Aprilia Sr Motard 125 4t Workshop Repair Service Manual

SERVICE STATION MANUAL 677206(EN)

Sr Motard 125 4T

SERVICE STATION MANUAL

Sr Motard 125 4T

IL VALORE DELL'ASSISTENZA Grazie ai continui aggiornamenti tecnici e ai programmi di formazione specifica sui prodotti Aprilia, solo i meccanici della Rete Ufficiale Aprilia conoscono a fondo questo veicolo e dispongono dell'attrezzatura speciale occorrente per una corretta esecuzione degli interventi di manutenzione e riparazione.

L'affidabilità del veicolo dipende anche dalle condizioni meccaniche dello stesso. Il controllo prima della guida, la regolare manutenzione e l'utilizzo esclusivo dei Ricambi Originali Aprilia sono fattori essenziali !

Per avere informazioni sul Concessionario Ufficiale e/o Centro Assistenza più vicino, riferirsi alle Pagine Gialle o cercare direttamente sulla cartina geografica presente nel nostro Sito Internet Ufficiale: www.aprilia.com Solo se si richiedono Ricambi Originali Aprilia si avrà un prodotto studiato e testato già durante la fase di progettazione del veicolo. I Ricambi Originali Aprilia sono sistematicamente sottoposti a procedure di controllo della qualità, per garantirne la piena affidabilità e durata nel tempo.

Le descrizioni ed illustrazioni fornite nella presente pubblicazione s'intendono non impegnative; Aprilia perciò si riserva il diritto, ferme restando le caratteristiche essenziali del tipo qui descritto ed illustrato, di apportare in qualunque momento, senza impegnarsi ad aggiornare tempestivamente questa pubblicazione, le eventuali modifiche di organi, particolari o forniture di accessori, che essa ritenga conveniente per scopo di miglioramento o per qualsiasi esigenza di carattere costruttivo o commerciale.

Non tutte le versioni riportate nella presente pubblicazione sono disponibili in ogni Paese. La disponibilità delle singole versioni deve essere verificata con la rete ufficiale di vendita Aprilia. © Copyright 2012 Aprilia. Tutti i diritti sono riservati. Vietata la riproduzione anche parziale. Aprilia After sales service.

Il marchio Aprilia è di proprietà di Piaggio & C. S.p.A.

SERVICE STATION MANUAL Sr Motard 125 4T This manual provides the main information to carry out regular maintenance operations on your vehicle.

This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures are not described in detail, be extremely cautious so as not to damage components or injure individuals.

In order to optimise customer satisfaction when using our vehicles, Piaggio & C. S.p.a. commits itself to continually improve its products and the relative documentation. The main technical modifications 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 and technical changes related to the vehicle

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee

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INDEX OF TOPICS

CHARACTERISTICS

CHAR

TOOLING

TOOL

MAINTENANCE

MAIN

TROUBLESHOOTING

TROUBL

ELECTRICAL SYSTEM

ELE SYS

ENGINE FROM VEHICLE

ENG VE

ENGINE

ENG

SUSPENSIONS

SUSP

BRAKING SYSTEM PRE-DELIVERY TIME

BRAK SYS PRE DE TIME

INDEX OF TOPICS

CHARACTERISTICS

CHAR

Sr Motard 125 4T

Characteristics

Rules This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed 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 PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, nuts and screws are not interchangeable with coupling members using English measurements. Using unsuitable coupling members and tools may damage the vehicle.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connections.

