APRILIA SR MAX 125 ie Скачать руководство пользователя

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- Hold the pads in the correct position and insert the calliper in the brake disc.

- Fix the support calliper by means of the two screws at the specified torque

- Secure the pipe fitting to the calliper at the specified torque.

- Bleed the air from the system.

Front brake calliper

Removal

- Remove the two front brake calliper devices fas-

tening them to the support as shown in the photo-

graph.

NOTE

WHEN A PROCEDURE IS PLANNED INCLUDING THE
SERVICE OR REPLACEMENT OF THE CALLIPER, FIRST
LOOSEN THE FITTING CONNECTING THE PIPE TO THE
BRAKE CALLIPER

Overhaul

- Remove the brake calliper.

- Suitably support the brake calliper in a vice

- Remove the two pad fixing screws.

- Remove the pads being careful with the stop

spring.

- Remove the fixed plate by undoing the screw

shown in the photograph.

Braking system

SR MAX 125 ie

BRAK SYS - 234

Содержание SR MAX 125 ie

Страница 1: ...SERVICE STATION MANUAL 677506 EN SR MAX 125 ie ...

Страница 2: ...pare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only and are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publication beforehand...

Страница 3: ... and changes in repair procedures are communicated to all Aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult Aprilia CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates an...

Страница 4: ......

Страница 5: ...HAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE DELIVERY PRE DE ...

Страница 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Страница 7: ...ed air in such a way that you do not breathe in the dust produced by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original APRILIA spare parts and lubricants recommended by the Manufacturer Non original or non conforming spare parts may damage the vehicle Use only the appropriate tools designed for this vehicle Always ...

Страница 8: ...ix lift the saddle and re move the lid A The engine prefix B is stamped near the rear left shock absorber lower support VEHICLE IDENTIFICATION Specification Desc Quantity Chassis prefix M35700 ENGINE PREFIX M357M Characteristics SR MAX 125 ie CHAR 8 ...

Страница 9: ... 4 stroke with double spark plug Engine capacity 124 cm Bore x stroke 57 0 x 48 6 mm Compression ratio 11 5 13 0 1 Engine idle speed 1 750 50 rpm Valve clearance Intake 0 10 mm Exhaust 0 15 mm Max power 11 0 kW at 9 500 rpm MAX torque 12 0 Nm at 8000 rpm Lubrication With lobe pump inside crankcase controlled by a chain with double filter mesh and paper Lubrication pressure 3 4 bar Minimum lubricat...

Страница 10: ... oil 1 30 l Transmission oil 250 cm Cooling system fluid 1 75 l Fuel tank reserve approx 15 00 l approx 2 80 l Electrical system ELECTRICAL SYSTEM Specification Desc Quantity Starter Electric Ignition Electronic inductive discharge ignition high efficiency with separate HV coil Ignition advance α N three dimensional map managed by control unit Spark plug NGK CR8EKB Battery Sealed 12 V 12 Ah Altern...

Страница 11: ...esc Quantity Wheel rim type Light alloy wheel rims Front rim 15 x 3 00 Rear rim 14 x 3 50 Front tyre Tubeless 120 70 15 56P Rear tyre Tubeless 140 70 14 64P Front tyre pressure with passenger 2 1 bar Rear tyre pressure with passenger 2 4 bar NOTE CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE REGU LATE PRESSURE ACCORDING TO THE WEIGHT OF BOTH RIDER AND ACCESSORIES Overhaul data A...

Страница 12: ...18 to 57 425 57 366 57 373 0 045 0 059 Cylinder 3rd Oversize A 3 57 597 to 57 604 57 545 57 552 0 045 0 059 Cylinder 3rd Oversize B 3 57 604 to 57 611 57 552 57 559 0 045 0 059 Piston 3rd Oversize C 3 57 611 to 57 618 57 559 57 566 0 045 0 059 Piston 3rd Oversize D 3 57 618 to 57 625 57 566 57 573 0 045 0 059 NOTE THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE THE PIST...

Страница 13: ...D D Fit rings 2 and 3 with the word TOP facing upwards Position the port of the rings as shown here Value A of the sealing ring inside the cylinder fitting clearance Check the size of the sealing ring opening Compression ring 0 15 0 30 mm Max value 0 5 mm Oil scraper ring 0 10 0 30 mm Max value 0 65 mm Oil scraper ring 0 15 0 35 mm Max value 0 65 mm NOTE FITTING CLEARANCE VALUES ARE THE SAME FOR B...

Страница 14: ...o 29 010 If the crankshaft is within the set limits replace the crankshaft half bearings mounting the crankcase so as to suit the specified couplings The crankcase halves can be mounted with four types of crankshaft half bearings identified by letters B blue C yellow E green CRANKCASE Specification Desc Quantity Category 1 32 959 35 965 Category 2 32 953 to 32 959 CRANKCASE CRANKSHAFT COUPLING CRA...

Страница 15: ...SE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Transmissionside half shaft 16 6 0 0 05 A D 0 20 0 50 Flywheel side halfshaft 16 6 0 0 05 B D 0 20 0 50 Connecting rod 18 0 10 0 15 C D 0 20 0 50 Spacer tool 51 4 0 05 E D 0 20 0 50 SR MAX 125 ie Characteristics CHAR 15 ...

Страница 16: ...o components Shaft and Crankcase featuring the same category Cylinder head Before performing head service operations thoroughly clean all coupling surfaces Note the position of the springs and the valves so as not to change the original position during refitting Using a trued bar and a feeler gauge check that the cylinder head surface is not worn or distorted Characteristic Maximum allowable run o...

Страница 17: ...th a bore meter HEAD BEARINGS Specification Desc Quantity Bearing A 37 0 025 Bearing B 20 0 021 Bearing C 12 0 018 Measure the unloaded spring length Characteristic Standard length 40 5 mm Allowable limit after use 39 7 mm Clean the valve seats of any carbon residues Using the Prussian blue check the width of the impression on the valve seat V Characteristic Admissible limit 1 6 mm If the width of...

Страница 18: ...ETER Specification Desc Quantity Intake 4 987 4 972 mm Exhaust 4 975 4 960 mm MINIMUM ADMISSIBLE DIAMETER Specification Desc Quantity Intake 4 96 mm Exhaust 4 945 mm Calculate the clearance between valve and valve guide Check the deviation of the valve stem by resting it on a V shaped abutment and measuring the extent of the deformation with a dial gauge Characteristic Limit values admitted 0 1 mm...

Страница 19: ... 012 mm After measuring the valve guide diameter and the valve stem diameter check clearance between guide and stem EXHAUST Specification Desc Quantity Standard clearance 0 025 to 0 052 mm Admissible limit 0 09 mm INTAKE Specification Desc Quantity Standard clearance 0 013 0 04 mm Admissible limit 0 08 mm Check that there are no signs of wear on the faying surface with the articulated set screw te...

Страница 20: ...G SURFACE DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED CAUTION DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES RIGHT LEFT Check that the camshaft bearings exhibit no scores or abnormal wear Using a micrometer measure the camshaft bearings STANDARD DIAMETER Speci...

Страница 21: ... intake 17 130 mm Exhaust 16 310 mm standard axial clearance 0 11 0 41 mm maximum admissible axial clearance 0 42 mm Check that the rocking lever pins exhibit no scores or wear Characteristic Standard diameter Diameter 11 977 11 985 mm Measure the inside diameter of each rocker Characteristic Standard diameter Ø 12 0 011 mm SR MAX 125 ie Characteristics CHAR 21 ...

Страница 22: ...the piston crown protrudes from the plane formed by the upper part of the cylinder The further the piston protrudes from the cylinder the thicker the base gasket to be used to restore the compression ratio and vice versa NOTE NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT A TO BE TAKEN WITH...

Страница 23: ...fluid Synthetic fluid SAE J 1703 FMVSS 116 DOT 3 4 ISO 4925 CUNA NC 956 DOT 4 AGIP PERMANENT SPECIAL Ethylene glycol based antifreeze fluid with organic inhibition additives Red ready to use ASTM D 3306 ASTM D 4656 ASTM D 4985 CUNA NC 956 16 AUTOSOL METAL POLISH Silencer cleaning paste special product for cleaning and polishing stainless steel silencer AGIP GREASE PV2 Ivory smooth textured slightl...

Страница 24: ...INDEX OF TOPICS TOOLING TOOL ...

Страница 25: ...14 Calliper to extract ø 15 mm bearings 005095Y Engine support 002465Y Calliper for circlips 006029Y Punch for fitting steering bearing seat on steering tube 020004Y Punch for removing steering bearings from headstock 020055Y Wrench for steering tube ring nut SR MAX 125 ie Tooling TOOL 25 ...

Страница 26: ...4Y Support base for checking crankshaft alignment 020150Y Air heater mounting 020151Y Air heater 020193Y Oil pressure check gauge 020262Y Crankcase splitting plate 020263Y Driven pulley assembly sheath Tooling SR MAX 125 ie TOOL 26 ...

Страница 27: ...escription 020306Y Punch for assembling valve seal rings 020329Y Vacuum pump Mity Vac 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator SR MAX 125 ie Tooling TOOL 27 ...

Страница 28: ...e Description 020648Y Single battery charger 020335Y Magnetic mounting for dial gauge 020357Y 32x35 mm Adaptor 020359Y 42 x 47 mm adaptor 020360Y 52x55 mm Adaptor 020363Y 20 mm guide Tooling SR MAX 125 ie TOOL 28 ...

Страница 29: ...0375Y 28 x 30 mm adaptor 020376Y Adapter handle 020382Y Valve cotters equipped with part 012 re moval tool 020382Y011 adapter for valve removal tool 020393Y Piston assembly band 020412Y 15 mm guide SR MAX 125 ie Tooling TOOL 29 ...

Страница 30: ... lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting 020444Y Tool for fitting removing the driven pulley clutch Tooling SR MAX 125 ie TOOL 30 ...

Страница 31: ...e Description 020456Y Ø 24 mm adaptor 020477Y 37 mm adaptor 020483Y 30 mm guide 020489Y Hub cover support stud bolt kit 020428Y Piston position check mounting 020680Y Diagnosis Tool SR MAX 125 ie Tooling TOOL 31 ...

Страница 32: ...r 001467Y035 Bell for 47 mm outside diameter bearings 020626Y Driving pulley lock wrench 020626Y008 Driving pulley lock wrench 001467Y013 Calliper to extract ø 15 mm bearings 020627Y Flywheel lock wrench 020467Y Flywheel extractor Tooling SR MAX 125 ie TOOL 32 ...

Страница 33: ...20430Y Pin lock fitting tool 020622Y Transmission side oil seal punch 020480Y Petrol pressure check kit 020244Y 15 mm diameter punch 020115Y Ø 18 punch 020271Y Tool for removing fitting silent bloc SR MAX 125 ie Tooling TOOL 33 ...

Страница 34: ...ramming kit for vehicle diagnostic tester 001467Y017 Driver for OD 36 mm bearings 020234y extractor 020441Y 26 x 28 mm adaptor 020362Y 12 mm guide 020358Y 37x40 mm Adaptor 001467Y002 Driver for OD 73 mm bearing Tooling SR MAX 125 ie TOOL 34 ...

