Service Station Manual: SR MAX 125 Ie

SERVICE STATION MANUAL
677506 EN
SR MAX 125 ie
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SERVICE STATION
MANUAL
SR MAX 125 ie
THE VALUE OF SERVICE

As a result of continuous updates and specific technical training programmes for Aprilia products, only
Aprilia Official Network mechanics know this vehicle fully and have the specific tools necessary to carry
out maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding
it, its regular maintenance and the use of original Aprilia spare parts only are essential factors!
For information on the nearest Official Dealer and/or Service Centre consult our website:
www.aprilia.com
Only by requesting aprilia original spare parts can you be sure of purchasing products that were
developed and tested during the actual vehicle design stage. All aprilia original spare 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,
to make any changes to components, parts or accessories, which it considers necessary to improve the
product or which are required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of individual
models should be confirmed with the official aprilia sales network.
The Aprilia trademark is the property of Piaggio & C. S.p.A.
© Copyright 2012 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com

SERVICE STATION MANUAL
SR MAX 125 ie
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

INDEX OF TOPICS
CHARACTERISTICS CHAR
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

INDEX OF TOPICS
CHARACTERISTICS CHAR

SR MAX 125 ie Characteristics
This section describes the general specifications of the vehicle.
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 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 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.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. 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 electric connections have been made properly, particularly the ground and battery connections.
CHAR - 7

Characteristics SR MAX 125 ie
Vehicle identification
To read the chassis prefix, 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
CHAR - 8

Dimensions and mass
WEIGHTS AND DIMENSIONS

Kerb weight 169 ± 5 kg
Maximum weight allowed 370 Kg
Maximum height 1.400 mm
Width 780 mm
Wheelbase 1.515 mm
Maximum length 2,110 mm
Engine
ENGINE
Type Single-cylinder, 4-stroke with double spark plug
Engine capacity 124 cm³
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 lubrication pressure (90° C) 0.6 ÷ 1.2 bar
CHAR - 9

Fuel system 32 MIU2.E0 Electronic injection with Ø 32-mm throttle body and
electric fuel pump.
Cooling Forced-circulation coolant with electric pump commanded by
the control unit.
Fuel Unleaded petrol (95 RON)
Transmission
TRANSMISSION
Transmission Automatic expandable pulley variator with torque server, V-
belt, self-ventilating dry automatic centrifugal clutch and trans-
mission housing with forced-circulation air cooling.
Final reduction gear Gear reduction unit in oil bath.
Capacities
CAPACITY
Engine oil 1.30 l
Transmission oil 250 cm³
Cooling system fluid 1.75 l
Fuel tank (reserve) approx.15.00 l (approx. 2.80 l)
Electrical system
ELECTRICAL SYSTEM
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
Alternator alternating current
Frame and suspensions
CHASSIS AND SUSPENSIONS

Chassis Tubular and steel sheets.
Front suspension Hydraulic telescopic fork with Ø 35-mm stem
Front suspension travel 104 mm
Rear suspension Two double-acting shock absorbers with preloading adjust-
ment in 4 positions.
Rear suspension travel 95.5 mm
CHAR - 10

Brakes
BRAKES
Front brake Ø 260-mm disc brake with hydraulic control activated by han-
dlebar right-side lever.
Rear brake Ø 240 mm disc brake with hydraulic control activated by han-
dlebar left lever.
Wheels and tyres
WHEELS AND TYRES

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
Assembly clearances
Cylinder - piston assy.
CHAR - 11

ENGINE COUPLING CATEGORIES

Name Initials Cylinder Piston Play on fitting
Cylinder A 56.997 to 57.004 56.945 - 56.952 0.045 - 0.059
Cylinder B 57.004 to 57.011 56.952 - 56.959 0.045 - 0.059
Piston C 57.011 to 57.018 56.959 - 56.966 0.045 - 0.059
Piston D 57.018 to 57.025 56.966 - 56.973 0.045 - 0.059
Cylinder 1st Oversize A1 57.197 to 57.204 57.145 - 57.152 0.045 - 0.059
Cylinder 1st Oversize B1 57.204 to 57.211 57.152 - 57.159 0.045 - 0.059
Piston 1st Oversize C1 57.211 to 57.218 57.159 - 57.166 0.045 - 0.059
Piston 1st Oversize D1 57.218 to 57.225 57.166 - 57.173 0.045 - 0.059
Cylinder 2nd Oversize A2 57.397 to 57.404 57.345 - 57.352 0.045 - 0.059
Cylinder 2nd Oversize B2 57.404 to 57.411 57.352 - 57.359 0.045 - 0.059
Piston 2nd Oversize C2 57.411 to 57.418 57.359 - 57.366 0.045 - 0.059
Piston 2nd Oversize D2 57.418 to 57.425 57.366 - 57.373 0.045 - 0.059
Cylinder 3rd Oversize A3 57.597 to 57.604 57.545 - 57.552 0.045 - 0.059
Cylinder 3rd Oversize B3 57.604 to 57.611 57.552 - 57.559 0.045 - 0.059
Piston 3rd Oversize C3 57.611 to 57.618 57.559 - 57.566 0.045 - 0.059
Piston 3rd Oversize D3 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 PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.
- Calculate the coupling clearance between pin

and connecting rod small end.
Characteristic
Standard diameter:
Ø 14.996 - 15.0 mm
Standard clearance:
0.015 - 0.029 mm
- Measure the diameter of the bearings on the pis-

ton.
Characteristic
Standard diameter:
15 +0.006 + 0.001mm
- Calculate the piston pin coupling clearance.

NOTE
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT
MUST BE MADE ACCORDING TO THE PISTON AXIS.
Characteristic
Standard clearance:
0.001 - 0.010 mm
CHAR - 12

- Check that coating is free from flakes.

- Check that the head matching surface exhibits no
deformations or wear.
Characteristic
Maximum allowable run-out:
0.05 mm
- Pistons and cylinders are classified into categories based on their diameter. The coupling is carried
out in pairs (A-A, B-B, C-C, 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 BOTH THE STANDARD SEALING RINGS
AND THE OVERSIZES.
CHAR - 13

Crankcase - crankshaft - connecting rod
- Measure the diameter of bushings «A» in the

three directions shown in the figure.
- Measure the diameter of the crankshaft bearings
«B».
- Check that the diametral clearance «A-B» is be-
tween the pre-set interval.
Characteristic
Diameter clearance
0.023 - 0.041 mm
If value «A-B» is above the limit, check that value «B» is within the admissible values of the categories.
CRANKSHAFT
Category 1 28.998 to 29.004
Category 2 29.004 to 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
Category 1 32.959 - 35.965
Category 2 32.953 to 32.959
CRANKCASE - CRANKSHAFT COUPLING / CRANKSHAFT HALF-BEARINGS

Crankshaft category 1 - Crankcase category 1 E+E
Crankshaft category 2 - Crankcase category 1 C+C
Crankshaft category 1 - Crankcase category 2 C+C
Crankshaft category 2 - Crankcase category 2 B+B
CHAR - 14

Characteristic
Axial crankshaft/crankcase clearance:
0.5 - 0.40 mm
CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name Description Dimensions Initials Quantity
Transmissionside half- 16.6 +0-0.05 A D = 0.20 ÷ 0.50
shaft
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
CHAR - 15

THE CRANKSHAFT is available in two CATEGO-

RIES:
Characteristic
Crankshaft category:
CAT. 1 - CAT. 2
CRANKSHAFT CATEGORY IDENTIFICATION:

The identification is indicated on the counterweight shoulder «*1 - *2», if carried out with micropinholing.
Otherwise, «1 - 2» if done manually with an electric pen. The spare part identification is located on the
package with a drawing number plus FC1/FC2 or (001/002).
If a crankshaft comprising two half-shafts of different categories needs to be replaced, also replace both
crankcase halves, combining the two 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-out
0.09 mm
- In case of faults, replace the head.

- Check the sealing surfaces for the intake and exhaust manifold.
- Check that the camshaft and the rocking lever pin capacities exhibit no wear.
- Check that the head cover surface is not worn.
- Check that the coolant seal plug exhibits no oxidation.
CHAR - 16

- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust
valves.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
Measure the camshaft bearing seats and rocking

lever support pins with a bore meter
HEAD BEARINGS
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 the impression on the valve seat exceeds the specified limits, replace the cylinder head.
CHAR - 17

- In case of excessive wear or damage, replace the head.
STANDARD VALVE LENGTH

Intake 84.5 mm
Exhaust 94.5 mm
- Measure the diameter of the valve stems in the three positions indicated in the diagram.
STANDARD DIAMETER
Intake: 4.987 - 4.972 mm
Exhaust: 4.975 - 4.960 mm
MINIMUM ADMISSIBLE DIAMETER

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
CHAR - 18

- Check the concentricity of the valve head by ar-

ranging a dial gauge at right angle relative to the
valve head and rotate it on a "V" shaped abutment.
Characteristic
Admissible limit:
0.03 mm
Measure the valve guide.
Characteristic
Valve guide:
5 +0.012 mm
- After measuring the valve guide diameter and the

valve stem diameter, check clearance between
guide and stem.
EXHAUST
Standard clearance: 0.025 to 0.052 mm
Admissible limit: 0.09 mm
INTAKE
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 terminal.
CHAR - 19

- If no faults are found during the above checks,

you can use the same valves. To obtain better
sealing performance, grind the valve seats. Grind
the valves gently with a fine-grained lapping com-
pound. During the grinding, keep the cylinder head
with the valve axes in a horizontal position. This
will prevent the lapping compound residues from
penetrating between the valve stem and the guide
(see figure).
CAUTION
TO AVOID SCORING THE FAYING 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
Bearing A Ø: 37 - 0.025 -0.050 mm
Bearing B diameter: 19 - 0.020 -0.041 mm
MINIMUM ADMISSIBLE DIAMETER

Bearing A Ø: 36.940 mm
Bearing B diameter: 19.950 mm
CHAR - 20

-Using a gauge, measure the cam height.
STANDARD HEIGHT
intake 17.382 mm
Exhaust 16.563 mm
ADMISSIBLE LIMITS
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
CHAR - 21

- Check that the cam contact sliding block and the

articulated register cap is free from wear.
- In case of wear, replace the component.
Slot packing system
Characteristic
Compression ratio
Cr: 11.50 - 13:1
Measurement «A» to be taken, is a value of piston protrusion. It indicates by how much the plane formed
by 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 THE PISTON AT TOP DEAD CENTRE POSITION AND
ON A RECTIFIED PLANE.
CHAR - 22

MODELS WITH METAL HEAD GASKET (0.3)

Name Measure A Thickness
Shimming 125 - Cylinder 67.8 - Head 1.40 - 1.60 0.60 ± 0.05
gasket 0.3 - Base gasket 0.6
Shimming 125 - Cylinder 67.8 - Head 1.60 - 1.80 0.80 ± 0.05
gasket 0.3 - Base gasket 0.8
Products
RECOMMENDED PRODUCTS TABLE

Product Description Specifications
AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmis- API GL-4
sions.
eni i-Ride PG 5W-40 Synthetic based lubricant for high-per- JASO MA, MA2 - API SL - ACEA A3
formance four-stroke engines.
AGIP GP 330 Water repellent springy calcium spray R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 -
grease. I.A.T.A. 2 - I.M.D.G. class 2 UN 1950 Pag.
9022 EM 25-89
eni i-Ride PG 5W-40 Synthetic based lubricant for high-per- JASO MA, MA2 - API SL - ACEA A3
formance four-stroke engines.
AGIP BRAKE 4 Brake 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 ASTM D 3306 - ASTM D 4656 - ASTM D
with organic inhibition additives. Red, 4985 - CUNA NC 956-16
ready to use.
AUTOSOL METAL POLISH Silencer cleaning paste special product for cleaning and polishing
stainless steel silencer
AGIP GREASE PV2 Ivory smooth-textured, slightly-stringy TL 9150 066, symbol NATO G 460
anhydrous calcium-base grease.
UNIT OF MEASURE - CONVERSION - ENGLISH SYSTEM TO INTERNATIONAL SYSTEM (IS).