CHAR - 7

Characteristics

Vehicle identification Prefisso Telaio LBMM701 Prefisso Motore M701M

Dimensions and mass

CHAR - 8

Sr Motard 125 4T

Sr Motard 125 4T

Characteristics

WEIGHTS AND DIMENSIONS Specification Maximum length Overall width Max. height to the windshield Wheelbase Kerb weight

Desc./Quantity 1947 730 1130 mm 1355 117 kg

Engine ENGINE Specification Engine Timing system Valve clearance

Desc./Quantity Single cylinder 4-stroke Single overhead camshaft (SOHC) with 2 valves intake 0.10 exhaust 0.15 57 x 48.6 mm 124 cmÂł (10.6+/-0.5):1 KEIHIN CVEK26 approx. 1,600 - 1,800 rpm Electric starter 10.5 CV at 8000 rpm Forced-circulation air cooling.

Bore x stroke Engine capacity Compression ratio carburettor Engine idle speed Electric Max power to the shaft Cooling

Transmission TRANSMISSION

Specification Transmission

Desc./Quantity With continuously variable expandable pulley transmission with torque server, V belt, automatic clutch, gear reduction unit and transmission housing with forced air circulation cooling.

Capacities CAPACITY Specification Engine oil Rear hub oil Fuel tank capacity Fork stem (oil level height without spring, compressed fork)

Desc./Quantity 1.10 l approx. 250 cc ~ 7.0 litres (2.0 l of which is reserve) 85 mm

CHAR - 9

Sr Motard 125 4T

Characteristics

Electrical system IMPIANTO ELETTRICO Titolo IMPIANTO ELETTRICO

Durata/Valore

Testo Breve (< 4000 car.)

Indirizzo Immagine

Frame and suspensions CHASSIS AND SUSPENSION Specification Frame Front suspension Rear suspension

Desc./Quantity Tubular steel frame Ø 35 Hydraulic telescopic fork - travel: 90 mm Hydraulic single shock absorber and spring adjustable to 4 positions at preloading; travel: 80 mm.

Brakes BRAKES Specification Front brake

Desc./Quantity Disc brake (Ø 220 mm) with hydraulic control (lever on the far right of the handlebar) and floating calliper. Ø 110mm drum brake

Rear brake

Wheels and tyres WHEELS AND TYRES Specification Front wheel rim Front tyre Rear wheel rim Rear tyre Front tyre pressure Rear tyre pressure Rear wheel pressure (rider and passenger):

Secondary air

CHAR - 10

Desc./Quantity Die-cast aluminium alloy; 3.50 x 10" Tubeless 120/80 -10" Die-cast aluminium alloy: 3.50"x10" Tubeless 120/80 - 10" 1.5 bar 1.8 bar 2.0 bar

Sr Motard 125 4T

Characteristics

In order to reduce polluting emissions, the vehicle is furnished with a catalytic converter in the muffler.

To favour the catalytic process, an extra amount of oxygen is added via a secondary air system (SAS).

This system allows more oxygen to be added to the unburned gases before they reach the converter, thus improving the action of the catalytic converter.

The air enters the exhaust duct from the head, and is purified by a black filter.

The system is fitted with a control valve that disables operation while decelerating to avoid unwanted noise.

To ensure the best functioning of the SAS system, every 12,000 km the scooter should be taken to an Authorised Piaggio Service Centre to have the filter cleaned (Scheduled maintenance operations section).

The filter sponge should be cleaned with water and mild soap, then it should be dried with a cloth and slight blows of compressed air.

CAUTION

FOR THIS OPERATION, CONTACT AN AUTHORISED SERVICE CENTRE.

Carburettor 125cc Version Kehin CARBURETTOR SETTING Specification Type Throttle valve diameter Diffuser diameter Setting stamping Maximum jet

Desc./Quantity CVEK26 Ă&#x2DC; 26.5 Ă&#x2DC; 26.4 262A 82

CHAR - 11

Sr Motard 125 4T

Characteristics

Specification Maximum air jet (on the body) Tapered pin stamping Throttle valve spring Minimum jet Idle air jet (on the body) Idle mixture adjustment screw initial opening Starter nozzle Starter air jet (on the body) Starter pin travel Starter resistance

Desc./Quantity 85 NELA 130 ÷ 180 gr.

