APRILIA QUASAR 125 2003, Workshop Manual, Page: 16 / 168

QUASAR 125-180
GENERAL INFORMATION
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Release 00/2003 - 09
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 sub-
sequent 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 motorcy-
cle 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 com-
ponents 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.
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