1 Inch (in) 25.4 Millimetres (mm)
1 Foot (ft) 0.305 Meter (m)
1 Mile (mi) 1.609 Kilometre (km)
1 US Gallon (USgal) 3.785 Litre (l)
1 Pound (lb) 0.454 Kilogram (kg)
1 Cubic inch (in³) 16.4 Cubic centimetres (cm³)
1 Foot pound (ft lb) 1,356 Newton meter (Nm)
1 Miles per hour (mi/h) 1.602 Kilometres per hour (km/h)
1 Pound per square inch (PSI) 0.069 (bar)
1 Fahrenheit (°F) 32+(9/5) Celsius (°C)
CHAR - 23

INDEX OF TOPICS
TOOLING TOOL

SR MAX 125 ie Tooling
SPECIFIC TOOLS
Stores code Description
001330Y Tool for fitting steering seats
001467Y014 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
TOOL - 25

Tooling SR MAX 125 ie

020074Y 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
TOOL - 26


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
TOOL - 27


020648Y Single battery charger
020335Y Magnetic mounting for dial gauge
020357Y 32x35-mm Adaptor

020359Y 42 x 47-mm adaptor
020363Y 20-mm guide
TOOL - 28


020375Y 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
TOOL - 29


020423Y Driven pulley 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
TOOL - 30


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
TOOL - 31


020621Y HV cable extraction adaptor
001467Y035 Bell for 47-mm outside diameter bearings
020626Y Driving pulley lock wrench
020626Y008 Driving pulley lock wrench

020627Y Flywheel lock wrench
020467Y Flywheel extractor
TOOL - 32


020430Y 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
TOOL - 33


020469Y Reprogramming kit for vehicle diagnostic
tester
001467Y017 Driver for OD 36 mm bearings
020234y extractor
020362Y 12 mm guide

001467Y002 Driver for OD 73 mm bearing
TOOL - 34


020688Y Dial gauge support
TOOL - 35

INDEX OF TOPICS
MAINTENANCE MAIN

SR MAX 125 ie Maintenance
Maintenance chart
SCHEDULED MAINTENANCE TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
* Replace every 2 years
Km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60
Roller bearing - Driven pulley L L L L L L
Safety fasteners I I I I I
Spark plug R R R R R R
Drive belt I R I R I R I R
Throttle control A A A A A A A
Air filter C C C C C C
Oil filter R R R R R R R
CVT Filter C C C C C C
Valve clearance A A A
Electrical system and battery I I I I I I I
Brake levers L L L L L L L
Brake fluid * I I I I I I I
Coolant * I I I I I I I
Engine oil R I R I R I R I R I R I R
Hub oil R I R I R I R
Headlight 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. Disconnect the spark plug HV wire hood «B»;
4. Unscrew the spark plug using the wrench sup-
plied;
5. Upon refitting, place the spark plug into the hole
at the required angle and finger tighten it;
6. Use the wrench only to tighten it;
7. Push hood «B» fully over the spark plug.
WARNING
THE USE OF SPARK PLUGS OTHER THAN THOSE REC-
OMMENDED OR A SHIELDLESS SPARK PLUG CAP
COULD CAUSE DISTURBANCES TO THE SYSTEM.
CAUTION
MAIN - 37

Maintenance SR MAX 125 ie
THE SPARK PLUG MUST BE REMOVED WHEN THE EN-

GINE IS COLD. REPLACE THE SPARK PLUG AS INDICA-
TED IN THE SCHEDULED MAINTENANCE TABLE. USING
NON-COMPLYING ELECTRONIC IGNITIONS OR SPARK
PLUGS OTHER THAN THOSE PRESCRIBED MAY SERI-
OUSLY DAMAGE THE ENGINE.
Characteristic
Spark plug
NGK CR8EB
Electric characteristic
Electrode gap
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 oil.
-Screw up the oil dipstick again and make sure it
is locked properly into place.
MAIN - 38

Replacement
-Remove the oil filler cap «A».

- Unscrew the oil drainage cap «B» and drain out
all the oil.
- Screw in the drainage cap again and fill the hub
with the prescribed oil.
Recommended products
AGIP GEAR SAE 80W-90 Lubricant for gear-
boxes and transmissions.
API GL-4
Characteristic
Transmission oil
250 cm³

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:
MAIN - 39

• Wash the sponge «C» with water and mild soap.

• Dry it with a clean cloth and short blasts of compressed air.
• Soak it in a mixture of 50% petrol and 50% specified oil.
• Gently squeeze the filtering element, let it drip and then refit it.
CAUTION
IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE

CHECKS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.
AGIP FILTER OIL Special product for the treatment of foam filters.
-
Engine oil
In four stroke engines, the engine oil is used to lubricate the distribution elements, the bench bearings
and the thermal group. An insufficient quantity of oil can cause serious damage to the engine.
In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption 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; furthermore, to fa-
cilitate oil drainage, loosen the cap/dipstick «A».
Once all the oil has drained through the drainage
opening, unscrew and remove the oil cartridge fil-
ter «C ».
Since a certain quantity of oil still remains in the
circuit, fill adding approx. 600 ÷ 650 cm³ of oil
through the cap «A». Then start up the vehicle,
leave it running for a few minutes and switch it off:
After about five minutes, check the level and, if
necessary, top-up but never exceeding the MAX
level reference mark.
NOTE
THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.
MAIN - 40

eni i-Ride PG 5W-40 Synthetic based lubricant
for high-performance four-stroke engines.
JASO MA, MA2 - API SL - ACEA A3

Engine oil drainage plug 24 to 30
Check
This operation must be carried out with the engine

cold and following the procedure below:
1. Place the vehicle on its centre stand and on flat
ground.
2. Unscrew the cap/dipstick «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 correct check, wait at least 10
minutes after the engine has been stopped so as
to get the correct level.
Characteristic
Engine oil
1.30 l
MAIN - 41

Oil top-up
The oil should be topped up after having checked
the level and in any case by adding oil without
ever exceeding the MAX. level.
Restoration of the level from MIN to MAX requires
approximately 200 cc.
Engine oil filter
The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended
type for topping up and changing purposes.
Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the
mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge
filter being careful to lubricate the O-ring before fitting it. Change the engine oil.
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 lights up when the key is
turned to the «ON» position. However, this light
should switch off once the engine has been star-
ted.
If the light comes on during braking, at idling
speed or while turning, it is necessary to first
switch off the engine and then to check the oil
level and the lubrication system
MAIN - 42

Cooling system
Adding engine coolant.

Check coolant level when the engine is cold as in-
dicated in the scheduled maintenance table, fol-
lowing the steps below:
Place the scooter on its centre stand and on flat
ground.
- Remove the expansion tank cover «A».
CAUTION
DO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO AS
TO AVOID THE COOLANT ESCAPING FROM THE EXPAN-
SION TANK WHEN THE VEHICLE IS IN USE.
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
- 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 VEHICLE IS IN USE.
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
Braking system
MAIN - 43

Level check
- Position the vehicle on a flat surface and on the

centre stand.
- Check the brake fluid level via the special indi-
cator located on the pump.
NOTE
THE LEVEL TENDS TO DROP AS THE BRAKE PADS GET WORN, A MINIMUM LEVEL SHOULD
NOT BE REACHED. IF THE LEVEL IS TOO LOW, CHECK AND FIX THE SYSTEM SEALS, IF RE-
QUIRED. TOP UP THE PUMP 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 BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE
OF ACCIDENTAL CONTACT, WASH WITH WATER.
WARNING
MAIN - 44

BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; DO NOT LET IT COME INTO CONTACT WITH
THE PAINTED PARTS.
WARNING
THE BRAKE FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS MOISTURE FROM THE SUR-
ROUNDING AIR. IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, IT
WILL LEAD TO INEFFICIENT BRAKING; FOR THIS REASON, NEVER USE BRAKING FLUID
FROM CONTAINERS THAT HAVE ALREADY BEEN OPENED, OR PARTIALLY USED.
Characteristic
prescribed fluid:
AGIP BRAKE FLUID DOT 4
Under normal climatic conditions, the brake fluid should be replaced following the given instructions.
NOTE
SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID
AND THE 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 height from the ground and that it is not less than 7/10.
- Otherwise, adjust the right headlight by the screw

shown in the figure, which can be accessed by re-
moving the front shield connecting member.
NOTE
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.
MAIN - 45

INDEX OF TOPICS
TROUBLESHOOTING TROUBL

SR MAX 125 ie Troubleshooting
This section makes it possible to find what solutions to apply when troubleshooting.
For each failure, a list of the possible causes and pertaining operations is given.
Engine
Excessive oil consumption/Exhaust smoke
EXCESSIVE CONSUMPTION
Possible Cause Operation
Wrong valve adjustment Adjust the valve clearance properly
Overheated valves Remove the head and the valves, grind or replace the valves
Misshapen/worn valve seats Replace the head unit
Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings
Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings
fitted properly
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal
Worn valve oil seal Replace the valve oil seal
Worn valve guides Check and replace the head unit if required
Insufficient lubrication pressure
LOW LUBRICATION PRESSURE

By-Pass remains open Check the 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

Faulty clutch Check that there is no grease on the masses. Check that the
clutch mass faying surface with the bell is mainly in the centre
with equivalent characteristics on the three masses. Check that
the clutch housing is not scored or worn in an anomalous way
Insufficient braking
INEFFICIENT BRAKING SYSTEM

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are
not worn, scored or warped. Check the correct level of fluid in
the pumps and change brake fluid if necessary. Check there is
no air in the circuits; if necessary, bleed the air. Check that the
front brake calliper moves in axis with the disc.
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace
TROUBL - 47

Troubleshooting SR MAX 125 ie

Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift
of the disc with a dial gauge and with wheel mounted on the
vehicle.
Brakes overheating
BRAKE OVERHEAT
Defective plunger sliding Check calliper and replace any damaged part.
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Clogged compensation holes on the pump Clean carefully and blast with compressed air
Swollen or stuck rubber gaskets Replace gaskets.
Steering and suspensions
Heavy steering
STEERING HARDENING
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the 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

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 adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.
Noisy suspension
NOISY SUSPENSION
Faults in the suspension system If the front suspension is noisy, check: the efficiency of the front
shock absorber; the condition of the ball bearings and relevant
lock-nuts, the limit switch rubber buffers; and the movement
bushings. In conclusion, check the tightening torque of the
wheel hub, the brake calliper, the shock absorber disc in the
attachment to the hub and the steering tube.
TROUBL - 48

SR MAX 125 ie Troubleshooting
Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION

Faulty or broken seals Replace the shock absorber Check the condition of wear of the
steering covers and the adjustments.
TROUBL - 49

INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

SR MAX 125 ie Electrical system
LEGENDA
1. Batteria 12v - 14 Ah
2. Regolatore di tensione
3. Volano magnete
4. Teleruttore d'avviamento
5. Motorino d'avviamento
6. Massa motore
7. Fusibile N.01 - 30A
12. Fusibile N.06 - 7,5A
18. Devio luci
19. Teleruttore luci abbaglianti
ELE SYS - 51

Electrical system SR MAX 125 ie
20. Lampada luce abbagliante 12v-55w

21. Spia abbaglianti 12v-1,2w
22. Pulsante avviamento
23. N.2 pulsanti stop
24. Lampada luce stop 12v-21/5w
25. Claxon 12v c.c.
26. Pulsante claxon
27. Predisposizione antifurto
28. Contatto del commutatore a chiave
29. Presa 12v-180w max
30. Pulsante illuminazione vano casco
31. Lampada illuminazione vano casco 12v-5w
32. Gruppo strumenti
33. Lampade 12v-10w per lampeggiatori
34. Contagiri analogico
35. Sensore pressione olio
36. Pulsante mode remoto
37. Commutatore lampeggiatori
38. Trasmettitore 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 elettronica per iniezione
49. Diagnostica
50. Sensore temperatura liquido raffreddamento per c.d.i.
51. Sensore liquido di raffreddamento per strumento
52. Pulsante cavalletto
53. Deviatore arresto motore
54. Pompa della benzina
55. Iniettore carburante
56. Sonda lambda
57. Bobina a.t.
ELE SYS - 52

58. Sensore giri motore

59. Decoder
60. Antenna
61. Pompa acqua
KEY
Ar: Orange Az: Sky Blue Bi: White 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
ELE SYS - 53

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.
ELE SYS - 54

4. Injection ECU
To reach it, remove the inspection compartment
placed in the helmet compartment.
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.
ELE SYS - 55

9. Horn
To reach it, remove the lower cover.
10-11. Key switch/Immobilizer aerial

Remove the shield back 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.
ELE SYS - 56

15. Fuel pump
16. Oil pressure sensor

On the engine, on 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.
ELE SYS - 57

19. Wheel turning sensor

In the front wheel, on the right-hand side.
20. Electric fan

Remove the radiator.
Conceptual diagrams
Ignition
ELE SYS - 58

LEGENDA
6. Massa motore
57. Bobina a.t.
61. Pompa acqua
Battery recharge and starting
LEGENDA
2. Regolatore di tensione
ELE SYS - 59

3. Volano magnete
6. Massa motore
22. Pulsante avviamento
Level indicators and enable signals section
LEGENDA
6. Massa motore
ELE SYS - 60


34. Contagiri analogico
35. Sensore pressione olio
38. Trasmettitore livello carburante
47. Sensore giri ruota
59. Decoder
60. Antenna
Devices and accessories
ELE SYS - 61

LEGENDA
6. Massa motore
25. Claxon 12v c.c.
26. Pulsante claxon
27. Predisposizione antifurto
29. Presa 12v-180w max
36. Pulsante mode remoto
ELE SYS - 62

Lights and turn indicators
LEGENDA
6. Massa motore
18. Devio luci
19. Teleruttore luci abbaglianti
20. Lampada luce abbagliante 12v-55w
21. Spia abbaglianti 12v-1,2w
ELE SYS - 63


31. Lampada illuminazione vano casco 12v-5w
33. Lampade 12v-10w per lampeggiatori
37. Commutatore lampeggiatori
41. Lampada luce 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
6. Massa motore
ELE SYS - 64