Страница 35: ...Stores code Description 020688Y Dial gauge support SR MAX 125 ie Tooling TOOL 35 ...

Страница 36: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Страница 37: ...dlight direction adjustment A A A A Brake pads I I I I I I I I I I I I I Sliding shoes CVT rollers R R R R R R Tyre pressure and wear I I I I I I I Vehicle road test I I I I I I I Radiator external cleaning I I I I Suspension I I I I I I I Steering A A A A A A A Transmission L L L L Spark plug Proceed as follows 1 Lift the rubber mat 2 Remove the right side cover unscrewing the 3 fixing A screws 3...

Страница 38: ...ap 0 7 to 0 8 mm Locking torques N m Spark plug 12 14 Hub oil Check Park the vehicle on its centre stand on flat ground Remove the oil dipstick A dry it with a clean cloth Reinsert it tightening it fully Remove the dipstick and check that the oil level is slightly over the second notch starting from the lower end if the level is under the MAX mark it needs to be filled with the right amount of hub...

Страница 39: ...ear boxes and transmissions API GL 4 Characteristic Transmission oil 250 cm Locking torques N m Hub oil drainage screw 15 to 17 Nm Air filter To remove them proceed as follows 1 Unscrew the 9 fixing screws A 2 Remove the air filter B CAUTION IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NEC ESSARY TO CARRY OUT MAINTENANCE CHECKS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE Cleaning SR M...

Страница 40: ...nsumption should be considered normal especially if during the run in period Consumption levels in particular can be influenced by the conditions of use e g oil consumption increases when driving at full throttle Replacement Change oil as indicated in the scheduled mainte nance table The engine must be emptied by drain ing the oil through the drainage plug B of the mesh pre filter flywheel side fu...

Страница 41: ...k A dry it with a clean cloth and reinsert it screwing it all the way down 3 Remove the cap dipstick again and check that the level is between the min and max marks top up if required The MAX level reference mark indicates the amount of oil in the engine If the check is carried out after the vehicle has been used and therefore with a hot engine the level line will be lower in order to carry out a ...

Страница 42: ...the prescribed torque Refit the new cartridge filter being careful to lubricate the O ring before fitting it Change the engine oil Recommended products eni i Ride PG 5W 40 Synthetic based lubricant for high performance four stroke engines JASO MA MA2 API SL ACEA A3 Oil pressure warning light Warning light low oil pressure The vehicle is equipped with a warning light on the instrument panel that li...

Страница 43: ...antifreeze fluid with organic inhibition additives Red ready to use ASTM D 3306 ASTM D 4656 ASTM D 4985 CUNA NC 956 16 Top up if the fluid level is below the mark 3 The coolant consists of an ethylene glycol and corrosion inhibitor based 50 de ionised water antifreeze solution mix CAUTION DO NOT EXCEED THE MAX LEVEL WHEN FILLING SO AS TO AVOID THE COOLANT ESCAPING FROM THE EXPAN SION TANK WHEN THE...

Страница 44: ...RESERVOIR IF REQUIRED CONSIDERING THAT THE MAX LEVEL MUST ONLY BE OBTAINED WITH NEW PADS Top up CAUTION ONLY USE DOT 4 CLASSIFIED BRAKE FLUID Proceed as follows Position the vehicle on a flat surface and on the centre stand Remove the tank cap by removing the two screws remove the gasket and top up using only the liquid specified without exceeding the maxi mum level CAUTION AVOID CONTACT OF THE BR...

Страница 45: ... BLEEDING OF AIR FROM THE CIRCUITS Headlight adjustment Place the vehicle in use conditions with tyres inflated to the prescribed pressure on flat ground at 10 m from a white screen placed in dim light Make sure that the scooter axle is perpendicular to the screen Turn the headlight on and check that the limit of the light beam projected onto the screen does not exceed 9 10 of the headlight centre...

Страница 46: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Страница 47: ...By Pass and replace if required Carefully clean the By Pass area Oil pump with excessive clearance Perform the dimensional checks on the oil pump components Oil filter too dirty Replace the cartridge filter Oil level too low Restore the level by adding the recommended oil type Transmission and brakes Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE Possible Cause...

Страница 48: ...he steering even after making the above adjustments check the seats in which the ball bearings rotate if they are recessed or if the balls are squashed replace them Excessive steering play EXCESSIVE STEERING CLEARANCE Possible Cause Operation Torque not conforming Check the tightening of the top and bottom ring nuts If irregu larities continue in turning the steering even after making the above ad...

Страница 49: ...akage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Faulty or broken seals Replace the shock absorber Check the condition of wear of the steering covers and the adjustments SR MAX 125 ie Troubleshooting TROUBL 49 ...

Страница 50: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Страница 51: ... motore 7 Fusibile N 01 30A 8 Fusibile N 02 15A 9 Fusibile N 03 15A 10 Fusibile N 04 15A 11 Fusibile N 05 10A 12 Fusibile N 06 7 5A 13 Fusibile N 07 7 5A 14 Fusibile N 08 7 5A 15 Fusibile N 09 7 5A 16 Fusibile N 10 7 5A 17 Fusibile N 11 7 5A 18 Devio luci 19 Teleruttore luci abbaglianti SR MAX 125 ie Electrical system ELE SYS 51 ...

Страница 52: ...ettitore livello carburante 39 Dispositivo gestione comandi elettrici 40 Teleruttore centralina elettronica 41 Lampada luce posizione posteriore 12v 21 5w 42 Lampada 12v 5w per luce targa 43 N 2 lampade12v 5w per luce di posizione anteriore 44 Lampada 12v 1 2w per spia luce di posizione 45 Teleruttore per elettroventola radiatore 46 Elettroventola radiatore 47 Sensore giri ruota 48 Centralina elet...

Страница 53: ... Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Components arrangement 1 Remote control switches Remove the legshield to reach it High beam light remote control B Electric fan remote control C Injection load remote control SR MAX 125 ie Electrical system ELE SYS 53 ...

Страница 54: ...2 Electrical control device Remove the legshield to reach it 3 Main fuses To reach it remove the battery cover placed in the helmet compartment Electrical system SR MAX 125 ie ELE SYS 54 ...

Страница 55: ...mpartment 5 Auxiliary fuses Located in the helmet compartment 6 Starter motor Remove the helmet compartment to reach it 7 Starter remote control Remove the central chassis cover to reach it 8 Stand button Remove the left footrest to reach them SR MAX 125 ie Electrical system ELE SYS 55 ...

Страница 56: ...plate to reach it 12 Battery To reach it remove the battery cover placed in the helmet compartment 13 HV coil Remove the right side fairing to reach it 14 Magneto flywheel The connector is located near the fuel pump To reach it remove the central chassis cover Electrical system SR MAX 125 ie ELE SYS 56 ...

Страница 57: ... the right hand side of the vehi cle 17 Fuel level transmitter To reach it remove the central chassis cover The transmitter is integrated to the fuel pump 18 Voltage regulator To reach it remove the lower cover SR MAX 125 ie Electrical system ELE SYS 57 ...

Страница 58: ...19 Wheel turning sensor In the front wheel on the right hand side 20 Electric fan Remove the radiator Conceptual diagrams Ignition Electrical system SR MAX 125 ie ELE SYS 58 ...

Страница 59: ...e a chiave 32 Gruppo strumenti 40 Teleruttore centralina elettronica 48 Centralina elettronica per iniezione 54 Pompa della benzina 55 Iniettore carburante 57 Bobina a t 58 Sensore giri motore 61 Pompa acqua Battery recharge and starting LEGENDA 1 Batteria 12v 14 Ah 2 Regolatore di tensione SR MAX 125 ie Electrical system ELE SYS 59 ...

Страница 60: ...Fusibile N 08 7 5A 22 Pulsante avviamento 23 N 2 pulsanti stop 24 Lampada luce stop 12v 21 5w 28 Contatto del commutatore a chiave 48 Centralina elettronica per iniezione 53 Deviatore arresto motore Level indicators and enable signals section LEGENDA 1 Batteria 12v 14 Ah 6 Massa motore 8 Fusibile N 02 15A Electrical system SR MAX 125 ie ELE SYS 60 ...

Страница 61: ...lio 38 Trasmettitore livello carburante 39 Dispositivo gestione comandi elettrici 47 Sensore giri ruota 48 Centralina elettronica per iniezione 50 Sensore temperatura liquido raffreddamento per c d i 51 Sensore liquido di raffreddamento per strumento 52 Pulsante cavalletto 53 Deviatore arresto motore 59 Decoder 60 Antenna Devices and accessories SR MAX 125 ie Electrical system ELE SYS 61 ...

Страница 62: ... c 26 Pulsante claxon 27 Predisposizione antifurto 28 Contatto del commutatore a chiave 29 Presa 12v 180w max 30 Pulsante illuminazione vano casco 32 Gruppo strumenti 36 Pulsante mode remoto 39 Dispositivo gestione comandi elettrici 45 Teleruttore per elettroventola radiatore 46 Elettroventola radiatore 48 Centralina elettronica per iniezione Electrical system SR MAX 125 ie ELE SYS 62 ...

Страница 63: ...ile N 07 7 5A 14 Fusibile N 08 7 5A 15 Fusibile N 09 7 5A 16 Fusibile N 10 7 5A 17 Fusibile N 11 7 5A 18 Devio luci 19 Teleruttore luci abbaglianti 20 Lampada luce abbagliante 12v 55w 21 Spia abbaglianti 12v 1 2w 23 N 2 pulsanti stop 24 Lampada luce stop 12v 21 5w 28 Contatto del commutatore a chiave SR MAX 125 ie Electrical system ELE SYS 63 ...

Страница 64: ...ce posizione posteriore 12v 21 5w 42 Lampada 12v 5w per luce targa 43 N 2 lampade 12v 5w per luce di posizione anteriore 44 Lampada 12v 1 2w per spia luce di posizione Injection LEGENDA 1 Batteria 12v 14 Ah 6 Massa motore 8 Fusibile N 02 15A 11 Fusibile N 05 10A 17 Fusibile N 11 7 5A 28 Contatto del commutatore a chiave 32 Gruppo strumenti 40 Teleruttore centralina elettronica Electrical system SR...

Страница 65: ...ilt in transponder HV coil diagnosis LED decoder The diagnosis LED also works as a blinking light to deter theft This function is activated every time the key switch is set to OFF when the side stand is lowered or the engine emergency cut off switch is set to OFF It remains activated for 48 hours in order not to affect the battery charge When the ignition switch is turned to ON the deterring blink...

Страница 66: ...lts are found replace the control unit oth erwise check the wiring and the following compo nents Emergency cut off switch Side stand contacts Key switch contacts Virgin circuit If the ignition system has not been programmed the engine can be started but it will run limited to 2000 rpm When trying to accelerate some evident loss of power may be felt Program the system with the MASTER Brown and SERV...

Страница 67: ...rnings That is the led is off for 2 seconds and then diagnosis codes are transmitted with 0 5 second flashes After the failure code indication the LED remains on permanently to indicate that ignition is not possible Diagnostic code 2 flashes When the 2 flash code is detected carry out the following checks Check if the failure continues after changing key MASTER key included If the failure persists...