35 150 1¾ 42 Ø 1.5 10 mm (at 24°) 20 Ohm (at 24°)

Tightening Torques HEAD AND CYLINDER Name Ignition spark plug Head cover screws Nuts fixing head to cylinder (*) Head fixing screws (external) Starter ground screw Flywheel air duct screw Pressure reducer counterweight retainer Camshaft pulley screw Timing chain tensioner slider screw Starter counterweight support screw Tightener screw: Timing chain tensioner central screw Camshaft retention plate screw Nut fixing silencer to cylinder head Head intake manifold screw

Torque in Nm 18 Nm 11 - 13 28 to 30 11 to 13 7 to 8.5 3-4 7 - 8.5 12 - 14 10 to 14 11 to 15 5 to 6 5 to 6 5-6 16 to 18 11 to 13

(*) Lubricate the retainer threads before fitting and lock in a crossed sequence and repeat tightening 2 or 3 times.

TRANSMISSION Name Drive pulley nut (°) Transmission cover screw Driven pulley shaft nut Rear hub cap screws Clutch unit nut on driven pulley

Torque in Nm 75 - 83 11 to 13 54 - 60 24 - 27 55 to 60

(°) Apply LOCTITE 243 threadlock

FLYWHEEL Name Flywheel fan screws Stator assembly screws (°) Flywheel nut Pick-up screw

Torque in Nm 3 to 4 3 to 4 52 - 58 3 to 4

(°) Apply LOCTITE 243 threadlock

CRANKCASE AND CRANKSHAFT Name Internal engine crankcase bulkhead (transmission-side half shaft) screws Oil filter on crankcase fitting Rear brake cam tightening screw Engine-crankcase coupling screws Pre-filter cap Starter motor screws Silencer to crankcase fixing screws Engine oil drainage cap Oil sump screws

CHAR - 12

Torque in Nm 4 to 6 27 - 33 11 to 13 11 ÷ 13 24 to 30 11 - 13 24 ÷ 27 24 to 30 11 to 13

Sr Motard 125 4T

Characteristics

Name Oil pump central screw Oil pump cover screws Minimum oil pressure switch

Torque in Nm 12 to 14 0.7 - 0.9 12 - 14

STEERING ASSEMBLY Name Upper steering ring nut Lower steering ring nut Handlebar fixing screw Mirror fastening spacer

Torque in Nm 30 to 36 10 - 13 (loosen by 90°) 45 to 50 25

CHASSIS ASSEMBLY Name Engine arm pin - chassis arm Centre stand pivot on engine Silent block-swinging arm retaining bolts

Torque in Nm 45.5 42.5 42.5

FRONT SUSPENSION Name Piston tightening fork lower screw Front wheel axle nut Fork clamp screw Fork stanchion upper cap Safety screw on fork leg

Torque in Nm 25 - 35 45 - 50 20 to 25 15 ÷ 30 6÷7

FRONT BRAKE Name Brake fluid hose-pump fitting Brake fluid pipe-calliper fitting Calliper to fork tightening screw Disc tightening screw Oil bleed screw Pump U bolt screw Brake pad fastening screw

Torque in Nm 20 ÷ 25 20 to 25 20 to 25 8 to 12 8 - 12 8 15 to 20

REAR SUSPENSION Name Rear wheel axle Shock absorber nut

Torque in Nm 115 22.5

FUEL TANK UNIT Name Fuel tank to chassis fixing screw

Torque in Nm 10

SADDLE UNIT Name Saddle plate fixing nut

Torque in Nm 10

BODYWORK UNIT Name Helmet compartment fixing screw Rear grab handle fixing screw Battery cover fixing screw Front wheel housing to chassis fixing screw Front wheel housing to leg shield back plate fixing screw Front mudguard fixing screw Footrest fixing screw Screw fixing leg shield back plate to chassis Leg shield back plate to leg shield fixing screw Footrest spoiler fixing screw

Torque in Nm 3 20.5 6 6 3 6 6 6 3 6

CHAR - 13

Sr Motard 125 4T

Characteristics

Name Passenger footrest protection fixing screw Passenger footrest to side body panel fixing screw Rear mudguard fixing screw Rear brake adjustment nut

Torque in Nm 3 6 6 5

Overhaul data Assembly clearances Cylinder - piston assy.