49. Diagnostica
56. Sonda lambda
61. Pompa acqua
Checks and inspections
Immobiliser
The electric ignition system is fed with direct cur-

rent and is protected by an anti-theft immobilizer.
The ignition system consists of:
- an electronic control unit
- immobilizer aerial
- master and service keys with built-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 blinker function is deactivated. Subse-
quently, a flash confirms the switching to « ON».
The duration of the flash depends on the electronic
control unit program (see figure).
ELE SYS - 65

In case the LED turns off and remains so even

when switching over to «ON», check if:
- the battery is charged
- the 15A fuse (No. 2) is in working order.
If the deterring LED remains off, check the control
unit power supply as follows:
- Disconnect the control unit connector and check
if:
- There is battery voltage between terminal No. 6
(Red/White) and the ground lead.
- There is battery voltage between the terminal No.
6 (Red/White) and the terminal No. 26 (Negative)
as shown in the figure.
- There is battery voltage between the terminals

No. 5 and No. 8 with the key switch set to «ON»,
the side stand folded up and the emergency cut-
off switch set to «RUN».
If no faults 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 SERVICE (Black) keys as follows:
- Insert the MASTER key, turn it to "ON" and keep it in that position for 2 seconds (limit values: 1 ÷ 3
seconds).
- Alternately insert all the available black keys and turn each one of them to "ON" for 2 seconds.
- Insert the MASTER key again and turn it to "ON" for 2 seconds.
The maximum time to change keys is 10 seconds.
A maximum of 7 (Black) service keys can be programmed at one time.
ELE SYS - 66

Sequence and times must be strictly observed or it will be necessary to repeat the procedure from the
start.
Once the control unit has been programmed, the decoder is inseparably matched with the MASTER
key transponder.
With this link established, it is now possible to encode new service keys, in the event of losses, re-
placements, etc. Each new programming deletes the previous one.
If a service key setting is lost, it is essential to carefully check the efficiency of the high voltage system:
Shielded cap resistance ~ 5000 Ω.
In any case it is advisable to use resistive spark plugs.
Diagnostic codes
The flash indicating the switching to "ON" can be followed by a phase of programmed failure warnings.
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 with
any key, disconnect the aerial connector from the decoder and check the aerial for continuity with the
recommended tool.
If non-conforming values are measured, replace the aerial.
If no failures are found in the aerial, replace the control unit.
CAUTION
BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE
CODE IS INDICATED. THIS IS NECESSARY TO AVOID SPOILING A NEW CONTROL UNIT
Specific tooling
ELE SYS - 67

immobilizer aerial
~ 7 ÷ 9 Ohm
2-FLASH CODE - Example with programmed control unit, no transponder and/or malfunctioning aerial.
Ignition disabled-Vehicle immobilised
Diagnostic code - 3 flashes
If the 3-flash code is detected, check if the failure occurs when the MASTER key in inserted into the
key switch.
- If the failure disappears when the MASTER key is used, proceed with coding a new service 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 enabled (regular use conditions)
3-FLASH CODE - Example with programmed decoder, aerial working properly and unknown trans-
ponder code. Ignition disabled-Vehicle immobilised
ELE SYS - 68

Ignition circuit
Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a
spark in the spark plug.
The battery provides the basic power supply. The system is adjusted so that the start-up system im-
mediately detects an eventual battery voltage drop, but this is practically irrelevant for the ignition
system.
The Pick-Up is connected to the control unit by a single cable; then, for the ground circuit, the control
unit is connected to the Pick-Up by the chassis and the engine ground lead.
To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis
ground connection bonding 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:
Pick-up resistance value
105 ÷ 124 Ohm
If a break in the circuit is found, check again the flywheel and the engine ground connectors (see engine
manual). If non-conforming values are measured, replace the Pick-Up; otherwise, repair the cable har-
ness.
In case conforming values are measured, try replacing the control unit (without programming) and make
sure the failure has been solved by checking sparks are produced in the spark plug; only then program
the control unit.
ELE SYS - 69

- HV primary coil check

Disconnect the connector of the HV coil and check
again the HV primary coil directly on the positive
and negative terminals. If non-conforming values
are measured, repair the cable harness or else re-
place the HV coil.
High voltage coil primary resistance value
~ 1 ohm
HV coil secondary check

Disconnect the spark plug cap from the HV cable
and measure the resistance between the HV cable
terminal and the HV coil negative terminal (see
figure).
If non-conforming values are measured, replace
the HV coil. To carry out a more complete diagno-
sis, check the peak voltage with the multimeter
adaptor.
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-up system to run the engine and
measure the voltage produced by the Pick-Up.
- Replace the Pick-Up if non-conforming values
are measured.
NOTE
THE MULTIMETER MUST BE SELECTED TO DETECT
CONTINUOUS VOLTAGE.
Specific tooling
020409Y Multimeter adaptor - Peak voltage de-
tection
ELE SYS - 70

Voltage value
> 5 Volt
- HV coil
With the control unit and HV coil connected, meas-
ure the voltage of the coil primary during the start-
up test with the voltage peak adaptor and con-
necting the positive terminal to the ground one and
the negative to the coil positive connector.
If non-conforming 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.
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 cables.
Ohm value:
0.7 ÷ 0.9 Ohm
ELE SYS - 71

Also check that all yellow cables are insulated 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.
ELE SYS - 72

Voltage regulator check
With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running
engine.
The voltage should not exceed 15.2 Volt.
In case higher voltages are detected, replace the regulator.
In case of voltage values lower than 14 Volt, check the stator and the corresponding cable harness.
Recharge system voltage check
L'impianto di ricarica prevede un generatore tri-

fase con volano a magnete permanente.
Il generatore è collegato direttamente al regolatore
di tensione.
A sua volta quest'ultimo 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 che il
minimo sia regolato secondo prescrizione.
Collegare la pinza ad induzione di un amperome-
tro al cavetto positivo del regolatore di tensione,
misurare la tensione della batteria e accendendo
le luci del veicolo a motore fermo, attendere che la
tensione si assesti a circa 12 Volt. Avviare il mo-
ELE SYS - 73

tore e misurare la corrente erogata dall'impianto

con luci accese e motore a regime elevato.
Nel caso che il valore di corrente erogata sia infe-
riore a 10A, ripetere la prova utilizzando alternati-
vamente regolatore e/o statore nuovo.
Turn signals system check
Verifica alimentazioni gruppo strumenti:

- Scollegare il connettore del gruppo strumenti e verificare che tra il terminale n° 11/20 (Rosso-Nero) e
massa ci sia la tensione di batteria.
- Verificare che la stessa cosa ci sia tra il terminale n° 11/20 ed il terminale n° 16/20 (Nero).
- Ripetere la verifica tra il terminale n° 13/20 (Bianco-Nero) ed il terminale n° 16/20 con il commutatore
a chiave in «ON», con il cavalletto laterale alzato e con l'interruttore di emergenza in «RUN».
Se non si rileva alcuna tensione, verificare il cablaggio, le connessioni e l'integrità dei fusibili n° 10 (7,5A)
e n° 11 (7,5A). Altrimenti procedere come di seguito:
- Collegare il terminale n° 18/20 (Blu) del gruppo strumenti a massa e controllare che si accendano i
lampeggiatori 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.
- Repeat the test between terminals No 5 and No 4 with the turn indicator switch activated to the left.
If there is no continuity, check the connection cable harness between the instrument panel, the electric
control management device and the turn indicator switch, then repeat the test.
If there is still no continuity between the terminals, replace the electric control management device
because it is faulty. If there is continuity, replace the turn indicator switch because it is certainly dam-
aged.
Lights list
BULBS
1 High/low beam light bulb Type: Halogen (H7)
Power: 12V - 55W
Quantity: 2
2 Front position light bulb Type: Incandescent (W2.1x9.5d)
Power: 12V - 5W
Quantity: 2
3 Rear turn indicator light bulb Type: Incandescent (BAU 15s)
ELE SYS - 74

Power: 12V - 10 W
Quantity: 1 RHS + 1 LHS
4 Front turn indicator bulb Type: Incandescent (W2.1x9.5d)
Power: 12V - 5 W
Quantity: 2 RHS + 2 LHS
5 Tail light and stop light bulb Type: Incandescent (W2.1x9.5d)
Power: 12V - 21/5W
Quantity: 1
6 License plate bulb Type: Incandescent (W2.1 x 9.5D)
Power: 12V - 5W
Quantity: 1
7 Helmet compartment light bulb Type: Incandescent (SV 8.5)
Quantity: 1
Power: 12V - 5W
Fuses
L'impianto elettrico è dotato di due blocchi porta-

fusibili:
Portafusibili «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

THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY
TO REPLACE THE FUSE WITH ANY OTHER MATERIAL
(E.G., A PIECE OF ELECTRIC WIRE).
FUSIBILI
1 Fuse no. 1 Capacity: 30 A
Protected circuits: Battery recharge circuit.
ELE SYS - 75

Protected circuits: Lines protected by fuses No.10 and
11 (live), plug socket, helmet compartment lighting.
Protected circuits: Electric fan (via solenoid)
Protected circuits: Lines protected by fuses No. 6, 7, 8
and 9.
5 Fusibile n°5 Capacità: 10A
Circuiti protetti: Teleruttore carichi iniezione, bobina
A.T., iniettore carburante, pompa benzina, alimenta-
zione da batteria per centralina iniezione.
6 Fuse No. 6 Capacity: 7.5A
Protected circuits (live): Low beam headlight bulb.
Protected circuits (live): High beam bulb, high beam
light relay, high beam warning light.
Protected circuits (live): Engine start up circuit, horn,
stop light bulb.
Protected circuits (live): Analogue rpm indicator, in-
strument panel lighting, daylight running light bulbs, li-
cense plate bulb, bulb for daylight running warning light.
Protected circuits: Pre-installation for antitheft device,
battery-powered instrument panel.
Protected circuits (live): Instrument panel, turn indica-
tor bulbs, radiator electrical fan remote control, electronic
control unit relay, decoder, antenna, immobilizer, ignition
switched live for injection ECU, anti-theft device prepa-
ration.
Dashboard
The digital display has two service symbols:

SERVICE:
The lamp should come on after reaching 1,000 km,
then every 6,000 km or 1 year after the last acti-
vation.
BELT:
This lamp should turn on and flash every 6,000 km.
• Press buttons "MODE" and "ODO/SET" simultaneously at the moment you turn the key to
"ON" for more than 3 seconds: The "BELT" symbol starts to flash.
ELE SYS - 76

• Pressing the button "MODE" for less than 1 second displays the symbols in turn. The se-
lected symbol remains lit.
• Pressing button "MODE" for longer than 3 seconds resets the kilometre reading for the
symbol selected, in "SERVICE" mode the date is also reset.
NOTE
• AT THE MOMENT THE DATE IS RESET, THE "SERVICE" SYMBOL IS ACTIVATED
AGAIN.
• PERFORM THE RESET PROCEDURE ONLY AT THE MOMENT OF DELIVERY OF THE
SCOOTER TO THE CUSTOMER IN ORDER THAT THIS SYMBOL SIGNALS THE NEED
FOR THE FIRST SERVICE IN RELATION TO THE DISTANCE TRAVELLED AND THE
TIME SINCE THE ACTIVATION.
Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if re-
quired, before storing the vehicle and afterwards every six months.
INSTRUCTIONS 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 to 14.40 to 14.70V
- Initial charge voltage equal to 0.3 to 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the nominal capacity of the battery
- Charge time: 5 h
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. THE USE OF A
FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE-
HICLE OR EVEN CAUSE A FIRE.
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE
CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED
SHORTENS THE LIFE OF THE BATTERY.
IF THE VEHICLE IS NOT USED FOR SOME TIME (1 MONTH OR MORE) THE BATTERY NEEDS
TO BE RECHARGED PERIODICALLY. THE BATTERY RUNS DOWN COMPLETELY IN THE
ELE SYS - 77

COURSE OF THREE MONTHS. IF IT IS NECESSARY TO REFIT THE BATTERY IN THE vehicle,

BE CAREFUL NOT TO REVERSE THE CONNECTIONS TAKING INTO ACCOUNT THAT THE
GROUND WIRE (BLACK) MARKED (-) MUST BE CONNECTED TO THE - NEGATIVE TERMINAL,
WHEREAS THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMI-
NAL MARKED WITH THE +POSITIVE SIGN
WARNING
WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT OCCUR THAT 5 HOURS
OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.
GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CON-
TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
Normal bench charging must be carried out using the specific battery charger 020333Y (single) or
020334 (multiple), setting the battery charge selector to the type of battery that needs recharging (i.e.,
at a current 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 WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN.
AND SEEK IMMEDIATE MEDICAL ATTENTION.
IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE
QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL.
SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS.
ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF REACH OF CHILDREN
1) Battery preparation
Position the battery on a flat surface. Remove the
adhesive sheet closing cells and proceed as quick-
ly as possible to run the subsequent activation
phases.
ELE SYS - 78

2) Electrolyte preparation.
Remove the container of the electrolyte from the
pack. Remove and preserve cover strips from the
container, in fact, the strip will later be used as a
closing cover.
Note: Do not pierce the sealing of the container or
the container itself because inside there is sulphu-
ric acid.
3) Procedure for filling the battery with acid.