Страница 68: ...e key Blue If the failure persists it means that the MASTER key and the decoder are not linked in this case replace the decoder and then encode the keys The immobilizer system is efficient when after switching over to ON only a 0 7 sec flash is detected see diagram In this case the engine can be started Example with programmed decoder transponder programmed key and working aerial The ignition is e...

Страница 69: ...onding is efficient No spark plug Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited follow this procedure Pick Up check Disconnect the control unit connector and check the resistance value between terminal No 13 Red and terminal No 15 White Check the Pick Up and its power line Electric characteristic Pick up resistance value 105 124 Ohm If a break i...

Страница 70: ...he HV coil To carry out a more complete diagno sis check the peak voltage with the multimeter adaptor Electric characteristic High voltage coil secondary resistance value 8 000 300 ohm Pick Up Disconnect the control unit connector and con nect the positive terminal to connector No 13 and the negative terminal to connector No 15 see fig ure The multimeter end of a scale should be 200V Use the start...

Страница 71: ...values are measured replace the control unit NOTE THE PLASTIC CAP OF THE POSITIVE TERMINAL ON THE HV COIL PRIMARY IS BLACK AND THE NEGATIVE TER MINAL ONE IS GREEN Electric characteristic High voltage coil voltage value High voltage coil voltage value 100 Volt Stator check Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two ca...

Страница 72: ...ated from the ground connection If non conforming values are detected repeat the checks directly to the stator In case of further repe titions of incorrect values replace the stator or repair the wiring Electrical system SR MAX 125 ie ELE SYS 72 ...

Страница 73: ...mo è collegato direttamente a massa ed al positivo batteria passando attraver so il fusibile di protezione da 30A N 1 Pertanto questo sistema non prevede alcun colle gamento con il commutatore a chiave Il generatore trifase permette una notevole poten za di ricarica ed ai giri più bassi viene ottenuto un buon compromesso tra potenza erogata e stabilità del minimo Per tale motivo è indispensabile c...

Страница 74: ...di destra Ripetere la verifica con il terminale n 19 20 Rosa Nero controllando però che si accendano i lamp eggiatori di sinistra If no lights turn on replace the instrument panel because it is faulty If they turn on carry out the following checks Check for the continuity between terminals No 3 and No 2 of the electric control management device with the turn indicator switch activated to the right...

Страница 75: ...ortafusibili A n 6 fusibili collocati nel vano portacasco vicino alla batteria Portafusibili B n 5 fusibili collocati nel vano portacasco vicino alla presa di corrente Per la sostituzione del fusibile utilizzare l apposita pinza a corredo nella borsa attrezzi La tabella riporta la posizione e le caratteristiche dei fusibili presenti sul veicolo CAUTION BEFORE REPLACING A BLOWN FUSE FIND AND SOLVE ...

Страница 76: ... Fuse No 9 Capacity 7 5A Protected circuits live Analogue rpm indicator in strument panel lighting daylight running light bulbs li cense plate bulb bulb for daylight running warning light 10 Fuse No 10 Capacity 7 5A Protected circuits Pre installation for antitheft device battery powered instrument panel 11 Fuse No 11 Capacity 7 5A Protected circuits live Instrument panel turn indica tor bulbs rad...

Страница 77: ...ONS FOR THE BATTERY REFRESH AFTER OPEN CIRCUIT STORAGE 1 Voltage check Before installing the battery on the vehicle check the open circuit voltage with a standard tester If voltage exceeds 12 60 V the battery can be installed without any renewal recharge If voltage is below 12 60 V a renewal recharge is required as explained in 2 2 Constant voltage battery charge mode Constant voltage charge equal...

Страница 78: ...equal to 1 10 of the battery rated capacity Connections to the power supply source must be implemented by connecting corresponding poles to and to Battery installation VRLA battery valve regulated lead acid battery Maintenance Free MF WARNING BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS IT CONTAINS SUL PHURIC ACID AVOID CONTACT WITH YOUR EYES SKIN AND CLOTHING IF COMING INTO CONTACT...

Страница 79: ...no air bubbles coming out of the filling holes lightly tap the bottom of the container two or three times Do not remove the container from the battery 5 Take out the container Make sure all the electrolyte in the battery is drained Gently tap the bottom of the container if electrolyte remains in the container Now gently pull the container out from the battery only do this when the container is com...

Страница 80: ... The dry charge battery MF like the completely loa ded YTX must have a no load voltage between 12 8 13 15 V Bring the battery to full charge us ing the 020648Y battery charger a select the type of battery with the red switch on the left of the panel battery charger panel b select NEW on the yellow timer c connect the clamps of the battery charger to the battery poles black clamp to negative pole a...

Страница 81: ...y and check the voltage if voltages are detected of less than 12 8 V proceed with a new recharge of the battery starting from point c of the recharge pro cedure of the new battery otherwise go to point i i The battery is now completely activated disconnect the battery charger from the fuel supply grid disconnect the clamps from the battery and proceed to fitting the battery on the vehicle SR MAX 1...

Страница 82: ...ning light White Blue 10 Left turn indicator warning light Pink 11 Battery Red Black 12 Immobilizer LED Grey Yellow 13 Live White Black 14 To electric control management device Grey 15 Fuel level signal White Green 16 Ground lead Black 17 Injection telltale light Brown White 18 To electric control management device Blue 19 To electric control management device Pink Black 20 Not used TONE WHEEL CON...

Страница 83: ...or positive Red 14 Injector Red Yellow 15 Rpm sensor negative White 16 Diagnosis Orange Black 17 Immobilizer warning light Grey Yellow 18 Stand button Brown Red 19 Not connected 20 Injection load remote control Black Purple 21 Not connected 22 HV coil Pink Black 23 Not connected 24 Start up enabling switch Green Blue 25 Not connected 26 Ground lead Black ANTITHEFT CONNECTOR 1 Left turn indicators ...

Страница 84: ...VOLTAGE REGULATOR CONNECTOR 1 Battery positive terminal Red White 2 Ground lead Black 3 Battery positive terminal Red White 4 Ground lead Black Electrical system SR MAX 125 ie ELE SYS 84 ...

Страница 85: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Страница 86: ...the head To unscrew the nuts that fix the silencer flange to the head properly use a jointed wrench that allows according to the travel direction to get also at the right nut That is difficult to do with a traditional straight wrench Undo the three screws that fix the silencer to the supporting arm Remove the full silencer unit Remove the lambda probe from the manifold Engine from vehicle SR MAX 1...

Страница 87: ...THE ENGINE IS COLD CAUTION SUPPORT THE VEHICLE ADEQUATELY Remove the central tunnel Remove the full muffler unit Remove the air filter Working on the vehicle right side remove the coolant inlet pipes and empty the system NOTE LET THE COOLANT DRAIN INTO A CONTAINER OF ADE QUATE CAPACITY Characteristic Cooling system fluid 1 75 l Remove the tube from the spark plug SR MAX 125 ie Engine from vehicle ...

Страница 88: ... the engine Disconnect the fuel pipe and the fitting to the control unit Disconnect the connector of the injector Disconnect the coolant temperature sensor Disconnect the control unit connector Engine from vehicle SR MAX 125 ie ENG VE 88 ...

Страница 89: ...ttle body from the manifold Unscrew the positive and negative cable har nesses of the starter motor Disconnect the throttle grip cables by undoing the set screws Disconnect the oil minimum pressure sensor SR MAX 125 ie Engine from vehicle ENG VE 89 ...

Страница 90: ...elease the cable harness Disconnect the power connector from the water pump and release the cable harness Take out the ground retainer on the engine and remove the clamp by pulling Remove the rear left shock absorber lower re tainer Engine from vehicle SR MAX 125 ie ENG VE 90 ...

Страница 91: ...respect the tightening torques shown in the Specifications Chapter Check the engine oil level and if necessary top it up with the recommended type Fill and bleed the cooling circuit Check accelerator and electric devices for correct functioning CAUTION PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY SR MAX 125 ie Engine from vehicle ENG VE 91 ...

Страница 92: ...INDEX OF TOPICS ENGINE ENG ...

Страница 93: ...ted nut and collect the washer Specific tooling 020423Y Driven pulley lock wrench Undo the eleven fixings screws to the engine and remove the transmission cover NOTE WHEN YOU ARE REMOVING THE TRANSMISSION COVER YOU MUST BE CAREFUL NOT TO DROP THE CLUTCH HOUSING Air duct Unscrew the two screws 1 fixing the air filter to the engine Unscrew the three screws 2 and remove the crankcase cover 3 SR MAX 1...

Страница 94: ...ing from the crankcase by means of Specific tooling 020376Y Adapter handle 020375Y 28 x 30 mm adaptor 020412Y 15 mm guide Refitting the driven pulley shaft bearing Heat the crankcase from the inside Insert the bearing in its seat Refit the Seeger ring CAUTION USE AN APPROPRIATE SUPPORT TO AVOID DAMAGING THE COVER SURFACE NOTE ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING Specific toolin...

Страница 95: ...ell is not worn or damaged Measure the clutch bell inside diameter Characteristic Max value clutch bell Max value Ø 134 5 mm clutch housing standard value Standard value Ø 134 134 2 mm Checking the bell working surface eccentricity Install the bell on a driven pulley shaft using 2 bearings inside diameter 15 and 17 mm Lock with the original spacer and nut Place the bell shaft unit on the support t...

Страница 96: ...ng 020074Y Support base for checking crankshaft alignment 020335Y Magnetic mounting for dial gauge Characteristic clutch bell inspection Limit eccentricity Admissible limit eccentricity 0 15 mm Inspecting the clutch Check the thickness of the clutch mass friction material The masses must not show traces of lubricants otherwise check the driven pulley unit seals NOTE Engine SR MAX 125 ie ENG 96 ...

Страница 97: ...11 with the chamfering facing the inside of the tool Fit the driven pulley unit on the tool with the in sertion of the 3 pins in the ventilation holes in the mass holder support Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to loosen tight en the clutch nut Use the special 46x55 wrench component 9 to remove the nut fixing the clutch in place Dismantle the ...

Страница 98: ...etaining collar Simultaneously turn and pull the collar manually to remove it NOTE USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICULTY NOTE BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O RING SEAL Remove the 4 torque server pins and pull the pulley halves apart Engine SR MAX 125 ie ENG 98 ...

Страница 99: ...ing adequately from the threaded side using a wooden surface Using a hammer and pin knock the ball bearing out as shown in the figure Support the pulley properly using the bell as shown in the figure Specific tooling 001467Y035 Bell for 47 mm outside diameter bearings Remove the roller bearing using the modular punch Specific tooling 020376Y Adapter handle 020456Y Ø 24 mm adaptor SR MAX 125 ie Eng...

Страница 100: ...aying surface with the belt to make sure there are no flaws Check the riveted joints are functional Check the evenness of the belt contact surface Characteristic Half pulley minimum diameter Minimum admissible diameter Ø 40 96 mm Half pulley standard diameter Standard diameter Ø 40 985 mm Wear limit 0 3 mm Engine SR MAX 125 ie ENG 100 ...