125 version

PISTON TO CAST IRON CYLINDER COUPLING (125) Name Coupling Coupling Coupling Coupling coupling 1st oversize coupling 1st oversize coupling 1st oversize coupling 1st oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 2nd oversize Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize

Initials M N O P M1 N1 O1 P1 M2 N2 O2 P2 M3 N3 O3 P3

Cylinder 56.997 - 57.004 57.004 - 57.011 57.011 - 57.018 57.018 - 57.025 57.197 - 57.204 57.204 - 57.211 57.211 - 57.218 57.218 - 57.225 57.397 - 57.404 57.404 - 57.411 57.411 - 57.418 57.418 - 57.425 57.597 - 57.604 57.604 - 57.611 57.611 - 57.618 57.618 - 57.625

Piston 56.944 - 56.951 56.951 - 56.958 56.958 - 56.965 56.965 - 56.972 57.144 - 57.151 57.151 - 57.158 57.158 - 57.165 57.165 - 57.172 57.344 - 57.351 57.351 - 57.358 57.358 - 57.365 57.365 - 57.372 57.544 - 57.551 57.551 - 57.558 57.558 - 57.565 57.565 - 57.572

Play on fitting 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060 0.046 - 0.060

Initials A A A A

Quantity 0.15 - 0.30 0.10 - 0.30 0.10 - 0.35 0.15 - 0.30

Piston rings

SEALING RINGS (125) Name Compression ring Oil scraper ring Oil scraper ring Compression ring 1st oversize

CHAR - 14

Description

Dimensions 57 x 1 57x1 57x2.5 57.2 x 1

Sr Motard 125 4T

Name Oil scraper ring 1st oversize Oil scraper ring 1st oversize Compression ring 2nd oversize Oil scraper ring 2nd oversize Oil scraper ring 2nd oversize Compression ring 3rd oversize Oil scraper ring 3rd oversize Oil scraper ring 3rd oversize

Characteristics

Description

Dimensions 57.2x1

Initials A

Quantity 0.10 - 0.30

57.2x2.5

A

0.10 - 0.35

57.4x1

A

0.15 - 0.30

57.4x1

A

0.10 - 0.30

57.4x2.5

A

0.10 - 0.35

57.6x1

A

0.15 - 0.30

57.6x1

A

0.10 - 0.30

57.6x2.5

A

0.10 - 0.35

Maximum clearance after use: 1 mm

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Half shaft, transmission side

Description

Dimensions 16.6 +0-0.05

Initials A

Quantity D = 0.20 รท 0.50

CHAR - 15

Sr Motard 125 4T

Characteristics

Name Half shaft, flywheel side Connecting rod with PP Crank pin width

Description

Dimensions 16.6 +0-0.05 18 -0.10 -0.15 51.400

Initials B C E

Quantity D = 0.20 รท 0.50 0.20 to 0.50

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS Name Crankshaft Crankshaft Crankcase Crankcase Crankshaft half-bearing Crankshaft half-bearing Crankshaft half-bearing Crankshaft category 1 Crankcase category 1 Crankshaft category 1 Crankcase category 2 Crankshaft category 2 Crankcase category 1 Crankshaft category 2 Crankcase category 2

Description

Crankshaft/crankcase axial clearance: 0.15 รท 0.40

Slot packing system

CHAR - 16

Dimensions

Initials Category 1 Category 2 Category 1 Category 2 Category B - blue Category C - yellow Category E - green E-E C-C C-C B-B

Quantity 28.998 to 29.004 29.004 to 29.010 32.953 to 32.959 32.959 to 32.965 1.973 to 1.976 1.976 to 1.979 1.979 to 1.982

Sr Motard 125 4T

Characteristics

- Provisionally fit the piston into the cylinder, without any base gasket.