Position the electrolyte container upside down with
the six areas sealed in line with the six battery filler
holes. Push the container down with enough force
to break the seals. The electrolyte should start to
flow inside the battery.
Note: Do not tilt the container to prevent the flow
of electrolyte from pausing or stopping.
4) Control the flow of electrolyte

Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20
minutes or more.
Note:If there are 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 completely empty, and proceed immediately to the next point.
6) Battery closing.
Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure
that the strip is levelled with the top part of the battery.
Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect
your hands and do not bring your face close to the battery.
The filling process is now complete.
Do not remove the strip of caps under any circumstances, do not add water or electrolyte.
Place the battery down for 1 to 2 hours prior to the charging from the battery.
ELE SYS - 79

7) Recharging the new battery

With the above-mentioned procedure, the battery
will have gained around 70% - 75% of its total
electrical capacity. Before installing the battery on
the vehicle, it must be fully charged and then must
be recharged.
If the battery is to be installed on the vehicle
prior to this pre-charged one, the battery will
not be able to exceed 75% charge without jeop-
ardising its useful life on vehicle.
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 (-) and
red clamp to positive pole (+)).
d - Press the red button, as shown in figure.
e - Press the "MF" black button to activate the bat-

tery recharge Maintenance Free as shown in fig-
ure.
ELE SYS - 80

f - Check the ignition of the green LED indicated

with a red arrow in figure.
g - The activation cycle of the new battery lasts for

30 minutes after the ignition of the recharge LED
has taken place
h - Disconnect the clamps from the battery 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.
ELE SYS - 81

Connectors
INSTRUMENT PANEL CONNECTOR

1. To the wheel turning sensor (Red)
2. To the wheel turning sensor (Blue)
3. To the wheel turning sensor (Grey-Black)
4. Panel lighting and headlight warning light (Yel-
low-Black)
5. Rpm indicator signal (Green)
6. Thermistor signal (Orange)
7. Ground lead (Sky blue-Black)
8. . Oil pressure signal (White)
9. Right turn indicator warning 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 CONNECTOR

1. To the instrument panel (Blue)
2. To the instrument panel (Grey-Black)
3. To the instrument panel (Red)
ELE SYS - 82

CONTROL UNIT CONNECTOR

1. Injection telltale light (Brown-White)
2. Rpm indicator (Green)
3. Not connected
4. Lambda probe negative (Light blue-Black)
5. Live power supply (White-Black)
6. Live power supply (White-Red)
7. Immobilizer aerial (Orange-White)
8. Electric fan remote control (Green-White)
9. temperature sensor (Yellow-Pink)
10. Not connected
11. Lambda probe positive (Light blue-Yellow)
12. Engine stop switch (Orange)
13. Rpm sensor 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
ANTITHEFT CONNECTOR
1. Left turn indicators (Pink)
2. Right turn indicators (White-Blue)
6. Helmet compartment light (Blue-Yellow)
7. Not connected
8. Not connected
ELE SYS - 83

VOLTAGE REGULATOR CONNECTOR

1. Battery positive terminal (Red-White)
3. Battery positive terminal (Red-White)
ELE SYS - 84

INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Engine from vehicle SR MAX 125 ie
This section describes the operations to carry out when removing the engine from the vehicle.
Exhaust assy. Removal
- Remove the Lambda probe from its support and

disconnect it.
- Undo the two exhaust manifold fixings on 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.
ENG VE - 86

SR MAX 125 ie Engine from vehicle
CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE SILENCER TIP, ALWAYS RE-
PLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP.
Removal of the engine from the vehicle

CAUTION
THIS OPERATION MUST BE CARRIED OUT WHEN 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.
ENG VE - 87

- Remove the coolant outlet pipe from 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
ENG VE - 88

- Remove the clamp indicated and slide the throttle

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.
ENG VE - 89


- Disconnect the voltage regulator connector and
release 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.
ENG VE - 90

- Remove the pin fixing the engine to the swinging

arm.
- The engine is now free.
When refitting the engine onto the vehicle, carry out the removal operations but in reverse order and
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.
ENG VE - 91

INDEX OF TOPICS
ENGINE ENG

SR MAX 125 ie Engine
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
- Remove the air duct.

- With the specific tool lock the driven pulley, undo
the indicated nut and collect the washer.
Specific tooling
- 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».
ENG - 93

Engine SR MAX 125 ie
- Unscrew the three screws «4» and remove the

transmission housing filter cover «5».
- Take out the filtering element «6» from the cover.
Removing the driven pulley shaft bearing
- Remove the clip from the inside of the cover.

- Remove the bearing from the crankcase by
means of:
Specific tooling
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 tooling
ENG - 94


020412Y 15-mm guide
Removing the driven pulley
- Remove the stationary driving half-pulley and the

clutch housing.
- Remove the driven pulley together with the belt.
Inspecting the clutch drum
- Check that the clutch bell 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 to check the crankshaft alignment.
ENG - 95

- Using a feeler dial gauge and the magnetic base, measure the bell eccentricity.
- Repeat the measurement in 3 positions (Central, internal, external).
- If faults are found, replace the bell.
Specific tooling
020074Y Support base for checking crankshaft alignment
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
ENG - 96

UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST
NOT BE DIFFERENT FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN
SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
Removing the clutch
Fit the driven pulley spring compressor specific

tool with medium length pins screwed in position
«C» on the tool internal side.
- Introduce the adapter ring 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 driven pulley components (Clutch
and spring with its plastic holder)
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND
THE CENTRAL SCREW MUST BE BROUGHT INTO CON-
TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE
THE SPECIFIC TOOL TO BUCKLE.
ENG - 97

Specific tooling
020444Y011 adapter ring
020444Y009 wrench 46 x 55
020444Y Tool for fitting/ removing the driven
pulley clutch
Pin retaining 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.
ENG - 98

Removing the driven half-pulley bearing
- Check there are no signs of wear and/or noisiness; - Replace with a new one if there are.
- Remove the retainer ring using two flat blade screwdrivers.
- Support the pulley bushing 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
ENG - 99

020363Y 20-mm guide
Inspecting the driven fixed half-pulley
Version 250
- Measure the outside diameter of the pulley bushing.
- Check the faying 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
ENG - 100

Inspecting the driven sliding half-pulley

- Remove the two seal rings and the two O-rings.
- Measure the movable half-pulley bushing inside
diameter.
- Check the faying 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.
MOVABLE DRIVEN HALF-PULLEY DIMENSIONS

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 figure.
ENG - 101

- For the fitting of the new ball bearing, follow the example in the figure using a modular punch.
Fit the retainer ring
WARNING
NOTE
FIT THE BALL BEARING WITH THE VISIBLE SHIELDING
Specific tooling
020424Y Driven pulley roller casing fitting punch
ENG - 102

Refitting the driven pulley
- Insert the new oil seals and O-rings on the mov-

able half-pulley.
- Lightly grease the O-rings «A» shown in the fig-
ure.
- Fit the half-pulley over the bushing using the spe-
cific tool.
- Check that the pins are not worn and proceed to
refitting them in their slots.
- Refit the torque server closure collar.
- Using a curved-spout grease gun, lubricate the
driven pulley unit with approximately 6 grams of
grease. Apply grease through one of the holes in
the bushing 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
AGIP GREASE SM 2 Gray black smooth-tex-
tured lithium grease, containing molybdenum
disulphide.
-
Inspecting the clutch spring
- Measure the length of the spring when it is re-

laxed.
Characteristic
Standard length
145 mm
Acceptable limit after use
140 mm
ENG - 103

Refitting the clutch
- Support the driven pulley spring compressor spe-

cific tool with the control screw in vertical axis.
- Arrange the tool with the medium length pins
screwed in position "C" on the inside.
- Introduce the adapter ring No. 11 with the cham-
fering facing upwards.
- Insert the clutch on the adapter ring.
- Lubricate the end of the spring that abuts against
the torque server closing collar.
- Insert the spring with its plastic holder in contact
with the clutch.
- Insert the drive belt into the pulley unit according
to their direction of rotation.
- Insert the pulley unit with the belt into the tool.
- Slightly preload the spring.
- Make sure that the clutch is perfectly 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 specific
tool.
- Preload the clutch return spring with a traction/
rotation combined action and place the belt in the
smaller diameter rolling position.
- Remove the driven pulley /belt unit from the tool.
NOTE
DURING THE SPRING PRELOADING PHASE, BE CARE-
FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND
THE BUSHING THREADING.
NOTE
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-
METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-
TED IN CONTACT WITH THE CLUTCH.
ENG - 104

Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
020444Y011 adapter ring
020444Y009 wrench 46 x 55

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.
ENG - 105

Removing the driving pulley
- Turn the crankshaft until the ropes of the pulley

are on a horizontal axis
- Insert the adaptor sleeve of the appropriate tool

in the hole shown 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
- Remove nut «1», Belleville spring «2», and wash-
er «3».
ENG - 106

- Remove the stationary driving half-pulley.
- Detach the drive belt from the crankshaft, remove

the sliding bushing and the entire roller housing.
Inspecting the rollers case
- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inner
diameter A.
- Measure outer diameter B of the pulley sliding
bushing shown in the figure.
- Check 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 NOT LUBRICATE OR CLEAN SINTERED BUSHINGS
Characteristic
movable driving half-pulley bushing: Standard
Diameter
26.000 - 26.021 mm
ENG - 107

movable driving half-pulley bushing: Maxi-

mum allowable diameter
Ø 26.12 mm
Sliding bushing: Standard Diameter
Ø 25.959 ÷ 25.98 mm
Sliding bushing: Minimum admissible diame-
ter
Ø 25.95 mm
Roller: Standard diameter
Ø 19.5 - 20.1 mm
Roller: Minimum admissible weight
5.4 ± 0.15 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 pulley/Clutch/belt unit on the en-
gine.
ENG - 108

- Fit the steel shim in contact with the bushing and

the stationary drive pulley.
- Install the appropriate tool as described in the re-
moval phase.
-Tighten the nut with washer to the prescribed tor-
que.
Specific tooling

Drive pulley nut 75 - 83
Refitting the transmission cover
- Check 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

Transmission cover screws 11 to 13 Driven pul-
ley shaft nut 54 ÷ 60
End gear
ENG - 109

Removing the hub cover
- Empty the reduction oil through the 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.
ENG - 110

Removing the hub bearings
- Check the state of the bearings being examined (wear, clearance and noisiness). If faults are detected,
do the following.
- Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).
Specific tooling
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
020477Y 37 mm adaptor
020483Y 30 mm guide
020489Y Hub cover support stud bolt kit
ENG - 111

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.
ENG - 112

- Remove the Seeger ring indicated.
Specific tooling
020363Y 20-mm guide
- Remove the driven pulley shaft bearing using the

modular punch.
Specific tooling
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.
ENG - 113

Characteristic
Connection diameter for countershaft:
A = Ø 15 - 0.01 -0.02 mm
Connection diameter for wheel shaft:
B = Ø 25 - 0.020 -0.035 mm
C = diameter 15 - 0.01 -0.02 mm
Bearing diameter for driven pulley shaft:
D = Ø 15 - 0.01 -0.02 mm
E = 19.8 ± 0.1
F = Ø 20 - 0.01 -0.02 mm
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted.

- Check the bearing bearings.
- In case of faults, replace 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-mm side.
The 52-mm side of the adapter must be turned towards the bearing.
Specific tooling
020483Y 30 mm guide
ENG - 114

ENG - 115

Refitting the hub cover bearings
In order to fit the hub box bearings, the engine crankcase and the cover must be heated with the special
heat gun.
- The three 15-mm bearings must be fitted using the appropriate tools:
- The 42-mm side of the adapter must be turned towards the bearing.
Specific tooling
020150Y Air heater mounting
020151Y Air heater
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
ENG - 116

IF THE BEARING HAS AN ASYMMETRICAL BALL RETAINER, PLACE IT SO THAT THE BALLS
ARE VISIBLE FROM THE HUB INNER SIDE.
Specific tooling
020363Y 20-mm guide
NOTE
WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASE
PREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.
- Refit the Seeger 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 pipe is in the correct position.
- Position the shorter screw that can also be recognised from the different colour as shown in the figure.
ENG - 117

- Fix the breather tube support by means of the lower screw.

- Fit the remaining screws and tighten the seven screws to the prescribed torque.

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.
ENG - 118

- Remove the seven screws fixing the flywheel

cover.
- Remove the flywheel cover.
- 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.
ENG - 119

Refitting the stator
- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-
ers to the specified torque.

Stator fixing screws 8 to 10 Pickup fixing
screws 3 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.

Transmission cover screw 11 to 13
ENG - 120

Flywheel and starting
Removing the starter motor
- Remove the two screws indicated in the figure

- Take the 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
ENG - 121

- Undo the flywheel screw and remove the washer.

- Manually screw the nut without washer, being
careful not to leave the first threads uncovered.
CAUTION
SCREWING UP THE NUT WITHOUT WASHER HELPS PRO-

TECT THE THREAD AGAINST THE STRAIN EXERTED BY
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 control plate.
ENG - 122

Starter gear rim
See also
Intermediate gear
- Remove the flywheel cover.

- Remove the intermediate gear and take it out of
its housing.
Refitting the free wheel
- Make sure the freewheel faying surfaces are in good condition.

- Thoroughly clean the free wheel to remove LOCTITE residue.
- Degrease the threading of the holes in the free wheel and the clamping screws.
- Apply the recommended product to the end of the screws.
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 prescribed torque.

Screw fixing freewheel to flywheel 13 - 15
ENG - 123

- Oil the free wheel "rollers".
Refitting the flywheel magneto
- Remove the freewheel retaining plate indicated

in the picture
- Remove the transmission gear and the freewheel
- 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

Flywheel nut 94 - 102
ENG - 124

Refitting the starter motor
- Fit a new O-ring on the starter motor and lubricate

it.
- Fit the starter motor on the crankcase and lock
the 2 screws to the prescribed torque.

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.
ENG - 125

Removing the timing system drive
- Remove the oil pump control gear and the pinion

separation washer as described in the «Engine/
Lubrication/Oil pump» section.
- Undo the central screw and collect the washer.
Undo the two fixing screws to the cylinder and re-
move the tensioner together with the gasket.
- 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 TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
ENG - 126

Removing the cam shaft
- Undo the two indicated fixing screws to the cyl-

inder and remove the fixing plate.
- 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.
ENG - 127

Removing the cylinder head
- Undo the two screws «1» fixing the head to the

transmission-side crankcase half.
- Unscrew the four nuts «2» by loosening them in
two or three stages and in a crossed sequence.
- Remove the head.

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.
- 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 RECOGNISE THEIR ORIGINAL POSITION ON
THE HEAD.
Specific tooling
020382Y Tool to extract valve cotters
ENG - 128

- Use the specific tool to remove the valve oil seal.
Specific tooling
020306Y Punch for assembling valve seal
rings
ENG - 129

- Slide off the valve and remove the lower support.
Specific tooling
- Remove the calibrated washer and replace, if re-

quired, as indicated 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.
ENG - 130

- Remove the sealing rings, the pin and remove

the piston.
CAUTION
TO PREVENT DAMAGING THE PISTON, SUPPORT IT
WHILE REMOVING THE CYLINDER.
NOTE
BE CAREFUL NOT TO DAMAGE THE SEALING RINGS
DURING REMOVAL.
Inspecting the small end

NOTE
TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-
TER.
See also
Inspecting the wrist pin

NOTE
TER.
See also
Inspecting the piston

NOTE
TER.
See also
Inspecting the piston rings

NOTE
TER.
See also
Interventions rules
ENG - 131

Removing the piston
- Install piston and wrist pin onto the connecting

rod, aligning the piston arrow the arrow facing to-
wards the exhaust.
- Fit the pin retainer ring onto the appropriate tool

- With opening in the position indicated on the tool
S = left
D= right
- Place the wrist pin retainer ring into position using
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 union, as shown in the figure.
Specific tooling
020475Y Piston position checking tool
ENG - 132

- Using an abutment plane, reset the dial gauge

with a preload of a few millimetres.
- Finally fix the dial gauge.
- Check the perfect sliding of the feeler pin.
- Install the tool on the cylinder without changing
the dial gauge position.
- Lock the tool using the original head fixing nuts.
- Rotate the crankshaft up to the TDC (the inver-
sion point of the dial gauge rotation)
- Measure the deviation from the reset value.
- By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to
be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct 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 arrow faces the exhaust duct. The letter
is found at the centre of the piston.
- Fit the sealing rings with the word TOP or the
identification letter facing upwards. In any case,
the step must be facing opposite the piston crown.
- Sealing rings are manufactured with a cylinder
contact conical cross-section and piston gaps
must be offset by 120° in order to obtain a better
bedding.
ENG - 133

- Lubricate rings with engine oil when fitting them.
Refitting the cylinder

NOTE
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL
THE 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
ENG - 134

Inspecting the cylinder head

NOTE
TER.
See also
Inspecting the timing system components
- Check that the guide slider and the tensioner

slider are not worn out.
- Ensure that the camshaft control pulley chain as-
sembly and the 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
TER.
See also
ENG - 135

Inspecting the valves

NOTE
THE RESIDUAL STROKE OF THE INTAKE SPRINGS MUST
RANGE BETWEEN 0.8 - 1.8 MM SO THAT THERE ARE NO
RESONANCES. TO SOLVE THIS, THE SPRING IS SHIM-
MED WITH CALIBRATED WASHERS: 0.4 - 0.8 - 1.2 MM
RESIDUAL STROKE CHECK

Follow these steps to check the residual stroke:
- Fit 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
WHICH THE NEEDLE STARTS TURNING IN THE OPPOSITE SENSE.
ENG - 136

- Reset the dial gauge.
- Unscrew the stop nut of the set screw.
- Using the dial gauge measure the residual stroke

value by undoing the set screw 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
ENG - 137

RESIDUAL STROKE OVER 1.7 mm

- Replace the calibrated washer with a thicker one
so that it is within the residual stroke values.
RESIDUAL STROKE SMALLER THAN 0.9 mm
- Replace the calibrated washer with a thinner one
so that it is within the residual stroke values. -
USE LIMITS
- Replace the head if values exceed the use limits
of the residual stroke.
CAUTION
CHECK BOTH INTAKE VALVES.
ADJUST EACH TIME A VALVE OR ANY COMPONENT OF
THE VALVE RETURN MECHANISM HAS TO BE RE-
PLACED.
WHEN THE CALIBRATED WASHER IS 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
TER.
See also
- Check that the upper and lower supporting spring

washers, the cotters and the oil seal show exhibit
no signs of abnormal wear. Replace a component
when worn.
NOTE
TER.
See also
ENG - 138

Refitting the valves
- Lubricate the valve guides with engine oil.

- Place the valve spring supports on the head.
- Using the special punch, fit the four valve seal rings.
- Fit the valves, the springs and the caps. Using the appropriate 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
Inspecting the cam shaft

NOTE
ENG - 139

TER.
See also
Refitting the head and timing system components
Assemble the timing chain sprocket wheel on the

crankshaft with the chamfering facing the insertion
side and observing the position of the reference
dowel.
- Loop the timing control chain «1» around the

crankshaft.
- Fit the guide slider and the tensioner pad «2» on
the head side.
- Fit spacer «5» with fixing screw «6».
- Tighten the screws to the prescribed torque.

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 the outside of the timing
chain side and tighten them to the specified torque.
NOTE
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN USING A COM-
PRESSED AIR JET.

Timing chain tensioner support screw 11 to 13
ENG - 140

Fit the pins and rocking levers.

- Lubricate the two rocking levers through the
holes at the top.
- Lubricate the 2 bearings and insert the camshaft
in the cylinder head with the cams corresponding
to the rocking levers.
- Insert the retention plate and tighten the two
screws shown in the figure to the prescribed tor-
que.

Plate screws 4 - 6 Nm
Insert the spacer on the cam shaft.
- Rotate the engine so that the piston is at top dead
centre, using the reference marks on 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.

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, and tight the two screws to the pre-
scribed torque.
Insert the chain tensioning screw, together with the
spring and washer, tightening it to the prescribed
torque.

Tensioner screws 11 to 13 Tensioner cover 5 - 6
Nm
- Check valve clearance.
ENG - 141

Characteristic
Valve clearance
Intake: 0.10 mm Exhaust: 0.15 mm
Refitting the rocker-arms cover
- Refit the cylinder head cover and tighten the 5

clamping screws to the prescribed torque.
- Make sure the gasket is positioned properly.

Tappet cover screws 5 - 6 Nm
Refitting the intake manifold
- Fit the intake manifold and do up the three

screws.

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 - crankcase supporting surfaces.
Specific tooling
020262Y Crankcase splitting plate
ENG - 142

Characteristic
Axial crankshaft/crankcase clearance: Stand-
ard clearance
0.15 - 0.40 mm (when cold)
Axial connecting rod - crankshaft clearance
Standard clearance
0.20 to 0.50 mm
CRANKCASE OPENING
- Undo the ten crankshaft coupling screws.
- Separate the crankcase halves while 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 WHEN SEPARATING IT. IF YOU FAIL
TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY
FALL.
ENG - 143

- Remove the crankcase halves gasket and be

careful with the two alignment dowels.
- Unscrew the oil filter fitting if required.
- Once the crankcase halves have been separa-

ted, reach and remove the internal bulkhead and
the protection bulkhead for the mesh pre-filter.
Inspecting the crankshaft components

crankshaft components
NOTE
TER.
See also
Inspecting the crankshaft alignment

crankshaft alignment
NOTE
TER.
See also
ENG - 144

Inspecting the crankcase halves

crankcase halves
- Before proceeding to check the crankcase
halves, thoroughly clean all surfaces and oil ducts.
- On the transmission-side crankcase half, take
particular care when handling the oil pump com-
partment and the oil ducts, the by-pass duct, the
main bushings and the cooling jet on the trans-
mission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the piston, which regulates the oil pressure.
- On the flywheel side crankcase half, take partic-
ular care cleaning the oil ducts for the main bush-
ings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the fly-
wheel side oil seal.
- 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 bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and di-
mensions.
NOTE
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-
ER OPERATION OF THIS COMPONENT IMPROVES PIS-
TON CROWN COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-
CREASE). FAILURE OR LEAKS CAN CAUSE A CONSID-
ERABLE DROP IN THE LUBRICATION PRESSURE FOR
MAIN BUSHINGS AND CONNECTING ROD.
ENG - 145

NOTE
THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH
A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD
LUBRICATION; THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP. THE JET CLOG-
GING IMPAIRS THE HEAD LUBRICATION AND THE TIM-
ING MECHANISMS. A JET FAILURE CAUSES A DE-
CREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
Inspecting the crankshaft plain bearings

crankshaft plain bearings
- To obtain a good bushing lubrication it is neces-
sary to have both an optimal lubricating pressure
(3.2 bar) and a good oil flow rate; the bushings
must be correctly positioned so as not to obstruct
the oil supply channels.
- The main bushings 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 in the figure.
- The oil feeding channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
NOTE
TER.
See also
Coupling chart
NOTE
TER.
See also
Refitting the crankcase halves

crankcase halves
ENG - 146

- Fit the internal bulkhead and lock the two screws

to the prescribed torque.
- 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.
ENG - 147

- Lubricate the main bushings with engine oil and

insert the crankshaft in the transmission-side
crankcase half.
- Reassemble both crankcase halves.
- Fit the ten screws and tighten them to the pre-
scribed torque.
- Assemble a new O-Ring on the pre-filter and lu-
bricate it with engine oil.
- Insert the filter on the engine with the relative cap.
- Tighten to the specified torque.

Internal engine crankcase bulkhead (transmis-
sion-side half shaft) screws 4 to 6 Engine-crank-
case coupling screws 11 to 13 Oil filter on
crankcase fitting 27 to 33 Engine oil drainage
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 the picture, remove
the stud bolt from its seat.
Clean the threaded seat on the carter thoroughly.
Refit a new stud bolt and apply the special product
on the threading crankcase side.
Tighten up to the depth of the driving indicated.
Loctite Quick Set Loctite 270 high strength
threadlock
Loctite 270 high strength threadlock
ENG - 148

Lubrication
Conceptual diagrams
The high pressure circuit is highlighted in blue. The low pressure circuit is highlighted in green
The lobe pump «1» sucks in oil from the sump through the mesh pre-filter «2», pushes it into the car-
tridge filter «3»; the main bushings and the big 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 conduit and returns to the sump «8» by gravity
ENG - 149

Oil pressure check
- Remove the electrical minimum oil pressure

switch connection and remove the switch.
- Check that the oil pressure reading is between
0.5 and 1.2 atm with the engine idling at 1650 rpm
and the oil at the required temperature (wait for at
least one electric ventilation).
- Check that the oil pressure is between 3.2 and
4.2 atm with the engine running at 6000 rpm and
the oil at the required temperature.
- Remove the 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 FILTER IN PROPER
CONDITION.
Characteristic
Oil pressure
Minimum pressure admitted at 6000 rpm: 3.2 atm.

Minimum oil pressure sensor 12 to 14
Crankshaft oil seals

Crankshaft oil seals
ENG - 150

Removal
- Remove the transmission cover and the com-

plete drive pulley beforehand
- Install the base of the appropriate tool on the oil

seal using the screws provided.
Specific tooling
- Screw the threaded bar onto the base of the tool

and extract the oil seal.
Specific tooling
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 the adaptor bushing of the tool in the hole
on the crankcase.
ENG - 151

- Orientate the oil seal by inserting the bracket

which is part of the appropriate tool.
- Tighten the threaded bar onto the crankshaft as
far as it will go.
- Use the nut to move the base of the tool until you
can see the end of the oil seal driving stroke
- Remove all the tool components following the
procedure but in reverse order
CAUTION
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 TENSIONING OF THE OIL PUMP CONTROL
CHAIN.
Specific tooling
Oil pump
ENG - 152

Removal
- Undo the two clamping screws in the figure and

remove the cover over the pump control sprocket.
- Block the rotation of the oil pump control pulley

with a screwdriver inserted through one of its two
holes.
- Remove the central screw with Belleville washer,
as shown in the diagram.
- Remove the chain with the crown.
- Remove the control sprocket 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 air.
- Reassemble the rotors in the pump body, keep-
ing the two reference marks visible Replace the
retainer ring.
ENG - 153

- Check the clearance between the rotors in the

position shown in the diagram using a feeler
gauge.
Measure the distance between the outer rotor and
the pump body (see figure).
- Check the axial clearance of the rotors using a
trued bar as shown in the figure.
Characteristic
Axial rotor clearance
Limit values admitted: 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 pump cover in the position that permits the
crankcase clamping screws to be aligned.
ENG - 154

- Make sure the gasket is positioned properly and

refit the pump on the engine crankcase. The pump
can only be fitted in one position. - Tighten the
screws to the prescribed torque.
- Fit the sprocket wheel with a new O-ring.
- Fit the chain.
- Fit the central screw and the cup washer. Tighten
-Fit the oil pump cover, by tightening the two
screws 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.

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 rear brake pipes.
- Check the correct position of the three alignment

dowels «1» and remove gasket «2», spring and
by-pass piston «3».
ENG - 155

Inspecting the by-pass valve
- Check the unloaded spring length.

- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and
that it guarantees a good seal.
- If not, eliminate any impurities or replace 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.

Oil sump screws 10 to 14
ENG - 156

INDEX OF TOPICS
INJECTION INJEC

Injection SR MAX 125 ie
INJEC - 158

SR MAX 125 ie Injection
TRANSPARENCY
1 Throttle body and electronic injection control unit (MIU)
2 Fuel injector
3 Instrument panel
4 Injection load remote control
5 Water temperature sensor
6 Fuel pump
7 HV coil
8 Lambda Probe
9 Engine Speed sensor
10 Battery 12V - 12 Ah
11 Diagnostics socket connector
MIU injection system

This vehicle is fitted with an integrated injection and ignition system.
Injection is indirect in the manifold through an electro-injector.
The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the
crankshaft (24-2 teeth) and pick-up sensor.
Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further
corrections are made according to the following parameters:
- Coolant temperature.
- Intake air temperature
- Lambda probe
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 kept constant based on the ambient pressure.
The fuel supply circuit consists of:
- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
The pump, the filter and the regulator are placed inside the fuel tank on a single support.
The injector is connected by two pipes provided with quick couplings. This allows obtaining a continuous
circulation, thereby avoiding the risk of fuel boiling. The pressure regulator is situated at the end of the
circuit.
The fuel pump is controlled by the MIU control unit; this ensures safety of the vehicle.
The ignition circuit consists of:
- HV coil
- HV cable
- Shielded cap
INJEC - 159

- MIU control unit

- Spark plug
The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only
in the compression phase) at the same time.
The MIU injection-ignition system controls engine functions by means of a pre-set program.
Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to
reach a service station.
Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the
control circuits:
- Fuel pump
- HV coil
- Injector
The control unit is provided with a self-diagnosis

system connected to an indicator light in the in-
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
The MIU injection-ignition system carries out

checks on the rpm indicator and the electric fan for
radiator cooling.
The MIU control unit has a decoder for the anti-
theft immobilizer system.
The MIU control unit is connected to a diagnostic
LED on the instrument panel, that also carries out
the deterrent flashing functions.
The MIU control unit power supply is furthermore controlled by the emergency switch; that is to provide
further safety for the vehicle.
INJEC - 160

Precautions
Troubleshooting hints
1 A MIU failure is more likely to be due to the connections than to the components.
Before troubleshooting the MIU system, carry out the following checks:
A: Electrical power supply
a. Battery voltage
b. Blown fuse
c. Remote controls
d. Connectors
B: Chassis ground
C: Fuel system
a. Broken fuel pump
b. Dirty fuel filter
D: Ignition system
a. Faulty spark plug
b. Broken coil
c. Broken shielded cap
E: Intake circuit
a. Dirty air filter
b. Dirty by-pass circuit
c. Faulty Stepper motor
F: Other
a. Incorrect distribution timing
b. Wrong idle mixture
c.Incorrect reset of the throttle valve position 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 fixed by replacing the MIU control unit,
install the original control unit again and check if the fault occurs again.
4 Use a multimeter with an internal resistance of more than 10K Ohm /V when troubleshooting. Instru-
ments that are not suitable might damage the MIU central control unit. Use instruments with definitions
over 0.1V and 0.5 W , the precision must be greater than 2%.
INJEC - 161

1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not
disconnect the battery before checking for faults.
2. The fuel feed system is pressurised at 250 kPa (2.5 BAR). Before disconnecting the fast-release
fitting of the fuel supply pipe, check that there are no naked flames. Do not smoke. Act with caution to
avoid spraying fuel to your eyes.
3. When fixing electric components, operate with the battery connected only when actually required.
4. When functional checks are performed, check that the battery voltage is over 12V.
5. Before trying to start the vehicle, check to make sure there is at least two litres of fuel in the tank.
Failure to respect this norm will damage the fuel pump.
6. If the vehicle is expected to remain unused for a long time, refill the tank up to a little over half the
level. This will ensure the pump will be covered 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.
10. Do not invert the polarity when fitting the battery.
11. To avoid damage, only disconnect and reconnect the MIU system connectors if required. Before
reconnecting, check that the connectors are dry.
12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not
take measurements not specifically foreseen by the manual.
13. At the end of every check performed with the diagnostic tester, protect the system connector with
its cap. Failure to observe this precaution may damage the MIU control unit.
14. Before reconnecting the quick couplers of the power supply system, check that the terminals are
perfectly clean.
INJEC - 162

Terminals setup
TERMINAL LAYOUT
1 Injection telltale light
2 Rpm indicator
3 -
4 - Lambda probe
5 + battery under permanent power supply
6 + Battery
7 Immobilizer aerial
8 Electric fan remote control
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 -
21 -
22 HV coil
23 -
24 Start up enabling
25 -
26 Ground lead
INJEC - 163

EMS circuit diagram
LEGENDA
6. Massa motore
49. Diagnostica
INJEC - 164


56. Sonda lambda
57. Bobina a.t.
59. Decoder
60. Antenna
61. Pompa acqua
Troubleshooting procedure
Engine does not start
ENGINE DOES NOT START IF ONLY PULLED

Immobiliser enabling signal System not encoded
System not efficient, repair according to the indications of the
self-diagnosis
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution 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

HV coil
Injector
Air temperature
Coolant temperature
Starter speed Starter motor and solenoid
Battery
Ground connections
End of compression pressure End of compression pressure
Power to the spark plug Spark plug
Shielded cap
HV coil
INJEC - 165


Speed-timing sensor
Ignition advance
Fuel system Fuel pressure (low)
Injector capacity (low)
Injector sealing (poor)
Correctness of the parameters Coolant temperature
Stepper throttle valve position intake air temperature (steps
and actual opening)
Cleaning of the auxiliary air pipe and throttle valve; air filter ef-
ficiency
Engine stops at idle
ENGINE DOES NOT IDLE/ IDLING IS UNSTABLE/ IDLING TOO LOW

HV coil
Injector
Air temperature
Coolant temperature
Ignition efficiency Spark plug
Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air 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

HV coil
Injector
Air temperature
Coolant temperature
Ignition efficiency Ignition timing
Stepper
Intake sleeve
Filter box
Pressure regulator
Fuel filter
Injector capacity
INJEC - 166

Exhaust backfires in deceleration
EXHAUST BACKFIRES WHEN DECELERATING

HV coil
Injector
Air temperature
Coolant temperature
Lambda probe
Stepper
Intake sleeve
Filter box
Pressure regulator
Fuel filter
Injector capacity
Exhaust system sealing (infiltrations) Manifold - head
Manifold - silencer
silencer welding
Engine revs irregularly
ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN

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
TPS reset successful TPS reset successful
HV coil
Injector
Air temperature
Coolant temperature
Lambda probe
Poor performance at full throttle
POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM-

ANCE ON PICKUP
HV coil
Injector
INJEC - 167


Air temperature
Coolant temperature
Lambda probe
Spark plug power supply Spark plug
Shielded cap
HV cable
HV coil
Intake system Air filter
Filter box (sealing)
Intake sleeve (sealing)
Ignition advance
Fuel system Fuel level in the tank
Fuel pressure
Fuel filter
Injector capacity
Engine knocking
PRESENCE OF KNOCKING (COMBUSTION SHOCKS)

HV coil
Injector
Air temperature
Coolant temperature
Lambda probe
Ignition efficiency Spark plug
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 the cylinder base gasket thickness
Fuel supply system
The fuel system circuit includes the electric pump, the filter, the pressure regulator, the electro-injector
and the fuel delivery pipes.
The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through
the filter.
The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.
INJEC - 168

Removing 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.
INJEC - 169

Remove the injector connector.
Remove the 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.
INJEC - 170

Remove the gas command fitting as indicated in

the picture
Refitting the 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
INJEC - 171

INJECTION LOADS
2 Fuse 10 A
3 Fuse 15 A
4 Ignition key contacts
5 Fuse 7.5 A
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda Probe
When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When 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 iniezione.
Verificare l'efficienza del fusibile N° 8 da 7,5 A ali-
mentazione centralina da chiave.
INJEC - 172

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.
Check the power supply line of the injection load

remote control energising 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 CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (REMOTE CONTROLS,
ELECTRONIC CONTROL UNIT, FUSES, ETC.).
INJEC - 173

INJEC - 174

Verificare la presenza di tensione fissa tra cavetto

Rosso-Blu dello zoccolo teleruttore e massa. In
caso contrario verificare la continuità del cavetto
Rosso-Blu tra scatola portafusibili (N° 5 10 A) e lo
zoccolo teleruttore.
NOTE
pump circuit 6
Check, on switching to "ON", 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
ground.
If, when switching to "ON", the pump continues to
turn after two seconds of activation, check, with the
control unit disconnected and the injection load re-
INJEC - 175

mote control disconnected, that the Black-Purple

cable (pin 20 on the interface wiring) is insulated
from the ground.
Specific tooling
Circuit leak test
Install the appropriate tool for fuel pressure control

with the pipe fitted with the pressure gauge on the
delivery pipe..
Check during regular operation by placing the ap-

propriate tool between the pump and the injector.
With the battery voltage> 12 V check 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 pliers, choke the fuel pipe making the pressure stabilise at approx. 2.5 BAR.
Check that within 15 seconds the pump has a flow rate of approx. 110 cm³.
Specific tooling
INJEC - 176

Fuel filter check
Disconnect the terminals 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.
INJEC - 177

Remove the filter from the pump mounting
Inspecting the injector circuit
INJECTION LOADS
2 Fuse 10 A
3 Fuse 15 A
5 Fuse 7.5 A
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda Probe
Checking the resistance at the injector ends: 14.5 ± 5% Ohm
INJEC - 178


ichi iniezione.

INJEC - 179


NOTE
INJEC - 180


NOTE
INJEC - 181

With the control unit and the injector disconnected,

check the continuity of the Red-Yellow cable be-
tween pin 14 of the interface wiring and the injector
connector
Switch 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.
INJEC - 182

Inspecting the injector hydraulics
To carry out the injector check, remove the intake

manifold by removing the three clamping screws
at the head and the clip connecting the control unit
to the manifold.
Install the appropriate tool for checking fuel pres-

sure and position the manifold over a container
graduated by at least 100 cm³. Connect the injec-
tor with the cable making up part of the supply 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 cm³ of fuel is dis-
pensed with an adjustment pressure of approxi-
mately 2.5 BAR.
Specific tooling
Proceed with the injector seal test.

Dry the injector outlet with a blast of compressed
air. Activate the fuel pump. Wait for one minute,
making sure there are no leaks coming from the
injector. Slight oozing is normal.
Value limit = 1 drop per minute
INJEC - 183

Components location
INJEC - 184

TRANSPARENCY
1 Throttle body and electronic injection control unit (MIU)
2 Fuel injector
3 Instrument panel
6 Fuel pump
7 HV coil
8 Lambda Probe
9 Engine Speed sensor
11 Diagnostics socket 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 that the voltage between
pins 13 and 15 is around 2.8 V
INJEC - 185

With the interface cabling disconnected from the

control unit, check for continuity between pin 13
and the red cable of the rev sensor connector and
between pin 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
INJEC - 186

HT coil
INJECTION LOADS
2 Fuse 10 A
3 Fuse 15 A
5 Fuse 7.5 A
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda Probe
The combined ignition/injection system is a high-efficiency induction system.

The control unit manages two significant 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 recognises the 4-stroke cycle so ignition is only commanded in the compression
phase.
Specific tooling
INJEC - 187


ichi iniezione.

INJEC - 188


NOTE
INJEC - 189


NOTE
INJEC - 190

Check there is voltage between pins 22 and 26 of

the interface wiring for around two seconds when
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
INJEC - 191

TEMPERATURE SENSOR 1
2 engine stop switch
With the control unit side connector disconnected

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
INJEC - 192

Zeroing the throttle
Resetting the throttle valve position signal (TPS reset)

The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated.
Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of
air under pre-set reference conditions.
Pre-calibration ensures optimal air flow to control idling.
This regulation must not be tampered with in any way whatsoever.
The injection system will complete the management of the idling through the Stepper motor and the
variation of the ignition advance.
The throttle body after the pre-calibration has an opened 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
match the throttle body with the control unit following the procedure known as TPS resetting.
With this operation we inform the control unit, as the starting point, of the mV value corresponding to
the pre-calibrated position.
To reset, proceed as follows.
Connect the diagnostic tester.

Switch to «ON».
Select the functions of the diagnostic tester on «TPS RESET».
Specific tooling
INJEC - 193

Make sure that the throttle valve with the control is

supporting the stop screw.
Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure.
Reset should be performed in the following cases:

- on first fitting.
- if the injection control unit is replaced.
NOTE
THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY
BECAUSE POSSIBLE VALVE WEAR 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 electric fan
switches on.
Use an analogue multimeter with a direct voltage
scale measuring down to 2 V.
Place the tips of the multimeter between pins 4 (-)
and 11 (+)
INJEC - 194

With the engine running at idle speed, check that

the voltage oscillates between 0V and 1V
With the throttle valve completely open, the volt-
age is approx. 1V.
During the closing phase, the voltage is approx.
0V.
If the voltage remains constant, the sensor may be
damaged. Remove the sensor and check that
there are no oil or carbon deposits inside it..
INJECTION LOADS
2 Fuse 10 A
3 Fuse 15 A
5 Fuse 7.5 A
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda Probe
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 the ON/OFF type, i.e. whether
there is oxygen or not. The probe is positioned on the exhaust manifold before the catalytic converter
INJEC - 195

in an area where the gas temperature is always high. The temperature at which the probe works is at
least 350°C at 600°C and it has a reaction time of just 50 milliseconds. The signal generated passes
from a high value to a low one with a mixture with lambda =1. Since the probe only works at high
temperatures, it has an electric preheating element inside, controlled by the control unit, to make it start
operating quickly.
Specific tooling
020481Y Control unit interface wiring

ichi iniezione.

INJEC - 196


NOTE
INJEC - 197


NOTE
INJEC - 198

INJEC - 199

INDEX OF TOPICS
SUSPENSIONS SUSP

SR MAX 125 ie Suspensions
This section is dedicated to operations that can be carried out on the suspensions.
Front
Removing the front wheel
- Remove the fixing nut from the wheel axle on the

left side 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.
SUSP - 201

Suspensions SR MAX 125 ie
- Support the front wheel with two wooden shims

that make it possible to avoid scratching in the
case of contact with the rim.
- Insert the punch (consisting of adaptor handle,
24 mm adaptor and 15 mm guide) from the brake
disc side to permit the removal of the opposite side
bearing and the spacer bushing.
Specific tooling
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.
SUSP - 202

- Reinsert the spacer bushing on the brake disc

side using the appropriate tool and take it to the
stop.
Specific tooling
020412Y 15-mm guide
020201Y Spacer bushing driving tube
- Refit the cap and tighten the five fixing screws.
SUSP - 203

- Turn over the wheel and insert the internal spacer

with the part fitted with the Seeger ring facing the
bearing on the brake disc side.
- Heat the bearing seat on the side the brake disc

with the heat gun.
2 - Insert the two bearings 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
020412Y 15-mm guide
Refitting the front wheel
- When refitting, pay attention in repositioning the

odometer drive correctly.

Wheel axle nut 45 to 50 Wheel axle clamp
screws 6 - 7 Nm
Handlebar
SUSP - 204

Removal
• Remove the two handlebar covers as

explained in the Bodywork Chapter.
• Remove the handlebar wiring fixing
clips and disconnect the electric con-
nectors from the brake levers.
• Unscrew the fittings, then remove the

front and rear brake pump piping.
• Remove the flexible transmission of
the accelerator and remove the throt-
tle.
• Loosen the clamp fixing 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 reverse order from that used for removal.

Handlebar fixing screw (*) 43 ÷ 47
Front fork
Removal
See also
SUSP - 205

Overhaul
- Support the fork in a vice.

- Loosen the two tightening screws of the stem
supporting clamp.
- Unscrew the stem closing cap and slide off the
complete fork leg from the corresponding support.
CAUTION
THE STEM CLOSING 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.
SUSP - 206

- Remove the stem dust guard with a screwdriver.
- Remove the circlip retaining 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
SUSP - 207

- Take out the oil seal using the appropriate tools.

- Fit the tie rod into the oil seal.
- Insert in sequence the two half-rings per Ø 35-
mm stems.
Specific tooling
020487Y Fork oil seal extractor
- Hold the tie rod manually so that it 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.
SUSP - 208

- Check that the fork leg is not cracked or broken

in the attachments.
- Check that the stem is not scored, dented or dis-
torted.
- Check that 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.
SUSP - 209

- Check that the closing cap O-ring of the stem is

in good conditions.
Refitting
- First grease the splitting chamber of the two seal-

ing lips of a new oil seal.
- Fit the sealing ring on the stem and keep the
identification words facing upwards.
- Drive the oil seal as far as it will go using the ap-
propriate tool.
Specific tooling
- 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.

Hydraulic rod fixing screw 25 ÷ 35*
(°) Apply LOCTITE 243 threadlock
SUSP - 210

- Lock hydraulic rod rotation using a 19-mm hex-

agonal spanner.
- Fit the oil seal retaining circlip.
- Grease 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.

Stem support clamp tightening screws 20 to 25
SUSP - 211

- Refill the fork leg with the recommended product

to the prescribed amount.
AGIP FORK 7.5 W Oil for fork.
-
Characteristic
Oil quantity per stem
133 ± 3 cm³
- Bleed the hydraulic rod by actuating the stem re-

peatedly.
- Fit the spring into 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

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 WITH THE LEFT ONE.
SUSP - 212

Steering column
Removal
- Remove the front wheel.

- Remove the front mudguard
- Remove the front brake calliper
- Remove the shield back plate upper side.
- Remove the pin mounting the handlebar to the
steering tube.
- Remove the handlebar and rest it on the shield
back plate.
- 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
SUSP - 213

Refitting
- Fit the lower steering bearing on the steering

tube.
- Fit the fork together with the lower steering bear-
ing on the headstock and hold it so that it does not
fall.
NOTE
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.
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.
SUSP - 214

- Fit the cover plate.
- Insert the spacer.
- Insert the lower tightening ring nut, screw until it

stops and, with the specific tool, tighten to the pre-
scribed torque.
Specific tooling

Steering tube lower ring nut 14 ÷ 17
SUSP - 215

- Fit the spacer between the two ring nuts on the

steering tube in the position indicated.
- Insert the upper tightening ring nut, screw until it

stops and, with the specific tool, tighten to the in-
dicated torque.
Specific tooling

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
SUSP - 216

Removal
- Clean thoroughly and visually inspect if the com-

ponents are in good conditions.
- Check the upper steering bearing for wear.
- Check the lower steering bearing for wear.
- Visually inspect that the steering fifth wheel

tracks, the headstock and the steering tube exhibit
no scores or abnormal wear. Otherwise, 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 tooling
from headstock
SUSP - 217

- Repeat the procedure for the lower steering bearing track.
- Remove the lower steering bearing seat on the

steering tube using the specific tool.
Specific tooling
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.
SUSP - 218

NOTE
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH RECOMMENDED GREASE BEFORE
USE.
Specific tooling
001330Y Tool for fitting steering seats
AGIP GREASE PV2 Ivory smooth-textured, slightly-stringy anhydrous calcium-base grease.
SUSP - 219

SUSP - 220

- Fit the lower fifth wheel seat on the steering tube.

- Using the specific tool, fit the lower fifth wheel
seat on the steering tube.
NOTE
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.
Specific tooling
020459Y Punch for fitting bearing on steering
tube
AGIP GREASE PV2 Ivory smooth-textured,
slightly-stringy anhydrous calcium-base
grease.
Rear
Removing the rear wheel
- Remove the mudflap undoing the four screws.

- Remove the exhaust silencer.
- Remove the cotter pin.
SUSP - 221

- Remove the cap.
- Unscrew the wheel 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.
SUSP - 222

- Undo the five wheel fixing screws and collect the

wheel.
Refitting the rear wheel
To fit, follow the removal procedure but in reverse order.

Silencer arm clamping screws 27 - 30 Rear wheel axle 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
SUSP - 223

- Remove the buffer cover undoing the screws in-

dicated .
- Remove the clamp by undoing the screw indica-

ted..
- Unscrew the two«A» 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.
SUSP - 224

Overhaul
- Make sure the silent bloc is not broken. If it is,

replace the coupling.
- Remove the Seeger ring shown in the picture
- Remove the full 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
SUSP - 225

- Install a new silent bloc, making sure it aligns

properly with the reference tooth.
- Fit the silent blocs, making sure the chamfered
part of the silent bloc matches the chamfered part
of the bracket
- Using the appropriate tool, fit the silent bloc as

shown in the picture
- Check there is no sticking in the movement of the

connection of the swinging arm on the 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
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. Alternatively,
use two washers with 12-mm inside diameter for
pins, minimum 30-mm outside diameter and 4-mm
thick at least.
SUSP - 226

- Check there is no sticking in the rotation.

- Check the axial clearance of the swinging arm on
the chassis side
Characteristic
Standard clearance
0.40 - 0.60 mm
1.5 mm
- Separate the swinging arm on the engine side

from the vehicle side arm.
- Remove the plastic bushings and 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 internal swinging arm spacer on
the engine side:
L 183 + 0.3 0
SUSP - 227

Engine side swinging arm plastic bushing

shim:
3.5 ± 0.05 mm
Chassis side swinging arm plastic bushing
shim:
3.5 ± 0.05 mm
Length of the internal swinging arm spacer on
the frame side:
290 ± 0.1 mm
Length of the swinging arm tube on the chas-
sis side:
283 ± 0.1 mm
- Lubricate roller casings and the plastic bushings with grease

- Insert the spacers
- Assemble the two arms with the relative bolt in the position shown in the 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
AGIP GREASE PV2 Ivory smooth-textured, slightly-stringy anhydrous calcium-base grease.
Refitting
- To refit, perform the removal operations in reverse.

- Grease the bearings and the rolling parts with the recommended grease.
-Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque.
See also
Shock absorbers
SUSP - 228

Removal
Proceed as follows:
- place the vehicle on its centre stand;
- lift the engine a little with a jack so as to free the
two shock absorbers;
- remove the silencer
- undo the shock absorber spring assembly clamp-
ing screw from the support fixed to the engine on
the one side and from that fixed to the silencer on
the other;
- unscrew the two upper nuts (one on each side)
fixing the shock absorber spring assembly to the
frame and remove the shock absorbers.
Refitting
Carry out the previous operations but in reverse order.

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 the right side.
- Remove the centre stand.
FITTING
- On refitting tighten the nut to the specified torque.

Centre stand bolt 32 to 40
SUSP - 229

Side stand
REMOVAL
- Uncouple the centre stand 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.

Side stand fixing bolt 35 to 40
SUSP - 230

INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

Braking system SR MAX 125 ie
This section è is dedicated to the description of the brake system components.
Rear brake calliper
Removal
- Remove the rear wheel.

- Remove the two rear brake calliper devices fas-
tening them to the support as shown in the picture.
NOTE
IF IT IS NECESSARY TO REPLACE OR SERVICE 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 screw

shown in the photograph.
BRAK SYS - 232

SR MAX 125 ie Braking system
- Remove the internal parts from the floating body

with short blasts of compressed air through the
brake liquid pipe to facilitate expelling the plung-
ers.
- Check:
• that the plates and the body are whole

and in good condition;
• that the cylinders of the calliper floating
body do not show signs of scratches or
erosion, otherwise replace the entire
calliper:
• that the guides of the fixed 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» correctly as
indicated in the photo.
- Fit the pad retention spring

- Fit the pads and screw up the relative clamping screws to the specified torque
BRAK SYS - 233

- 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

- 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.
BRAK SYS - 234

- Remove the internal parts from the floating body

with short blasts of compressed air through the
brake liquid pipe to facilitate expelling the plung-
ers.
- Check:
• that the plates and the body are whole

and in good condition;
• that the cylinders of the calliper floating
body do not show signs of scratches or
erosion, otherwise replace the entire
calliper:
• that the guides of the fixed 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» correctly as
indicated in the photo.
- Fit the pad retention spring

- Fit the pads and screw up the relative clamping screws to the specified torque
BRAK SYS - 235

- 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.
Rear brake disc
Removal
- Remove the rear wheel.

- 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.

Brake disc fixing screw 5 to 6.5
Disc Inspection
- Remove the rear brake calliper.
BRAK SYS - 236

- Check the disc thickness with a micrometer
Characteristic
Standard thickness:
5 +0.2-0.1 mm
- Repeat the measurement at no fewer than six points on the disc.

- Check the regular nature of the rotation of the brake disc assembly using the appropriate tool fixed
onto the brake calliper as shown in the photo.
- In order to be able to anchor the appropriate tool properly 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
Characteristic
Max. deviation allowed:
0.1 mm
- If you detect incorrect values, replace the disc. If

the anomaly persists, replace the hub.
Front brake disc
BRAK SYS - 237

Removal
- Remove the front wheel.

- Undo the five clamping screws shown in the pho-
tograph
Refitting
For fitting, position the disc correctly using the arrow stamped on it as reference.
- Do up the screws to the prescribed torque and apply the recommended product
NOTE
THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED
TOWARDS THE OUTSIDE OF THE VEHICLE.