Страница 101: ...ed joints are functional Check the evenness of the belt contact surface MOVABLE DRIVEN HALF PULLEY DIMENSIONS Specification Desc Quantity Wear limit 0 3 mm standard diameter Ø 41 000 41 035 mm maximum allowable diameter Ø 41 08 mm Refitting the driven half pulley bearing Support the pulley bushing adequately from the threaded side using a wooden surface Fit a new roller bearing as shown in the fig...

Страница 102: ...n the figure using a modular punch Fit the retainer ring WARNING NOTE FIT THE BALL BEARING WITH THE VISIBLE SHIELDING Specific tooling 020376Y Adapter handle 020375Y 28 x 30 mm adaptor 020424Y Driven pulley roller casing fitting punch Engine SR MAX 125 ie ENG 102 ...

Страница 103: ...shing until it comes out through the hole on the opposite side This operation is necessary to avoid the presence of grease beyond the O rings NOTE THE TORQUE SERVER CAN BE GREASED WHETHER WITH BEARINGS FITTED OR WHEN THEY ARE BEING RE PLACED UNDERTAKING THE OPERATION WHEN THE BEARINGS ARE BEING SERVICED MIGHT BE EASIER Specific tooling 020263Y Driven pulley assembly sheath Recommended products AGI...

Страница 104: ...ly inserted into the adapter ring before proceeding to tighten the clutch nut Place the tool in the clamp with the control screw on the horizontal axis Fully preload the spring Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench Loosen the tool clamp and insert the belt accord ing to its direction of rotation Lock the driven pulley again using the spe...

Страница 105: ... N m Clutch unit nut on driven pulley 45 to 50 Refitting the driven pulley Fit the clutch housing on the driven pulley paying attention to the position of the washer indicated Drive belt Make sure the drive belt is not damaged and does not show abnormal wear Replace as indicated in the scheduled maintenance table SR MAX 125 ie Engine ENG 105 ...

Страница 106: ...own in the picture Insert the tool in the hollows and apply the reten tion ring Bring in the ring s clamping screws while keeping the tool to support the pulley Remove the fixing nut and the washer Remove the stationary drive pulley half Specific tooling 020626Y008 Driving pulley lock wrench Remove nut 1 Belleville spring 2 and wash er 3 Engine SR MAX 125 ie ENG 106 ...

Страница 107: ...eck that the rollers are not damaged or worn Check the guide shoes for the variator back plate are not worn Check the wear of the roller housings and of the belt faying surfaces on both pulley halves Check that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt Check that the O ring is not pushed out of shape CAUTION DO NO...

Страница 108: ... 15 g Refitting the driving pulley Preassemble the movable half pulley with the roller contrast plate by putting the rollers in their housings with the larger support surface touching the pulley according to the direction of rotation Check that the roller contact plate does not have flaws and is not damaged on the grooved edge Mount the complete bushing unit on the crank shaft Fit the driven pulle...

Страница 109: ...k that there are two alignment dowels and that the sealing gasket for the oil sump on the transmission cover is adequately fitted Refit the cover and tighten the 12 screws to the specified torque Refit the steel washer and the driven pulley nut Tighten the nut to the prescribed torque using the lock wrench and the torque wrench tools Refit the plastic cover Specific tooling 020423Y Driven pulley l...

Страница 110: ...he drain screw 1 Undo the six screws 2 and the screw 3 Remove gasket 4 and make sure that align ment dowels 5 are adequately positioned Removing the wheel axle Remove the wheel axis complete with gear Remove the intermediate gear Engine SR MAX 125 ie ENG 110 ...

Страница 111: ... cover Specific tooling 001467Y013 Calliper to extract ø 15 mm bearings Removing the wheel axle bearings Take out the clip on the outside of the hub cover Support the hub cover and expel the bearing By means of the appropriate tools remove the oil guard as in the figure Specific tooling 020376Y Adapter handle 020477Y 37 mm adaptor 020483Y 30 mm guide 020359Y 42 x 47 mm adaptor 020489Y Hub cover su...

Страница 112: ...Removing the driven pulley shaft bearing Extract the driven pulley shaft from its bearing Remove the oil seal using a screwdriver and be careful not to damage the seat Engine SR MAX 125 ie ENG 112 ...

Страница 113: ...ley shaft bearing using the modular punch Specific tooling 020376Y Adapter handle 020375Y 28 x 30 mm adaptor 020363Y 20 mm guide Inspecting the hub shaft Check that the 3 shafts exhibit no wear or defor mation on the grooved surfaces at the bearings and at the oil seals In case of faults replace the damaged parts SR MAX 125 ie Engine ENG 113 ...

Страница 114: ... the damaged components Refitting the wheel axle bearing Support the hub cover on a wooden surface Heat the crankcase cover with the specific heat gun Fit the wheel shaft bearing with a modular punch as shown in the figure Fit the Seeger ring Fit the oil guard with seal lip towards the inside of the hub and place it flush with the internal surface by means of the appropriate tool used from the 52 ...

Страница 115: ...SR MAX 125 ie Engine ENG 115 ...

Страница 116: ...tools The 42 mm side of the adapter must be turned towards the bearing Specific tooling 020150Y Air heater mounting 020151Y Air heater 020376Y Adapter handle 020359Y 42 x 47 mm adaptor 020412Y 15 mm guide NOTE TO FIT THE BEARING ON THE COVER ADEQUATELY SUPPORT THE COVER WITH THE STUD BOLT KIT Refit the driven pulley shaft bearing with a modular punch as shown in the figure NOTE Engine SR MAX 125 i...

Страница 117: ...r ring with the opening facing the bearing and fit a new oil seal flush with the crankcase from the pulley side Refitting the hub bearings Install the three shafts in the engine crankcase as shown in the figure Refitting the ub cover Fit a new gasket together with the alignment dowels Seal the gasket of the breather pipe using black silicone sealant Fit the gearbox cover making sure the breather p...

Страница 118: ... prescribed torque Locking torques N m Hub cover fixing screws 24 to 27 Hub oil drain screws 15 to 17 Flywheel cover Removing the hub cover Remove the clamp fastening the pipe to the cyl inder undo the two screws fixing it to the engine and remove the electric pump together with its support Engine SR MAX 125 ie ENG 118 ...

Страница 119: ...ver Remove the gasket and be careful with the two alignment dowels Removing the stator Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure Remove the stator and its wiring SR MAX 125 ie Engine ENG 119 ...

Страница 120: ... to 4 Refitting the flywheel cover Fit the gasket and be careful with the two align ment dowels Fit the entire flywheel cover Undo the seven screws fixing the flywheel cover observing the position of the plate indicated Fasten the electric pump together with its support with the two screws indicated and fasten the pipes to the cylinder Locking torques N m Transmission cover screw 11 to 13 Engine S...

Страница 121: ...starter motor out of its seat Removing the flywheel magneto Remove the screw and the plate of the starting sprocket Fit the specific tool screw the guide bushing to the flywheel insert the flywheel stop tool as shown in the picture Specific tooling 020627Y Flywheel lock wrench SR MAX 125 ie Engine ENG 121 ...

Страница 122: ... THE EXTRACTOR AND ALSO PREVENTS DROPPING THE FLYWHEEL ACCIDENTALLY UPON EXTRACTING IT PO TENTIAL DROPS MAY DAMAGE THE CERAMIC INSERTS Insert the extractor Specific tooling 020467Y Flywheel extractor Act on the extractor to remove the flywheel to gether with the starting sprocket Inspecting the flywheel components Check the integrity of the internal plastic parts of the flywheel and the Pickup con...

Страница 123: ...les in the free wheel and the clamping screws Apply the recommended product to the end of the screws Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly wheel itself i e with wheel Seeger ring visible Lock the six clamping screws in criss cross fash ion to the...

Страница 124: ...el Insert the free wheel on the flywheel as shown in the picture Then refit the flywheel with free wheel and trans mission gear Using the special flywheel lock wrench tighten up the flywheel fixing nut to the prescribed torque Refit the retention plate Specific tooling 020627Y Flywheel lock wrench Locking torques N m Flywheel nut 94 102 Engine SR MAX 125 ie ENG 124 ...

Страница 125: ...k the 2 screws to the prescribed torque Locking torques N m Starter motor screws 11 13 Cylinder assy and timing system Removing the intake manifold Undo the three screws with an anti tampering device Removing the rocker arms cover Remove the five screws shown in the figure Remove the entire head cover SR MAX 125 ie Engine ENG 125 ...

Страница 126: ...ket Undo the two screws indicated Detach the timing chain and remove the camshaft control pulley and the corresponding washer Remove the screws indicated in the figure the spacer bar and the tensioner slider Remove the control sprocket wheel and the tim ing chain As regards the chain guide slider it may only be removed after the head has been removed NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER...

Страница 127: ...ate Remove the camshaft Acting on flywheel side holes push and slide off the rocking lever pins NOTE IF NEEDED THE HEAD MAY BE REMOVED WITH THE CAMSHAFT ROCKER PINS AND FIXING BRACKET THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER SR MAX 125 ie Engine ENG 127 ...

Страница 128: ...NKSHAFT CHAIN TENSIONER Remove the gasket Removing the valves NOTE CHECK RESIDUAL STROKE IN ORDER TO AVOID RESONANCES IN THE INTAKE VALVES AS DESCRIBED IN THE PAGE ON ENGINE THERMAL GROUP AND TIMING SYSTEM VALVE CHECK EVERY TIME THAT EITHER THE INTAKE VALVES OR THEIR COMPONENTS ARE RE MOVED Use the specific tool to remove the cotters cap and spring CAUTION REPLACE THE VALVES IN SUCH A WAY AS TO RE...

Страница 129: ... Use the specific tool to remove the valve oil seal Specific tooling 020306Y Punch for assembling valve seal rings SR MAX 125 ie Engine ENG 129 ...

Страница 130: ...cated above for checking residual stroke as described in the page on Engine Ther mal group and timing system valve check See also Removing the cylinder piston assy Remove the chain guide slider be careful with the two alignment dowels and remove the cylinder Remove the base gasket be careful with the two centring dowels and the dowel pin Engine SR MAX 125 ie ENG 130 ...

Страница 131: ...LING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Inspecting the wrist pin NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Inspecting the piston NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Inspecting the piston rings NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TE...

Страница 132: ...a punch Fit the wrist pin retainer ring using the plug as shown in the figure NOTE THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS HOUS ING Specific tooling 020430Y Pin lock fitting tool Choosing the gasket Provisionally fit the piston into the cylinder without any base gasket Install a dial gauge on the special tool using the short un...

Страница 133: ...compres sion ratio Remove the special tool and the cylinder NOTE IF DEVIATIONS OR RECESSES OR PROJECTIONS CLOSE TO THE CHANGE OF CATEGORY ARE MEASURED REPEAT THE MEASUREMENT AT THE OPPOSED SIDE TO DO SO REPEAT THE TOOL INSTALLATION BY INVERTING ITS POSITION See also Refitting the piston rings Pistons like cylinders are supplied in 4 catego ries A B C and D and must be fitted so that the reference ...

Страница 134: ...HE CYLINDER LINER Check the position of the alignment dowels and dowel pin and fit a gasket with a thickness previ ously determined Using the specific tool fit the cylinder paying at tention that the chain does not remain in the timing system compartment Specific tooling 020426Y Piston fitting fork 020393Y Piston assembly band Engine SR MAX 125 ie ENG 134 ...