- Assemble a dial gauge on the specific tool - Set the dial gauge to zero at a contrast plane with an average preload, for example 5 mm. Keeping the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure.

- Rotate the crankshaft up to the TDC (the inversion point of the dial gauge rotation) - Calculate the difference between the two measurements: use the chart below to identify the thickness of the cylinder base gasket to be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compression ratio.

- Remove the special tool and the cylinder.

Characteristic Compression ratio 10.6: 1

SHIMMING SYSTEM Specification Value measured Thickness Value measured Thickness Value measured Thickness

Desc./Quantity 0 - 0.1 0.8 ± 0.05 0.1 - 0.3 0.6 ± 0.05 0.3 - 0.4 0.4 ± 0.05

Products RECOMMENDED PRODUCTS TABLE Product AGIP GEAR SAE 80W-90 eni i-Ride PG 5W-40 AGIP FILTER OIL eni i-Ride PG 5W-40 AGIP GREASE MU3 AGIP BRAKE 4

Description Specifications Lubricant for gearboxes and transmisAPI GL-4 sions.

Synthetic based lubricant for high-perJASO MA, MA2 - API SL - ACEA A3 formance four-stroke engines.

Special product for the treatment of foam filters.

Synthetic based lubricant for high-perJASO MA, MA2 - API SL - ACEA A3 formance four-stroke engines.

Yellow-brown, lithium-base, medium-fi- ISO L-X-BCHA 3 - DIN 51 825 K3K -20 bre multipurpose grease.

Brake fluid.

Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4

CHAR - 17

Sr Motard 125 4T

Characteristics

Product AGIP GREASE PV2 AGIP GP 330

AGIP FORK 7.5 W

CHAR - 18

Description Ivory smooth-textured, slightly-stringy anhydrous calcium-base grease.

Water repellent stringy calcium spray grease.

Oil for fork.

Specifications TL 9150 066, NATO G 460 symbol R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 I.A.T.A. 2 - I.M.D.G. class 2 UN 1950 Page 9022 EM 25-89 -

INDEX OF TOPICS

TOOLING

TOOL

Sr Motard 125 4T

Tooling

SPECIFIC TOOLS

TOOL - 20

Stores code 001330Y

Description Tool for fitting steering seats

001467Y009

Bell for OD 42-mm bearings

001467Y013

Pliers to extract ø 15-mm bearings

002465Y

Pliers for circlips

005095Y

Engine support

006029Y

Punch for fitting fifth steering bearing on steering tube

008564Y

Flywheel extractor

Sr Motard 125 4T

Tooling

Stores code 020004Y

Description Punch for removing fifth wheels from headstock

020055Y

Wrench for steering tube ring nut

020074Y

Support base for checking crankshaft alignment

020150Y

Air heater support

020151Y

Air heater

020193Y

Gauge for oil pressure check

020201Y

Spacer bushing driving tube

TOOL - 21

Sr Motard 125 4T

Tooling

TOOL - 22

Stores code 020262Y

Description Crankcase splitting plate

020263Y

Driven pulley assembly sheath

020271Y

Tool for removing-fitting silent bloc

020306Y

Punch for assembling valve seal rings

020329Y

Vacuum pump Mity-Vac

020330Y

Stroboscopic light to check timing

Sr Motard 125 4T

Tooling

Stores code 020331Y

Description Digital multimeter

020332Y

Digital rpm indicator

020335Y

Magnetic mounting for dial gauge

020357Y 020359Y

32x35-mm Adaptor 42x47-mm Adaptor

020360Y

52x55-mm Adaptor

TOOL - 23

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL