screw (2). Save nut.
" Remove suspension arm (3).
2
3
1
1
2
6.3
4
5
6.3.1
SWINGING ARM
REMOVING THE REAR SHOCK ABSORBER
" Raise frame rear part on a suitable stand.
" Loosen and remove nut (1). Save screw (2).
" Remove split pin (3) and remove spindle (4).
" Remove the rear shock absorber (5).
3
6 - 22 - 00
Release 00/2003 - 09
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
1
2
ABSORBER).
" Loosen and remove nut (3).
" Remove swinging arm spindle (4). Save washer.
" Remove the complete swinging arm.
NOTE If necessary, remove the single parts.
3
4
Release 00/2003 - 09
6 - 23 - 00
CYCLE PARTS
QUASAR 125-180
6.4
1
6.4.1
FRONT BRAKES
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.
" Disconnect the two brake cables (2-3).
" Remove the brake block plate (4).
2
3
4
6.4.2
1
3
2
" Remove the complete wheel, see 6.4.1 (REMOVING THE BRAKE).
" Working from outside the wheel, remove the following parts in the
given
order:
- spacer (1);
- oil seal (2);
- bearing (3);
- spacer (4).
" Working from inside the wheel, remove the following parts in the given
order:
- oil seal (5);
- bearing (6).
4
6
6 - 24 - 00
DISASSEMBLING THE BRAKE DRUM
5
Release 00/2003 - 09
CYCLE PARTS
QUASAR 125-180
6.4.3
CHECKING THE PARTS
3
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).
2
1
BEARINGS
" Turn inner ring (4) by hand. It should run smoothly, silently and should not
jam at any position. Check also for any axial play. Change any faulty
bearing.
SEALS
" Check seals for wear. If excessively damaged or worn, change them.
BRAKE BLOCKS
" Check friction material (5) for wear.
4
Min. thickness: 1mm.
" Check springs (6). Change them if yielded.
Check the following parts for wear:
- brake cam (7);
- block holder plate (8);
- brake lever (9);
- spacers (2-3).
Change those parts which are excessively worn or damaged.
9
5
Release 00/2003 - 09
8
7
6
6 - 25 - 00
CYCLE PARTS
QUASAR 125-180
6.5
1
6.5.1
REAR BRAKE
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.
" Remove the complete left wheel.
" Loosen and remove the three screws (2).
" Remove drum cover (3).
" Bend washer so as to loosen nuts.
" Loosen and remove the four screws (4).
" Working from left side, remove the following parts in the given order: brake
2
3
drum (5) and brake blocks (6).
2
5
4
4
6
6 - 26 - 00
Release 00/2003 - 09
CYCLE PARTS
QUASAR 125-180
6.6
CHECKING THE PARTS
5
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).
6
SEALS
" Check seals for wear. If excessively damaged or worn, change them.
BRAKE BLOCKS
Check friction material (2) for wear.
Min. thickness: 1mm.
" Check springs (3). Change them if yielded.
" Check the following parts for wear:
- brake cam (4);
- block holder plate (5);
- brake lever (6).
1
4
3
Change those parts which are excessively worn or damaged.
2
6.7
6.7.1
CHAIN
DISASSEMBLING THE CHAIN
Carefully read see 1.3 (GENERAL SAFETY RULES).
" Slacken chain tension, see 6.7 (CHAIN).
" Turn rear wheels until having the master link exposed.
" Remove clip (1) and the plate underneath.
" Working on the opposite side, remove the master link (2).
" Remove chain.
1
If the chain is excessively worn, change the whole unit (front and rear
sprockets and chain).
1
2
6.7.2
REFITTING THE CHAIN
" Make sure that chain is correctly positioned on front and rear sprockets.
" Proceed to chain positioning: the two free ends to be joined together shall
be in a central point between front and rear sprockets, in the chain upper
section.
" Join the two chain ends and insert master link (1) pins from the inside to the
outside.
" Install plate (2) onto pins.
" Fit clip (3) onto pins.
NOTE Master link clip (3) opening shall be opposite to the direction of travel.