Страница 135: ...sprocket wheel are not worn If you detect wear replace the parts or if the chain sprocket wheel and pulley are worn replace the whole unit Remove the centre screw with the washer and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring If examples of wear are found replace the whole unit Inspecting the valve sealings NOTE TO MEASURE WEAR LIM...

Страница 136: ...it the specific tool on the head and fasten the dial gauge Specific tooling 020688Y Dial gauge support Check that the dial gauge is adequately posi tioned that is as parallel as possible to the valve axis and the cap must be within the level area Turn the crankshaft until the Intake valves are at their maximum lift NOTE USING A DIAL GAUGE IDENTIFY THE MAXIMUM LIFT AND LOCATE THE EXACT POINT AT WHI...

Страница 137: ...rew until the end of stroke Characteristic Residual stroke 0 8 1 8 mm Check residual stroke by comparing it with the data contained in the next page RESIDUAL STROKE CHECK Check the residual stroke and afterwards make sure that it falls within the predetermined limits Characteristic Residual stroke 0 8 1 8 mm SR MAX 125 ie Engine ENG 137 ...

Страница 138: ...REPLACED THE VALVE SEAL RING MUST BE REPLACED AS WELL WHEN A NEW HEAD OR VALVE IS FITTED THE 0 8 mm WASHER HAS TO BE CHECKED NEVER INSERT MORE THAN ONE WASHER IN THE SAME SEAT Characteristic Residual stroke 0 8 1 8 mm Refer to the Engine Thermal group and timing system Valve removal page to see the re placement steps See also NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIO...

Страница 139: ...riate tool with adapter compress the springs and insert the cotters in their seats NOTE DO NOT CHANGE THE VALVE FITTING POSITION FIT THE VALVE SPRINGS WITH THE REF ERENCE COLOUR ON COTTER SIDE TURNS WITH GREATER PITCH Specific tooling 020306Y Punch for assembling valve seal rings 020382Y011 adapter for valve removal tool 020382Y Tool to extract valve cotters Inspecting the cam shaft NOTE SR MAX 12...

Страница 140: ...que Locking torques N m Slider screw 10 14 Nm Fit the head gasket and check that the alignment dowels work properly Insert the head Lubricate the stud bolt threads with engine oil Tighten up the nuts to an initial pre torque of 7 1 Nm Tighten up the nuts to a second pre torque of 10 1 Nm To carry out the operations described above fol low the tightening sequence in the figure Fit the two screws on...

Страница 141: ...the flywheel and the crankcase Insert the pulley on the camshaft while keeping the reference 4V in correspondence with the ref erence mark on the head Holding this position insert the chain on the cam shaft control pulley Lock the fixing screws Locking torques N m Counterweight screw 7 to 8 5 Set the tensioner cursor to the rest position Fit the chain tensioner on the cylinder using a new gasket a...

Страница 142: ...he intake manifold and do up the three screws Locking torques N m Intake manifold screws 11 to 13 Crankcase crankshaft crankshaft Splitting the crankcase halves crankcase halves AXIAL CLEARANCE CHECK Before opening the engine crankcase it is ad visable to check the axial clearance of the crank shaft Use a specific tool to check axial clearance Higher clearances are signs of wear on the crank shaft...

Страница 143: ... keeping the crankshaft in one of these two halves Only after the halves have been separated can the crankshaft be checked CAUTION WHILE OPENING THE CRANKCASES AND REMOVING THE CRANKSHAFT CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH INGS FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WH...

Страница 144: ...ernal bulkhead and the protection bulkhead for the mesh pre filter Inspecting the crankshaft components crankshaft components NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Inspecting the crankshaft alignment crankshaft alignment NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Engine SR MAX 125 ie ENG 144 ...

Страница 145: ...al Inspect the coupling surfaces on the crankcase halves for scratches or deformation taking partic ular care with the cylinder crankcase surfaces and the crankcase halves surfaces Defects in the crankcase coupling gasket be tween the crankcase halves or the mating surfaces shown in the diagram could cause a drop in the oil pressure lubricating the main bushings and connecting rod Check the main b...

Страница 146: ...hings are comprised of two half bearings one with holes and channels for lubrica tion whereas the other is solid The solid half bearing is intended to stand the thrusts caused by combustion and for this reason it is arranged opposite the cylinder To prevent shutters in the oil feeding channels the matching surface of the two half bearings must be perfectly orthogonal to the cylinder axis as shown ...

Страница 147: ...Fit the oil filter fitting and tighten it to the prescri bed torque Position the oil pre filter element as shown in the picture Place a new gasket on one of the crankcase halves preferably on the transmission side to gether with the alignment dowels SR MAX 125 ie Engine ENG 147 ...

Страница 148: ...ge plug mesh filter 24 to 30 Studs Check that the stud bolts have not worked loose from their seat in the crankcase Check the depth of stud bolt driving with a gauge as indicated in the picture If it varies significantly from the driving depth indicated it means that the stud bolt has yielded In this case replace it By working on two fitted cylinder head fixing nuts nut and lock nut as shown in th...

Страница 149: ...g end are lubricated with high pressure through the suitable passages found in the crankcase halves 4 whereas the piston pin and connecting rod small end are lubricated via jet 5 Afterwards the oil through a nozzle 6 whose function is to reduce the flow rate reaches the timing system where it lubricates the camshaft and from there the valves and rockers 7 The oil passes through the timing chain co...

Страница 150: ...appropriate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the specified torque and fit the flywheel cover If the oil pressure is not within the specified limits in the following order check the oil filter the oil by pass valve the oil pump and the crankshaft seals NOTE THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND WITH AN OIL FI...

Страница 151: ... oil seal Specific tooling 020622Y Transmission side oil seal punch Refitting Always use a new oil seal upon refitting Prepare the new oil guard by lubricating the seal ing lip Preassemble the oil seal with the appropriate tool by positioning the screws Insert the sheath over the crankshaft Insert the tool with the oil seal on the crankshaft until it comes into contact with the crankcase Insert th...

Страница 152: ...N DO NOT LUBRICATE THE KEYING SURFACE ONTO THE ENGINE CRANKCASE CAUTION ORIENT THE OIL SEAL BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS WHEN THE POSITION IS REACHED DO NOT RETRACT THE OIL SEAL FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL SEAL SHEATH CAUTION FAILURE TO COMPLY WITH THIS ASSEMBLY PROCE DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO THE WRONG TE...

Страница 153: ...cket wheel with relative O ring Remove the oil pump by undoing the two screws in the figure Remove the oil pump seal NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED Inspection Remove the two screws and the oil pump cover Remove the circlip retaining the innermost rotor Remove and wash the rotors thoroughly with pet rol and compressed ...

Страница 154: ...ted 0 09 mm Distance between the outer rotor and the pump body Admissible limit clearance 0 20 mm Distance between the rotors Admissible limit clearance 0 12 mm Refitting Check there are no signs of wear on the oil pump shaft or body Check there are no signs of scoring or wear on the oil pump cover If you detect non conforming measurements or scoring replace the faulty parts or the unit Fit the pu...

Страница 155: ...rews to the prescribed torque NOTE FIT THE CUP WASHER SO THAT ITS OUTER RIM TOUCH ES THE PULLEY MAKE SURE THAT THE PUMP TURNS FREELY Locking torques N m Screws fixing oil pump to the crankcase 5 to 6 Oil pump command sprocket screw 10 to 14 Oil pump cover screws 0 7 0 9 Removing the oil sump oil sump Drain the oil from the sump Remove the seven screws indicated in the figure and the bracket of the...

Страница 156: ...eplace defec tive parts Characteristic By pass check up Standard length 54 2 mm Refitting the oil sump oil sump Check the correct position of alignment dowels 1 Fit a new gasket 2 Fit the by pass piston and spring 3 Assemble the oil sump by tightening the seven fixing screws and be careful with the plate indica ted Tighten to the specified torque Locking torques N m Oil sump screws 10 to 14 Engine...

Страница 157: ...INDEX OF TOPICS INJECTION INJEC ...

Страница 158: ...Injection SR MAX 125 ie INJEC 158 ...

Страница 159: ...robe The system implements an idle feeding correction with cold engine through a Stepper motor on a by pass circuit of the throttle valve The control unit manages the Stepper motor and the injector opening time thereby ensuring the idle steadiness and the proper combustion In all conditions of use mixture preparation is managed by modifying the injector opening time The fuel system pressure is kep...

Страница 160: ...strument panel Failures are detected and restored by the diagnostic tester In any case when the fault is no longer present the data storage is automatically cleared after 16 cycles of use cold start running at regular engine temperature stop The diagnostic tester is also required to adjust the idle mixture Specific tooling 020680Y Diagnosis Tool The MIU injection ignition system carries out checks...

Страница 161: ...sition sensor 2 MIU system faults may be caused by loose connectors Make sure that all connections have been correctly made Check the connections as follows A check that the terminals are not bent B check that the connectors have been properly connected C check whether the malfunction can be fixed by shaking the connector slightly 3 Check the entire system before replacing the MIUIf the fault is f...

Страница 162: ...d by fuel 7 When washing the vehicle be careful with the electric components and wiring 8 When an ignition problem is detected start the checks from the battery and the injection system connections 9 Before disconnecting the MIU control unit connector perform the following steps in the order shown Set the switch to OFF Disconnect the battery Failure to respect this norm may damage the control unit...

Страница 163: ...r aerial 8 Electric fan remote control 9 Water temperature sensor 10 11 Lambda probe 12 engine stop switch 13 Engine speed sensor 14 Fuel injector 15 Engine speed sensor 16 Diagnostics socket output 17 Immobilizer LED 18 Side stand short circuited on pin 19 19 20 Injection load remote control 21 22 HV coil 23 24 Start up enabling 25 26 Ground lead SR MAX 125 ie Injection INJEC 163 ...

Страница 164: ...e N 05 10A 16 Fusibile N 10 7 5A 17 Fusibile N 11 7 5A 28 Contatto del commutatore a chiave 32 Gruppo strumenti 40 Teleruttore centralina elettronica 45 Teleruttore per elettroventola radiatore 46 Elettroventola radiatore 48 Centralina elettronica per iniezione 49 Diagnostica 50 Sensore temperatura liquido raffreddamento per c d i Injection SR MAX 125 ie INJEC 164 ...

Страница 165: ... timing sensor Fuel system Fuel in the tank Fuel pump activation Fuel pressure low Injector capacity low Power to the spark plug Shielded spark plug cap HV coil secondary insulation Parameter reliability Coolant temperature Distribution timing injection ignition Intake air temperature End of compression pressure End of compression pressure Starting difficulties ENGINE STARTER PROBLEMS Possible Cau...

Страница 166: ... temperature sensor Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system sealing infiltrations Intake manifold head Throttle body manifold Intake sleeve Filter box Fuel system low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Engine does not rev down ENGINE DOES NOT RETURN TO IDLING SPEED IDLING SPEED TOO HIGH Possible Ca...

Страница 167: ...gularly ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system sealing Intake sleeve Filter box Ignition system Spark plug wear check Parameter reliability Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance T...

Страница 168: ...ure Lambda probe Ignition efficiency Spark plug Parameter reliability Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance Intake system sealing Intake sleeve Filter box TPS reset successful TPS reset successful Fuel system Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness Selection of ...