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 disc thickness
4.0 mm
Disc thickness at wear limit (front)
3.5 mm
BRAK SYS - 238

• Using the appropriate tool, measure

how much the disc protrudes when the
wheel is fitted properly. The protrusion,
measured near the external edge of
the disc, must be less than 0.1 mm.
• If a value is measured other than the
specified value, remove the front wheel
(Front/Rear Suspension chapter) and
check the protrusion of the disc. Maxi-
mum permissible 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
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 careful with the pad
spring clamp.
- Check the thickness of the pads.
Characteristic
Minimum value
1.5 mm
BRAK SYS - 239

See also
Refitting
To fit, proceed as follows:

- Insert the two pads in the callipers.
- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening 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.

Screw tightening calliper to support 24 to 27 Pad fastening pin 19.6 ÷ 24.5
Rear brake pads
BRAK SYS - 240

Removal
Proceed as follows:
- Remove the rear brake calliper.
- Loosen 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:
BRAK SYS - 241

- Insert the two pads in the callipers.

- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening 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.

Screw tightening calliper to support 24 to 27 Pad fastening pin 19.6 ÷ 24.5
Fill - Bleeding the braking system
Rear - combined
- Remove the rubber cap from the bleed screw.

- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the left-had brake lever, load the system and
bring it up to the required pressure.
- 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 vacuum pump
NOTE
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK 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

System bleed calliper fitting: 12 ÷ 16 Nm
BRAK SYS - 242

Front
- Remove the rubber cap from the bleed screw.

- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the right-hand brake lever, load the system
and bring it up to the required pressure.
- Keeping the right-hand brake lever pulled, loosen
the bleed screw to purge the air. 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 vacuum pump
NOTE
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK 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

System bleed calliper fitting: 12 ÷ 16 Nm
Front brake pump
Removal
The procedure is valid for both brake pumps.

- Remove the front and rear handlebar covers.
- Place a suitable container to collect the oil, dis-
connect the oil pipe from the calliper and operate
the brake lever until no more oil comes out.
- Disconnect the oil pipe «A» from the pump, then
unscrew the two retainers «B» from the U-bolt and
remove the pump.
- Upon refitting, tighten up the fitting to the speci-
fied torque and bleed the system.
BRAK SYS - 243


Brake fluid pump-hose fitting 16 - 20
BRAK SYS - 244

INDEX OF TOPICS
COOLING SYSTEM COOL SYS

Cooling system SR MAX 125 ie
Circuit diagram
Key
A = entering the engine (cold)
B = electric pump
C = thermostat with by-pass
D = leaving the engine (hot)
E = radiator
F = expansion tank
This is a forced circulation cooling system, with continuous purging and air pressurisation. Circulation
takes place by means of an electric centrifugal pump which sends 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:
~2l
TECHNICAL SPECIFICATIONS
Cooling system capacity: ~2l
COOL SYS - 246

SR MAX 125 ie Cooling system
Recommended fluid AGIP PERMANENT SPEZIAL (ready for use)
Sealing pressure Cap calibrated at 0.9 bar
THERMOSTAT
Type Wax-type, with deviator
Starts opening at 85 ± 2°C
ELECTRIC VENTILATION
Electric ventilation starts at 100° C
Electric ventilation stops at 90° C
WATER PUMP
Type Centrifugal
Control Electric, commanded by the control unit
RADIATOR
Type Aluminium, with horizontal circulation
EXPANSION TANK
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 commu-
nication hole is revealed with the head as shown
in the picture
- Wait until only coolant comes out of the rubber
pipe so as to eliminate any air bubbles inside the
circuit.
- Tighten the bleed valve respecting the maximum
torque.
- Bring the coolant up to the correct level inside the
expansion tank
COOL SYS - 247

Cooling system SR MAX 125 ie
Bleed screw 3
COOL SYS - 248

INDEX OF TOPICS
CHASSIS CHAS

Chassis SR MAX 125 ie
This section è is dedicated to the operations that can be carried out on the vehicle's bodywork.
Seat
Lift the saddle to remove it:

- Push and turn the ignition lock key anticlockwise
until it clicks.
- Lift the saddle.
- Remove the control button 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 PLASTIC.
CHAS - 250

SR MAX 125 ie Chassis
Instrument panel
- Remove the instrument panel.

- Loosen the five fixing nuts of the instrument pan-
el.
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».
CHAS - 251

Headlight assy.
The front headlight assembly has two units, the
procedure for both is the following:
- Remove the front lower frame (see FRONT
SHIELD).
- To remove the right headlight assembly undo the
two screws «A».
- To remove the left headlight assembly undo the
two screws «B».
- To remove the right assembly, remove the screw

located in the coolant 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 central cover has a central tunnel and two side fairings, the procedure is the following:
CENTRAL TUNNEL:
CHAS - 252

- Remove the saddle together with the hinge.
- Open the fuel tank flap.

- Unscrew the 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.
CHAS - 253

- Undo from both sides the screw indicated in the

figure.
- Remove the central tunnel sliding it from the
tongues.
SIDE FAIRING:
- Remove the side fairings.
- Remove the 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.
CHAS - 254

- Undo and remove the screw under the badge.
- Undo and remove the screw «A».
- Taking care not to damage the plastic 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.
CHAS - 255

FRONT TURN INDICATORS:

- Undo and remove the three screws indicated.
- Disconnect the front turn indicator connector.

- Undo and remove the three screws to remove the
bulb holder 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».
CHAS - 256

- Undo the central screw.
- Undo the rider footrest fixing screw «C» and the

spoiler fixing screw «D».
- Remove the front shield releasing the different
cable harness from the clamps.
To refit follow 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.
CHAS - 257

- Undo and remove the two screws «A».
- Working from 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.
CHAS - 258

- Undo and remove the expansion tank cap and

the gasket below.
- Remove the instrument panel and release the in-

strument panel connector «E» and the instrument
panel lighting 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).

move the two screws «A».
- Turn the key switch frame anticlockwise (it may

be necessary to use pliers), releasing the catch.
CHAS - 259

Removing the ignition key-switch when on *off*
- Remove the lower shield back plate.

- Unscrew the seat opening transmission from the
side.
- Remove in advance the ring of the immobiliser
antenna.
- Undo the two hexagonal male screws and re-
move the complete switch.
- From the bottom, it is possible to remove the

three fixing screws and to release the two hook
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 the
two lower retainers of the wheel housing.
- Remove the upper fixing screw of the wheel

housing to permit movement.
CHAS - 260

- In order to remove the wheel housing it is necessary to remove the front brake hose to the tank and
combination with the splitter.
Taillight assy.
To remove the rear light assembly, proceed as fol-

lows:
- Remove the rear upper central cover.
- Remove the handgrips and the upper side fair-
ings.
- Undo and remove the central screw.
- Using a jointed wrench 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:
PASSENGER FOOTREST:
- Unscrew the nut «A» from both vehicle sides and
release the footrests.
CHAS - 261

RIGHT AND LEFT FOOTREST:

- Working from both vehicle sides, remove the mat.
- Undo and remove the two screws «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.
CHAS - 262

Side fairings
- Remove 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.
CHAS - 263

- Remove the three screws indicated in the figure.
License plate holder
- Remove the rear lower central cover.

- Remove the four fixing screws (two per side) 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.
CHAS - 264

- Release the oil recovery pipe releasing the

clamp.
- Undo the 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».
CHAS - 265

- From the left side of the vehicle, undo the two

screws «B».
- Remove the rear mudguard.
Helmet bay
To remove the helmet compartment, proceed as follows:

- Remove the saddle.
- Remove the battery.
- Remove the rear upper central cover.
- Remove the handgrips and top side fairings.
- 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 the complete helmet compartment.
CHAS - 266

spoiler
To remove the spoiler, proceed as follows:

- Remove the footrest.
- Working from both vehicle sides, undo the two

fixing screws «A» with the front wheel housing.
- Working from both vehicle sides, undo the fixing

screw «B» with the front shield.

screw «C» with the chassis.

screw «D» with footrest chassis support.
- Slide off the spoiler from the bottom trying not to
touch the side stand.
CHAS - 267

Front mudguard

Slide the mudguard to the front part of the vehicle.
CAUTION
WHEN REFITTING PAY ATTENTION TO THE CORRECT
POSITION OF THE PIPE RETAINING STRAPS.
Fuel tank
To remove the fuel tank, proceed as follows:

NOTE
THIS OPERATION SHOULD PREFERABLY BE PERFORMED WITH THE TANK EMPTY.
- Remove the central frame cover.
- Remove the footrest.
- Remove the horn plate support bracket and the

voltage regulator unscrewing the two nuts shown
in the figure.
- Disconnect the fuel probe connector.
CHAS - 268

- Undo the two tank fixing screws.

- Remove the tank through the front lower 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.
CHAS - 269

Radiator fan

- 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 the
two lower retainers of the wheel housing.
- Remove the upper fixing screw of the wheel

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.
- Disconnect the expansion tank pipes.
CHAS - 270

- Remove it from the retaining seat.
Handles and top side fairings

- Remove the rear central cover.
- Working from both sides, undo the screw «A».
- Working from both sides, undo the three screws

«B».
- Remove the upper side fairings.
CHAS - 271

Flyscreen
- Remove the three hex. socket head screws, then

remove the windshield together with the rubber
rings.
To remove the windshield supports, proceed as

follows:
- Remove the caps and the gaskets on the two
windshield supports.
- Remove the FRONT UPPER FRAME.

- 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.
CHAS - 272

Battery
- Remove the elastic strap and the battery cover.
- First disconnect the negative terminal «A», then

the positive terminal «B».
- Remove the battery.
CHAS - 273

INDEX OF TOPICS
PRE-DELIVERY PRE DE

SR MAX 125 ie Pre-delivery
Carry out the listed tests before delivering the vehicle.

Warning - Handle fuel with care.
Aesthetic inspection
Appearance check:
- Paintwork
- Fitting of plastics
- Scratches
- Dirt
Tightening torques inspection

Lock check
- Safety locks
- Fixing screws
Safety locks
Rear shock absorber upper fixing
Rear shock absorber lower fixing
Lower front shock absorber fitting
Front wheel axle nut
Front wheel screws
Rear wheel screws
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 currently in force
• Front and rear stop light buttons and relative light •Turn indicators and relative telltales
• Instrument lighting
• instruments: fuel and temperature indicator
PRE DE - 275

Pre-delivery SR MAX 125 ie
•Instrument panel lights

• Horn
• Electrical start up
• Engine stopping with emergency stop switch
• electric saddle opening button
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR
ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF IT 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 FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
Level check:
- Hydraulic brake system liquid level.
- Rear hub oil level
- Engine coolant level
- Engine oil level
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
PRE DE - 276

SR MAX 125 ie Pre-delivery
- Abnormal noise
Static test
Static control after the test ride:

• Hot engine restart
• Minimum seal (turning the handlebar)
• Uniform steering rotation
• Possible losses
• electric radiator fan operation
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
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 any accessory fitting
PRE DE - 277

A
Accessories: 61
Air filter: 39, 264
B
Battery: 59, 77, 78, 273
Brake: 232, 234, 236, 237, 239, 240, 243
Brake calliper: 232, 234
Brake disc: 236, 237
Brake pads: 239, 240
Brake pump: 243
Bulbs:
C
Clutch: 47, 95–97, 103, 104
Coil: 187
Connectors: 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 plate holder: 264

M
Maintenance: 7, 37
Mudguard: 265, 268
O
Oil filter: 42
Oil sump: 155, 156
R
Radiator: 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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SERVICE STATION MANUAL

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THE VALUE OF SERVICE

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ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

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This section describes the general specifications of the vehicle.

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To read the chassis prefix, lift the saddle and re-

The engine prefix «B» is stamped near the rear left

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Dimensions and mass

WEIGHTS AND DIMENSIONS

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Frame and suspensions

CHASSIS AND SUSPENSIONS

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Wheels and tyres

WHEELS AND TYRES

Cylinder - piston assy.

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ENGINE COUPLING CATEGORIES

- Calculate the coupling clearance between pin

- Measure the diameter of the bearings on the pis-

- Calculate the piston pin coupling clearance.

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- Check that coating is free from flakes.

Check the size of the sealing ring opening:

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Crankcase - crankshaft - connecting rod

- Measure the diameter of bushings «A» in the

CRANKCASE - CRANKSHAFT COUPLING / CRANKSHAFT HALF-BEARINGS

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CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

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THE CRANKSHAFT is available in two CATEGO-

CRANKSHAFT CATEGORY IDENTIFICATION:

- Using a trued bar and a feeler gauge check that

- In case of faults, replace the head.

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- Insert the valves into the cylinder head.

Measure the camshaft bearing seats and rocking

- Measure the unloaded spring length.

- Clean the valve seats of any carbon residues.

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- In case of excessive wear or damage, replace the head.

STANDARD VALVE LENGTH

MINIMUM ADMISSIBLE DIAMETER

- Calculate the clearance between valve and valve

- Check the deviation of the valve stem by resting

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- Check the concentricity of the valve head by ar-

Measure the valve guide.

- After measuring the valve guide diameter and the