Release 00/2003 - 09
3
Direction of rotation
2
1
6 - 27 - 00
CYCLE PARTS
QUASAR 125-180
NOTES
6 - 28 - 00
Release 00/2003 - 09
TROUBLESHOOTING
QUASAR 125-180
TROUBLESHOOTING
Release 00/2003 - 09
7
7 - 1 - 00
TROUBLESHOOTING
QUASAR 125-180
TROUBLESHOOTING
CONTENTS
0
1
7.1
THE ENGINE DOES NOT START ............................................................................................. 7-3-00
7.2
POOR PERFORMANCE AT IDLE AND LOW SPEED.................................................................. 7-4-00
7.3
POOR PERFORMANCE AT HIGH SPEED ..................................................................................7-5-00
7.4
EXCESSIVE NOISE LEVEL....................................................................................................... 7-6-00
7.5
EXCESSIVE FUMES ................................................................................................................. 7-6-00
7.6
LOW POWER ............................................................................................................................ 7-7-00
7.7
POOR VEHICLE MANEUVERABILITY ...................................................................................... 7-8-00
2
3
4
5
6
7
i
9
7 - 2 - 00
Release 00/2003 - 09
TROUBLESHOOTING
7.1
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
Check spark plugs
-
Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty alternator
Faulty engine stop switch
Loose connection / broken or short-circuited wires
Broken or short-circuited ignition coil
Broken or short-circuited spark plug wire
Faulty pick-up sensor
Faulty ignition switch
Missing or weak spark
- Worn cylinder and/or worn piston rings
- Damaged cylinder head gasket
Check cylinder compression
Poor compression
The engine starts and
then stops immediately
-Damaged or blocked starter
-Disconnected starter power wire
-Wrong air screw adjustment
-Wrong engine timing
-Too weak air/fuel mixture
Wet spark plug electrode
-Flooded carburettor
-Wrong air screw adjustment
-Too rich air/fuel mixture
-Damaged or blocked starter
-Dirty air cleaner
Start engine
Remove spark plugs and check
7 - 3 - 00
Release 00/2003 - 09
TROUBLESHOOTING
7.2
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
Check spark plugs
-
7 - 4 - 00
Loose or disconnected ignition system wires
The spark plug is faulty, wet or with carbon deposits
Faulty alternator
Faulty CDI unit
Faulty ignition switch
Faulty ignition coil
Faulty pick-up sensor
Damaged spark plug electrode
Faulty engine stop switch
Release 00/2003 - 09
TROUBLESHOOTING
7.3
QUASAR 125-180
POOR PERFORMANCE AT HIGH SPEED
Possible causes
Check engine timing
- Faulty CDI unit or ignition coil
Check fuel delivery to carburettor
-
Blocked fuel flow
Remove carburettor and check jets
No fuel
Obstructed fuel line
Obstructed fuel filter
Obstructed fuel tank cap breather hole
- Clean jets
Obstructed
- Clean or change filter
Check filter
Dirty
7 - 5 - 00
Release 00/2003 - 09
TROUBLESHOOTING
7.4
QUASAR 125-180
EXCESSIVE NOISE LEVEL
Possible causes
Excessive noise level
7.5
-
Worn valve adjustment
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
Excessive fumes
7 - 6 - 00
-
Worn cylinder, piston or piston rings
Wrong piston ring assembly
Scores or scratches on piston or on cylinder walls
Damaged valve stem seal
Release 00/2003 - 09
TROUBLESHOOTING
7.6
QUASAR 125-180
LOW POWER
Possible causes
Raise wheels from ground and turn them by
hand
They do not turn freely
- Locked brake - Adjust it
- Drive chain is too tensioned
- Damaged axle bearing
- Punctured tyre
- Wrong inflation pressure
Check tyres inflation pressure
Poor inflation pressure
Open throttles slightly
Engine speed does not
increase
-
Too rich or too weak air/fuel mixture
Obstructed air filter cartridge
Obstructed muffler
Blocked fuel flow
• No fuel
• Obstructed fuel filter
• Obstructed fuel tank cap breather hole
Check engine timing
- Faulty CDI unit
- Faulty pick-up sensor
Check cylinder compression
- Leaks at head gasket
- Worn cylinder and/or piston rings
Poor pressure
- Clean fuel jets
- Clean floater
Check carburettor
Dirty
Check spark plug
Dirty or with an
abnormal colour
Overheating
-
Wrong type of fuel
Too weak air/fuel mixture
Poor quality or old fuel has been used
Too many carbon deposits inside the combustion chamber
Engine oil cooling system is not working properly
Detonations
-
Worn piston and/or cylinder
Too weak air/fuel mixture
Wrong type of fuel
Advance ignition timing
Too many carbon deposits inside the combustion chamber
Check for engine overheating
Accelerate or reach max. speed
7 - 7 - 00
- Clean/adjust electrodes gap
- Faulty spark plug
- Wrong spark plug heat rating
Release 00/2003 - 09
TROUBLESHOOTING
7.7
QUASAR 125-180
POOR VEHICLE MANEUVERABILITY
Possible causes
Hard steering
- Damaged steering bearing
- Damaged steering stem bushing
- Bent steering stem
One of the wheels vibrates
-
Bent rim
Wheel hub assembled in a wrong position
Excessive play at the wheel bearing
Damaged suspension
Bent frame
Excessive wear at the swinging arm bush
Bent shaft
The vehicle does not run straight
-
Bent linkage
Linkage wrong adjustment
Wrong rear tyre pressure
Wrong wheel toe in
Bent frame
Poor braking efficiency
-
Worn brake shoes
Worn brake drum
Dirty or oily/greasy friction material
Wrong brake adjustment
7 - 8 - 00
Release 00/2003 - 09
TROUBLESHOOTING
QUASAR 125-180
NOTE
7 - 9 - 00
Release 00/2003 - 09
TROUBLESHOOTING
QUASAR 125-180
NOTE
7 - 10 - 00
Release 00/2003 - 09
aprilia s.p.a.
via 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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