Страница 169: ...ng the butterfly valve Remove the helmet compartment Remove the fuel piping clamping screw indicated in the figure Remove the fast release fittings from the injector support SR MAX 125 ie Injection INJEC 169 ...

Страница 170: ...e three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold Remove the MIU ECU connector Remove the clip fixing the throttle body to the air cleaner bellows Injection SR MAX 125 ie INJEC 170 ...

Страница 171: ...e butterfly valve To refit perform the operations in the reverse or der from the removal operations being careful to position the clip fixing the throttle body to the air filter bellows at 45 as shown in the photograph Pump supply circuit SR MAX 125 ie Injection INJEC 171 ...

Страница 172: ...en the engine starts in the presence of rpm timing signal the pump is continuously supplied ELECTRICAL DATA Pump winding resistance 1 5 Ohm Input current during regular operation 1 4 1 8 A Input current to the closed hydraulic circuit 2 A to be checked with appropriate tool for fuel pressure control choking the circuit on the return pipe Verificare l efficienza del fusibile N 5 da 10 A car ichi in...

Страница 173: ...gising coil After switching to ON make sure there is battery voltage for two seconds between the black white cable and black violet cable of the remote control base If there is not check the continuity of the black white cable between fuse block and the remote control base and of the black violet cable between pin 20 of the control unit and the remote control base NOTE CONTINUITY TESTS MUST BE CAR...

Страница 174: ...Injection SR MAX 125 ie INJEC 174 ...

Страница 175: ...that there is battery voltage for about two seconds to the Black Green cable of the pump connector and ground with pump connector disconnected Otherwise check the continuity of the Black Green cable between the pump connector and the remote control base Check the efficiency of the ground line of the fuel pump by measuring the continuity between the pump connector black cable system side and the gr...

Страница 176: ...k that the fuel pressure is 2 5 BAR and that the input current is 1 4 to 1 8 A With the battery voltage 12 V check the pump flow rate by disconnecting from the injector the pipe equipped with the pressure gauge of the appropriate tool Get a graded burette with a flow rate of approximately 1 L Rotate the pump using the active diagnoses of the palm top computer Using a pair of long flat needle nose ...

Страница 177: ...inals from the electric pump Remove the screw shown in the picture Remove the clip fixing the piping to the filter shown in the picture Separate the lower part of the pump mounting as shown in the picture SR MAX 125 ie Injection INJEC 177 ...

Страница 178: ...n Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 15 A 4 Ignition key contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda Probe 11 Electric fan remote control Checking the resistance at the injector ends 14 5 5 Ohm Injection SR MAX 125 ie INJEC 178 ...

Страница 179: ...i mentazione centralina da chiave Check the efficiency of the injection load solenoid Check the resistance of the energising coil be tween pins 86 and 85 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85 make sure that there is continuity between pins 30 and 87 of the remote control SR MAX 125 ie Injection INJEC 179 ...

Страница 180: ...olet cable of the remote control base If there is not check the continuity of the black white cable between fuse block and the remote control base and of the black violet cable between pin 20 of the control unit and the remote control base NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS ELECTRONIC CONTROL UNIT FUSES ETC Injection SR MAX 125 ie INJEC 180 ...

Страница 181: ...e massa In caso contrario verificare la continuità del cavetto Rosso Blu tra scatola portafusibili N 5 10 A e lo zoccolo teleruttore NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS ELECTRONIC CONTROL UNIT FUSES ETC SR MAX 125 ie Injection INJEC 181 ...

Страница 182: ...ch to ON and check if there is voltage with injector disconnected and control unit connected between the Black Green cable of the injector con nector and the ground lead With injector disconnected and the injector load solenoid disconnected check the continuity of the Black Green cable between the injector connector and solenoid base Injection SR MAX 125 ie INJEC 182 ...

Страница 183: ...ply for the injection tester Connect the clamps of the ca ble to an auxiliary battery Activate the fuel pump with the active diagnosis Check that within fifteen seconds approximately 40 cm of fuel is dis pensed with an adjustment pressure of approxi mately 2 5 BAR Specific tooling 020480Y Petrol pressure check kit Proceed with the injector seal test Dry the injector outlet with a blast of compress...

Страница 184: ...Components location Injection SR MAX 125 ie INJEC 184 ...

Страница 185: ...ocket connector Tachometer With wiring disconnected from the control unit and connected to the system check that the sensor resistance between pins 13 15 is between 100 and 150 Ohm at an engine temperature of approx imately 20 Disconnect the fuel pipe connector Start up the engine and wait for it to stop With the wiring con nected to the control unit and system try to start up the engine and check...

Страница 186: ...n 15 and the white cable of the rev sen sor connector With the interface wiring disconnected from the control unit and rev sensor connector check that the red and white cables pin 13 15 are isolated from each other and insulated from the earth Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Injection SR MAX 125 ie INJEC 186 ...

Страница 187: ...ificant parameters Ignition advance This is optimised at once according to the engine revs engine load temperature and ambient pressure With idle engine it is optimised to obtain the stabilisation of the speed at 1450 50 R 1 Magnetisation time The coil magnetisation time is controlled by the control unit The power of the ignition is increased during the engine start up phase The injection system r...

Страница 188: ...i mentazione centralina da chiave Check the efficiency of the injection load solenoid Check the resistance of the energising coil be tween pins 86 and 85 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85 make sure that there is continuity between pins 30 and 87 of the remote control Injection SR MAX 125 ie INJEC 188 ...

Страница 189: ...olet cable of the remote control base If there is not check the continuity of the black white cable between fuse block and the remote control base and of the black violet cable between pin 20 of the control unit and the remote control base NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS ELECTRONIC CONTROL UNIT FUSES ETC SR MAX 125 ie Injection INJEC 189 ...

Страница 190: ...e massa In caso contrario verificare la continuità del cavetto Rosso Blu tra scatola portafusibili N 5 10 A e lo zoccolo teleruttore NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS ELECTRONIC CONTROL UNIT FUSES ETC Injection SR MAX 125 ie INJEC 190 ...

Страница 191: ...en switching to ON Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load solenoid base with the control unit disconnected and the solenoid discon nected Resistance of the primary 0 5 8 Ohm SR MAX 125 ie Injection INJEC 191 ...

Страница 192: ... and the coolant temperature sensor connector connected check the resistance between pins 9 and 26 in relation to the engine temperature 20 2500 100 Ω 80 308 6 Ω With the control unit side connector disconnected and the coolant temperature connector discon nected check the insulation between the two light blue green and pink yellow cables Injection SR MAX 125 ie INJEC 192 ...

Страница 193: ...pened valve with an angle that can vary depending on the tolerances of the machining of the pipe and the valve itself The valve position sensor can also assume various fitting positions For these reasons the mV of the sensor with the valve at idle can vary from one throttle body to another To obtain the optimum fuel mixture especially at small openings of the throttle valve it is essential to matc...

Страница 194: ...R AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE CALIBRATION Given that the TPS resetting is also done when the control unit is replaced place the control unit filter box bellows at 45 during the refitting operation as shown in the picture Lambda probe SIGNAL CONTROL Install the electronic control unit interface wiring Start the engine and warm up until the el...

Страница 195: ...pecification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 15 A 4 Ignition key contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda Probe 11 Electric fan remote control The lambda probe or oxygen sensor is a sensor which provides information about the oxygen content in the exhaust fumes The signal generated is not of the proportional but of t...

Страница 196: ...control unit to make it start operating quickly Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Verificare l efficienza del fusibile N 5 da 10 A car ichi iniezione Verificare l efficienza del fusibile N 8 da 7 5 A ali mentazione centralina da chiave Check the efficiency of the injection load solenoid Check the resistance of the energising coil be tween pins 86 and...

Страница 197: ...olet cable of the remote control base If there is not check the continuity of the black white cable between fuse block and the remote control base and of the black violet cable between pin 20 of the control unit and the remote control base NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS ELECTRONIC CONTROL UNIT FUSES ETC SR MAX 125 ie Injection INJEC 197 ...

Страница 198: ...e massa In caso contrario verificare la continuità del cavetto Rosso Blu tra scatola portafusibili N 5 10 A e lo zoccolo teleruttore NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS ELECTRONIC CONTROL UNIT FUSES ETC Injection SR MAX 125 ie INJEC 198 ...

Страница 199: ...SR MAX 125 ie Injection INJEC 199 ...

Страница 200: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Страница 201: ...of the vehicle Loosen the two screws fixing the wheel axle clamp and remove the clamp Front wheel hub overhaul Check that the wheel bearings do not show signs of wear If you have to replace the wheel bearings proceed as follows Remove the two bearings on the brake disc side using pliers 14 and the special bell 9 Remove the internal spacer SR MAX 125 ie Suspensions SUSP 201 ...

Страница 202: ...he brake disc side to permit the removal of the opposite side bearing and the spacer bushing Specific tooling 020376Y Adapter handle 020456Y Ø 24 mm adaptor 020412Y 15 mm guide Heat the bearing seat on the side opposite the brake disc with the heat gun Insert the bearing using the punch consisting of adaptor handle 40x37 mm adaptor and 15 mm guide and take it to the stop Suspensions SR MAX 125 ie ...

Страница 203: ...ing the appropriate tool and take it to the stop Specific tooling 020376Y Adapter handle 020359Y 42 x 47 mm adaptor 020412Y 15 mm guide 020201Y Spacer bushing driving tube Refit the cap and tighten the five fixing screws SR MAX 125 ie Suspensions SUSP 203 ...

Страница 204: ...ings one at a time using the punch consisting of adaptor handle 32x35 mm adaptor and 15 mm guide and take it to the stop Specific tooling 020376Y Adapter handle 020357Y 32x35 mm Adaptor 020412Y 15 mm guide Refitting the front wheel When refitting pay attention in repositioning the odometer drive correctly Locking torques N m Wheel axle nut 45 to 50 Wheel axle clamp screws 6 7 Nm Handlebar Suspensi...

Страница 205: ...xing the handlebar to the steering tube and pulling up wards remove the handlebar then re move the lower plastic cover NOTE IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING IT IS ONLY NECESSARY TO TILT THE HANDLEBAR FORWARD ONTO THE FRONT PART OF THE VEHICLE WITHOUT REMOVING THE PARTS FITTED SO AS TO AVOID DAMAGING THE SHAFTS Refitting Carry out the above operations by working in the rever...

Страница 206: ...CAP KEEPS THE MAIN SPRING PRE LOADED KEEP THE CAP PROPERLY FITTED DURING THE REMOVAL FINAL STAGE TO AVOID ACCIDENTS Support the fork leg properly remove the main spring and drain off the fork leg oil Remove the hydraulic rod fixing screw with the corresponding sealing gasket With a 19 mm hexagonal spanner lock hydraulic rod rotation Undo the fixing screw and collect the copper washer Suspensions S...

Страница 207: ...etaining the oil seal Take out the stem Check there are no signs of wear or seizing between the stem and the fork leg Otherwise replace the damaged parts Characteristic Maximum fork leg diameter 35 10 mm Minimum stem diameter 34 90 mm SR MAX 125 ie Suspensions SUSP 207 ...

Страница 208: ... does not fall into the fork leg and or that both half rings are not in their position Fit the bell Tighten the nut until it stops Act on the tool until the oil seal is completely re moved Specific tooling 020487Y Fork oil seal extractor Remove the hydraulic rod with the corresponding sealing gasket the spring and the stop bushing COMPONENT CHECK CAUTION CLEAN ALL THE COMPONENTS THOROUGHLY Suspens...

Страница 209: ...hat the stop bushing for the hydraulic rod is correctly fixed through caulking Check that hydraulic rod caulkings the return spring to the unloaded the end of stroke and the hydraulic rod sealing ring are in good conditions Check that the main spring exhibits no signs of yielding or abnormal wear SR MAX 125 ie Suspensions SUSP 209 ...

Страница 210: ...propriate tool Specific tooling 020376Y Adapter handle 020359Y 42 x 47 mm adaptor Pre fit the stem with the hydraulic rod the spring and the stop bushing Fit the pre assembled components inside the fork leg Fit the hydraulic rod fixing screw with the copper sealing washer and tighten to the prescribed tor que using the recommended product CAUTION ALWAYS USE NEW COPPER WASHER Locking torques N m Hy...

Страница 211: ...ase and fit a new dust guard Fit the fork leg together with the stem on the fork supporting clamp until it stops Tighten the two screws to the prescribed torque in the sequence indicated in the picture Locking torques N m Stem support clamp tightening screws 20 to 25 SR MAX 125 ie Suspensions SUSP 211 ...

Страница 212: ...the stem CAUTION FIT THE SPRING WITH THE SMALLER PITCH TO THE UP PER PART OF THE STEM Lubricate the closing cap O ring of the stem Preload the spring fit the closing cap and tighten to the prescribed torque Locking torques N m Fork locking screws cap 15 30 Repeat the procedure for the other fork leg NOTE IF BOTH FORK LEGS ARE SERVICED AT THE SAME TIME BE CAREFUL NOT TO INVERT THE RIGHT FORK LEG WI...

Страница 213: ...late Remove by releasing the cable passages and sliding the protection collar upwards Using the appropriate tool loosen and remove the upper ring nut the space washer the counter ring nut and the spacer Remove the cover plate and upper seat of the steering fifth wheel Extract the fork NOTE TAKE CARE TO SUPPORT THE FORK SO AS TO PREVENT IT FROM COMING OFF ABRUPTLY Specific tooling 020055Y Wrench fo...

Страница 214: ...ICATE THE STEERING FIFTH WHEEL TRACKS WITH RECOMMENDED GREASE BEFORE USE Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 symbol NATO G 460 Fit the upper steering bearing CAUTION INSERT THE UPPER STEERING BEARING WITH THE CAGE FACING UPWARDS Fit the steering bearing upper seat Suspensions SR MAX 125 ie SUSP 214 ...

Страница 215: ...wer tightening ring nut screw until it stops and with the specific tool tighten to the pre scribed torque Specific tooling 020055Y Wrench for steering tube ring nut Locking torques N m Steering tube lower ring nut 14 17 SR MAX 125 ie Suspensions SUSP 215 ...

Страница 216: ...stops and with the specific tool tighten to the in dicated torque Specific tooling 020055Y Wrench for steering tube ring nut Locking torques N m Steering tube upper ring nut 40 45 Insert the collar shown in the figure and restore the cable passage as shown in the figure Fit the front wheel Steering bearing Suspensions SR MAX 125 ie SUSP 216 ...

Страница 217: ...herwise replace them STEERING FIFTH WHEEL TRACK REMOVAL Remove the steering fifth wheel tracks on the chassis with the specific tool following the indica ted procedure Fit the specific tool from the lower part of the headstock until it makes contact with the upper track Hit with force the specific tool placing it at differ ent points diametrically opposed so as to remove the upper track Specific t...

Страница 218: ...ool Specific tooling 020004Y Punch for removing steering bearings from headstock Refitting STEERING FIFTH WHEEL TRACK FITTING Thoroughly clean the track seats on the headstock and the steering tube Fit the new tracks of the headstock with the specific tool Screw the nut until the tracks are fully inserted Suspensions SR MAX 125 ie SUSP 218 ...

Страница 219: ...COMMENDED GREASE BEFORE USE Specific tooling 001330Y Tool for fitting steering seats Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 symbol NATO G 460 SR MAX 125 ie Suspensions SUSP 219 ...

Страница 220: ...Suspensions SR MAX 125 ie SUSP 220 ...

Страница 221: ...MMENDED GREASE BEFORE USE Specific tooling 020459Y Punch for fitting bearing on steering tube Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 symbol NATO G 460 Rear Removing the rear wheel Remove the mudflap undoing the four screws Remove the exhaust silencer Remove the cotter pin SR MAX 125 ie Suspensions SUSP 221 ...

Страница 222: ...el fixing nut and collect the spacer Unscrew the shock absorber fixing nut on the right of the bracket Undo the two screws fixing the bracket to the en gine and remove the bracket Collect the spacer Suspensions SR MAX 125 ie SUSP 222 ...

Страница 223: ...nut 104 to 126 Shock absorber crankcase attachment bracket 20 to 25 Lower shock absorber clamping screw 33 41 Nm Rear brake cal liper fixing screws 25 30 Nm Swing arm Removal Place the vehicle on its centre stand Remove the swinging arm engine fitting shown in the picture Move the engine back Remove the spring anchoring the swinging arm to the chassis as shown in the picture SR MAX 125 ie Suspensi...

Страница 224: ...screw on each side of the vehicle Unscrew the B nut and extract the pin from the opposite side Check the entire swinging arm assembly Check all the centring bushing components and silent block rubber buffers Replace the work components that cause excessive clearance on the rear suspension Suspensions SR MAX 125 ie SUSP 224 ...

Страница 225: ...l silent bloc bracket Undo the silent bloc ring shown in the picture Hold the full silent bloc bracket in the clamp Using the appropriate tool remove the silent bloc from the bracket from the side corresponding to the inside of the vehicle This is to guarantee the tool is centred properly on the support SR MAX 125 ie Suspensions SUSP 225 ...

Страница 226: ...he engine side to the swinging arm on the chassis side Check the axial clearance between the two swinging arms using a feeler gauge Characteristic Standard clearance 0 40 0 60 mm Allowable limit after use 1 5 mm In order to check the clearance of the swinging arm on the frame side prepare a retainer using the fixing pin of the swinging arm on the frame and two rings from the special tool 020229Y A...

Страница 227: ... the internal spacer shown in the picture Using a suitable pin remove the roller casings as shown in the pictures Using an appropriate tool plant new roller cas ings being careful to position the bearings with the seal rings facing outwards Specific tooling 020244Y 15 mm diameter punch 020115Y Ø 18 punch Characteristic Length of the swinging arm tube on the engine side L 175 3 0 3 0 Length of the ...

Страница 228: ...he picture Adjust the bolt as shown in the picture Position the chassis side swinging arm with the most protruding part pointing towards the silent block side as shown in the picture Recommended products AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous calcium base grease TL 9150 066 symbol NATO G 460 Refitting To refit perform the removal operations in reverse Grease the bearings ...

Страница 229: ... absorber spring assembly to the frame and remove the shock absorbers Refitting Carry out the previous operations but in reverse order Locking torques N m Shock absorber lower clamping 33 to 41 Shock absorber upper clamp 33 to 41 Centre stand REMOVAL Use a jack to support the vehicle properly Remove the two return springs from the centre stand Undo the nut shown in the figure Remove the pin from t...

Страница 230: ...return spring Remove the screw shown in the photograph FITTING To refit carry out the removal operations in re verse order and comply with the specified torque Locking torques N m Side stand fixing bolt 35 to 40 Suspensions SR MAX 125 ie SUSP 230 ...

Страница 231: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Страница 232: ...RVICE THE BRAKE CALLIPER BEFORE REMOVING THE FITTINGS FIXING THE CALLIPER TO THE SUPPORT BRACKET FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING EMPTIED THE SYSTEM OF THE CIRCUIT BEING EXAM INED Overhaul Remove the brake calliper Suitably support the brake calliper in a vice Remove the two pad fixing screws Remove the pads being careful with the stop spring Remove the fixed plate by undoing the scr...

Страница 233: ... plate are not scratched or eroded otherwise re place the entire plate that the brake pad check spring works properly CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EV ERY TIME THE PUMP IS SERVICED Refitting Insert the O rings and small pistons the floating body lubricating all the components with brake fluid Fit the fixed plate being careful to grease the guide A and to insert washer B correc...

Страница 234: ...ke calliper devices fas tening them to the support as shown in the photo graph NOTE WHEN A PROCEDURE IS PLANNED INCLUDING THE SERVICE OR REPLACEMENT OF THE CALLIPER FIRST LOOSEN THE FITTING CONNECTING THE PIPE TO THE BRAKE CALLIPER Overhaul Remove the brake calliper Suitably support the brake calliper in a vice Remove the two pad fixing screws Remove the pads being careful with the stop spring Rem...

Страница 235: ... plate are not scratched or eroded otherwise re place the entire plate that the brake pad check spring works properly CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EV ERY TIME THE PUMP IS SERVICED Refitting Insert the O rings and small pistons the floating body lubricating all the components with brake fluid Fit the fixed plate being careful to grease the guide A and to insert washer B correc...

Страница 236: ...calliper Remove the disc from the wheel axle Undo the five screws and remove the disc from the wheel hub Refitting Follow the removal operations but in reverse order NOTE THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED TOWARDS THE OUTSIDE OF THE VEHICLE Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Brake ...

Страница 237: ... use a metal plate with M8 threaded hole and fix it to one of the two rear brake calliper attachment points Suitably fix the flange to the wheel axle with the original nut and spacer and a Æ 17 mm bearing NOTE SO AS NOT TO GET A DISTORTED READING CAUSE THE DRIVEN PULLEY SHAFT TO TURN IN ORDER TO ROTATE THE DISC Specific tooling 020335Y Magnetic mounting for dial gauge Characteristic Max deviation ...

Страница 238: ...RUNNING DIRECTION MUST BE FITTED TOWARDS THE OUTSIDE OF THE VEHICLE Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Brake disc fixing screw 5 to 6 5 Disc Inspection Checking the disc is important it must be perfectly clean with no sign of rust oil or grease or any other dirt and must show no signs of deep scoring Characteristic New rear...

Страница 239: ...ermissible out of true is 0 1 mm If the value measured is greater re place the disc and repeat the check If the problem persists check and re place the wheel hub if necessary Specific tooling 020335Y Magnetic mounting for dial gauge Front brake pads Removal Proceed as follows Remove the front brake calliper Loosen the two pins shown in the figure that lock the two pads Remove the pads being carefu...

Страница 240: ...htening the two screws to the prescribed torque NOTE IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT TING GENTLY EXPAND THE PADS Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Screw tightening calliper to support 24 to 27 Pad fastening pin 19 6 24 5 Rear brake pads Braking system SR MAX 125 ie BRAK SYS 2...

Страница 241: ...the two pins shown in the figure that lock the two pads Remove the pads being careful with the pad spring clamp Check the thickness of the pads Characteristic Minimum value 1 5 mm See also Refitting To fit proceed as follows SR MAX 125 ie Braking system BRAK SYS 241 ...

Страница 242: ...e Keeping the left hand brake lever pulled loosen the bleed screw to permit the air in the system to escape Then tighten the bleed screw Repeat the operation until only brake fluid comes out of the rubber pipe Remove the fluid recovery pipe and refit the rubber cap over the bleed screw Top up the brake fluid to the right level in the reservoir If necessary bleeding can be done using a special vacu...

Страница 243: ...ODYWORK SO AS NOT TO DAMAGE IT FURTHERMORE DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING AND EFFICIENCY OF THE BRAKING SYSTEM Specific tooling 020329Y Vacuum pump Mity Vac Locking torques N m System bleed calliper fitti...

Страница 244: ...Locking torques N m Brake fluid pump hose fitting 16 20 Braking system SR MAX 125 ie BRAK SYS 244 ...

Страница 245: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Страница 246: ...s coolant to the thermal group The thermostat is connected at the head output The radiator output is directly connected to the pump The expansion tank is connected to the radiator the radiator hot box is connected to the upper side of the expansion tank in air the radiator cold box is connected to the lower side of the expansion tank in fluid Characteristic Cooling system capacity 2 l TECHNICAL SP...

Страница 247: ...ntity Calibration Automatic bleeding in parallel with the radiator System bleed Start up the engine until the operating tempera ture is reached Remove the rubber hood over the bleed valve Obtain a rubber tube that is of the right length to connect the valve to the expansion tank Place one end of the pipe on the bleed valve and the other in the expansion tank Loosen the screw by two turns until the...

Страница 248: ...Bleed screw 3 Cooling system SR MAX 125 ie COOL SYS 248 ...

Страница 249: ...INDEX OF TOPICS CHASSIS CHAS ...

Страница 250: ...on of the under seat light Remove the two fixing screws to the chassis Rear handlebar cover Release the three retaining tabs of the rear han dlebar cover shown in the figure using a screw driver and paying attention not to damage the paintwork Remove the five fixing screws from the rear han dlebar cover Remove the rear cover NOTE WHEN INSTALLING THE CENTRE SCREW IS A METAL SCREW THE OTHER 4 ARE PL...

Страница 251: ...Front handlebar cover Remove the rear handlebar cover Remove the left and right frames of the brake pump secured with two retaining fins Loosen the four fixing screws of the front han dlebar cover with the handlebar itself Disconnect the warning light unit connector A SR MAX 125 ie Chassis CHAS 251 ...

Страница 252: ...nt loading compartment To remove the left hand light assembly remove the screw located in the left hand storage com partment Remove the light disconnecting the electric con nector from the light and the complete lamp holder of the position light NOTE THE TWO REAR ADJUSTMENT SCREWS SHOWN IN THE FIGURE ARE ADJUSTED DURING ASSEMBLY OF THE LIGHT AND MUST NOT BE ALTERED Frame central cover The chassis ...

Страница 253: ...e six ring gear fixing screws Remove the clamp indicated Undo and remove from both vehicle sides the screw indicated in the figure Working from both sides undo the screw indica ted and release the retaining tongues to remove the side air deflectors SR MAX 125 ie Chassis CHAS 253 ...

Страница 254: ...he handgrips and top side fairings Remove the right and left footrests see FOOTREST Working from both sides undo the screw indica ted in the figure Remove the side fairing sliding it from the tongues Legshield The front shield has a lot of sections The removal procedure is described below FRONT LOWER FRAME Using a screwdriver remove the clip on badge Chassis SR MAX 125 ie CHAS 254 ...

Страница 255: ...stic tongues remove the front lower frame sliding it upwards from bottom to top FRONT UPPER FRAME Remove the FRONT LOWER FRAME Remove the windshield together with the supports Undo and remove the two screws B and the four screws C Remove the frame sliding it from the tongues SR MAX 125 ie Chassis CHAS 255 ...

Страница 256: ... from the support FRONT SHIELD Remove the front lower frame Remove the front upper frame Remove the front headlight assemblies Remove the instrument panel see SHIELD BACK PLATE Remove the lower shield back plate see SHIELD BACK PLATE Remove the hand guards unscrewing from both sides the two screws A collecting the washers and the screw B Chassis SR MAX 125 ie CHAS 256 ...

Страница 257: ...low the reverse order paying attention to fasten the cable harness with the relative clamps Knee guard The shield back plate is made by two sections The instrument panel with instrument unit and lower shield back plate The procedure for both is described below INSTRUMENT PANEL Remove the windshield Remove the rear handlebar cover Remove the front handlebar cover Remove the handlebar SR MAX 125 ie ...

Страница 258: ...rom both vehicle sides undo and re move the screw B Undo and remove the two screws C placed on and inside the glove compartment Undo and remove the two screws D placed on and inside the coolant loading compartment Chassis SR MAX 125 ie CHAS 258 ...

Страница 259: ...ghting connector F Remove the instru ment panel LOWER SHIELD BACK PLATE Remove the central tunnel see CENTRAL CHASSIS COVER Remove the instrument panel see SHIELD BACK PLATE Working from both vehicle sides undo and re move the two screws A Turn the key switch frame anticlockwise it may be necessary to use pliers releasing the catch SR MAX 125 ie Chassis CHAS 259 ...

Страница 260: ... teeth to raise the retaining plate of the steering lock strut The latter has a retaining tab with cylindrical teeth that cannot be replaced Front wheel housing To remove the front wheel housing proceed as follows Remove the spoiler Remove the front fork Remove the plate supporting bracket for the horn and voltage regulator by loosening the two fixing screws shown in the figure in order to release...

Страница 261: ...nch between the helmet com partment and the chassis pipes loosen the two rear fixing nuts and then disconnect the light stud bolts from the support extensions Remove the light and disconnect the bulb holder by turning it through 30 in anticlockwise direction Footrest The footrest comprises a right and left footrest a passenger footrest and a rider footrest The whole procedure is described below PA...

Страница 262: ...B and the four screws C Remove the footrest RIDER FOOTREST To remove the rider footrest proceed as follows Remove the central cover Remove the shield back plate Remove the right and left footrest see FOOTREST Undo the screw D and the screw E and re move the rider footrest Chassis SR MAX 125 ie CHAS 262 ...

Страница 263: ...ve the rear central cover Remove the passenger handles Remove the lower cover Remove the lower side cover Remove the eight screws shown in the figure four on each side Pull out the fairing SR MAX 125 ie Chassis CHAS 263 ...

Страница 264: ...ide and disconnect the electric connectors To access the license plate light bulb remove the two fixing screws of the support rear cover and ex tract the complete bulb holder Air filter To remove the complete air filter from the engine proceed as follows Undo the two screws A and the screw B collecting the washers Chassis SR MAX 125 ie CHAS 264 ...

Страница 265: ... three screws and remove the cover of the air conduit Undo and remove the screw E Remove the clamp Remove the mudflap Rear mudguard To remove the rear mudguard proceed as follows From the right side of the vehicle undo the screw A SR MAX 125 ie Chassis CHAS 265 ...

Страница 266: ...Working from both vehicle sides undo the three screws A and the screw B Undo and remove the two screws C from the battery compartment Lift the helmet compartment from the rear side and remove the saddle lock Disconnect the connectors of the power socket and the under seat light Remove the plug socket due to the interference with the chassis Remove the fuse box releasing the side hook teeth Remove ...

Страница 267: ...l housing Working from both vehicle sides undo the fixing screw B with the front shield Working from both vehicle sides undo the fixing screw C with the chassis Working from both vehicle sides undo the fixing screw D with footrest chassis support Slide off the spoiler from the bottom trying not to touch the side stand SR MAX 125 ie Chassis CHAS 267 ...

Страница 268: ...AINING STRAPS Fuel tank To remove the fuel tank proceed as follows NOTE THIS OPERATION SHOULD PREFERABLY BE PERFORMED WITH THE TANK EMPTY Remove the shield back plate Remove the central frame cover Remove the footrest Remove the spoiler Remove the horn plate support bracket and the voltage regulator unscrewing the two nuts shown in the figure Disconnect the fuel probe connector Chassis SR MAX 125 ...

Страница 269: ...part of the vehicle Rear central cover Raise the saddle Remove the two fixing screws shown in the fig ure Remove the two screws indicated in the figure Remove the seven screws indicated in the figure Remove the central cover from its retainers SR MAX 125 ie Chassis CHAS 269 ...

Страница 270: ...heel housing to permit movement Drain the cooling system Remove the feed and return hoses from the ex pansion tank Remove the coolant feed and return hoses from the radiator Remove the fixing screws of the radiator to the frame shown in the figure Disengage the complete radiator and the electric fan Expansion tank To remove the expansion tank proceed as follows Drain the cooling system Remove the ...

Страница 271: ...p side fairings Remove the side fairings Remove the rear central cover Undo the two screws indicated Working from both sides undo the screw A Working from both sides undo the three screws B Remove the upper side fairings SR MAX 125 ie Chassis CHAS 271 ...

Страница 272: ...move the caps and the gaskets on the two windshield supports Remove the FRONT UPPER FRAME Working from both vehicle sides undo and re move the two screws A Remove the supports Pilot lights kit Remove the front handlebar cover Remove the three screws shown in the figure then slide off the complete unit from the front han dlebar cover Chassis SR MAX 125 ie CHAS 272 ...

Страница 273: ...Battery Remove the elastic strap and the battery cover First disconnect the negative terminal A then the positive terminal B Remove the battery SR MAX 125 ie Chassis CHAS 273 ...

Страница 274: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Страница 275: ...rews Front and rear wheel hub nut Front and rear brake calliper clamping screws Frame swinging arm bolt Swinging arm bolt Engine Engine arm pin Frame arm Handlebar lock nut Steering lower ring nut Upper steering ring nut Electrical system Main switch Lights high beam lights low beam lights taillights front and rear and relevant warning lights Headlight adjustment according to the regulations curre...

Страница 276: ...ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO ENSURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT OF THE REACH OF CHILDREN CAUTION NEVER USE ...

Страница 277: ...RATURE CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional Checks Hydraulic braking system lever travel Clutch proper functioning check Engine proper general functioning and no abnormal noise check Other papers check chassis and engine number check tools and equipment licence plate fitting lock check tyre pressure check rear view mirror and ...

Страница 278: ...tors 82 coolant 192 Coolant 192 Crankcase 14 142 145 146 Crankshaft 14 142 144 146 150 Cylinder 11 16 125 128 130 134 135 E Electrical system 10 51 275 Engine oil 40 Exhaust 86 167 F Fairings 263 271 Fork 205 Front wheel 201 204 260 Fuel 168 177 268 Fuses 75 H Handlebar 204 250 251 Headlight 45 252 Hub oil 38 I Identification 8 Instrument panel 251 Intermediate gear 123 L Lambda probe 194 License ...

Страница 279: ...r 270 Rear wheel 221 223 Recommended products S Scheduled maintenance Shock absorbers 228 Side fairings 263 271 Side stand 230 Spark plug 37 69 Stand 230 Starter motor 121 125 T Tank 268 270 Transmission 10 47 93 109 Turn indicators 63 Tyres 11 V Voltage regulator 73 W Water pump ...

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