Aprilia Sr Motard 125 4t Workshop Repair Service Manual

1. SERVICE STATION MANUAL
677206(EN)
Sr Motard 125 4T

2. SERVICE STATION
MANUAL
Sr Motard 125 4T
IL VALORE DELL'ASSISTENZA
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© Copyright 2012 Aprilia. Tutti i diritti sono riservati. Vietata la riproduzione anche parziale. Aprilia -
After sales service.
Il marchio Aprilia è di proprietà di Piaggio & C. S.p.A.

3. SERVICE STATION MANUAL
Sr Motard 125 4T
This manual provides the main information to carry out regular maintenance operations on your vehicle.
This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been
deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, Piaggio & C. S.p.a. commits itself
to continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all Aprilia Sales Outlets and its International
Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of
need or further queries on repair and check procedures, consult Aprilia CUSTOMER DEPARTMENT,
which will be prepared to provide any information on the subject and any further communications on
updates and technical changes related to the vehicle
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee

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6. INDEX OF TOPICS
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
PRE-DELIVERY PRE DE
TIME TIME

7. INDEX OF TOPICS
CHARACTERISTICS CHAR

8. Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec-
tions.
Sr Motard 125 4T Characteristics
CHAR - 7

9. Vehicle identification
Prefisso Telaio LBMM701
Prefisso Motore M701M
Dimensions and mass
Characteristics Sr Motard 125 4T
CHAR - 8

10. WEIGHTS AND DIMENSIONS
Specification Desc./Quantity
Maximum length 1947
Overall width 730
Max. height to the windshield 1130 mm
Wheelbase 1355
Kerb weight 117 kg
Engine
ENGINE
Specification Desc./Quantity
Engine Single cylinder 4-stroke
Timing system Single overhead camshaft (SOHC) with 2 valves
Valve clearance intake 0.10
exhaust 0.15
Bore x stroke 57 x 48.6 mm
Engine capacity 124 cm³
Compression ratio (10.6+/-0.5):1
carburettor KEIHIN CVEK26
Engine idle speed approx. 1,600 - 1,800 rpm
Electric Electric starter
Max power to the shaft 10.5 CV at 8000 rpm
Cooling Forced-circulation air cooling.
Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission With continuously variable expandable pulley transmission
with torque server, V belt, automatic clutch, gear reduction unit
and transmission housing with forced air circulation cooling.
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil 1.10 l
Rear hub oil approx. 250 cc
Fuel tank capacity ~ 7.0 litres (2.0 l of which is reserve)
Fork stem (oil level height without spring, compressed fork) 85 mm
Sr Motard 125 4T Characteristics
CHAR - 9

11. Electrical system
IMPIANTO ELETTRICO
Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
IMPIANTO ELETTRICO
Frame and suspensions
CHASSIS AND SUSPENSION
Specification Desc./Quantity
Frame Tubular steel frame
Front suspension Ø 35 Hydraulic telescopic fork - travel: 90 mm
Rear suspension Hydraulic single shock absorber and spring adjustable to 4 po-
sitions at preloading; travel: 80 mm.
Brakes
BRAKES
Specification Desc./Quantity
Front brake Disc brake (Ø 220 mm) with hydraulic control (lever on the far
right of the handlebar) and floating calliper.
Rear brake Ø 110mm drum brake
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Front wheel rim Die-cast aluminium alloy; 3.50 x 10"
Front tyre Tubeless 120/80 -10"
Rear wheel rim Die-cast aluminium alloy: 3.50"x10"
Rear tyre Tubeless 120/80 - 10"
Front tyre pressure 1.5 bar
Rear tyre pressure 1.8 bar
Rear wheel pressure (rider and passenger): 2.0 bar
Secondary air
Characteristics Sr Motard 125 4T
CHAR - 10

12. In order to reduce polluting emissions, the vehicle
is furnished with a catalytic converter in the muf-
fler.
To favour the catalytic process, an extra amount
of oxygen is added via a secondary air system
(SAS).
This system allows more oxygen to be added to
the unburned gases before they reach the con-
verter, thus improving the action of the catalytic
converter.
The air enters the exhaust duct from the head, and
is purified by a black filter.
The system is fitted with a control valve that disa-
bles operation while decelerating to avoid unwan-
ted noise.
To ensure the best functioning of the SAS system,
every 12,000 km the scooter should be taken to an
Authorised Piaggio Service Centre to have the
filter cleaned (Scheduled maintenance operations
section).
The filter sponge should be cleaned with water and
mild soap, then it should be dried with a cloth and
slight blows of compressed air.
CAUTION
FOR THIS OPERATION, CONTACT AN AUTHORISED
SERVICE CENTRE.
Carburettor
125cc Version
Kehin
CARBURETTOR SETTING
Specification Desc./Quantity
Type CVEK26
Throttle valve diameter Ø 26.5
Diffuser diameter Ø 26.4
Setting stamping 262A
Maximum jet 82
Sr Motard 125 4T Characteristics
CHAR - 11

13. Specification Desc./Quantity
Maximum air jet (on the body) 85
Tapered pin stamping NELA
Throttle valve spring 130 ÷ 180 gr.
Minimum jet 35
Idle air jet (on the body) 150
Idle mixture adjustment screw initial opening 1 ¾
Starter nozzle 42
Starter air jet (on the body) Ø 1.5
Starter pin travel 10 mm (at 24°)
Starter resistance 20 Ohm (at 24°)
Tightening Torques
HEAD AND CYLINDER
Name Torque in Nm
Ignition spark plug 18 Nm
Head cover screws 11 - 13
Nuts fixing head to cylinder (*) 28 to 30
Head fixing screws (external) 11 to 13
Starter ground screw 7 to 8.5
Flywheel air duct screw 3 - 4
Pressure reducer counterweight retainer 7 - 8.5
Camshaft pulley screw 12 - 14
Timing chain tensioner slider screw 10 to 14
Starter counterweight support screw 11 to 15
Tightener screw: 5 to 6
Timing chain tensioner central screw 5 to 6
Camshaft retention plate screw 5 - 6
Nut fixing silencer to cylinder head 16 to 18
Head intake manifold screw 11 to 13
(*) Lubricate the retainer threads before fitting and lock in a crossed sequence and repeat tightening 2 or 3 times.
TRANSMISSION
Name Torque in Nm
Drive pulley nut (°) 75 - 83
Transmission cover screw 11 to 13
Driven pulley shaft nut 54 - 60
Rear hub cap screws 24 - 27
Clutch unit nut on driven pulley 55 to 60
(°) Apply LOCTITE 243 threadlock
FLYWHEEL
Name Torque in Nm
Flywheel fan screws 3 to 4
Stator assembly screws (°) 3 to 4
Flywheel nut 52 - 58
Pick-up screw 3 to 4
(°) Apply LOCTITE 243 threadlock
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Internal engine crankcase bulkhead (transmission-side half
shaft) screws
4 to 6
Oil filter on crankcase fitting 27 - 33
Rear brake cam tightening screw 11 to 13
Engine-crankcase coupling screws 11 ÷ 13
Pre-filter cap 24 to 30
Starter motor screws 11 - 13
Silencer to crankcase fixing screws 24 ÷ 27
Engine oil drainage cap 24 to 30
Oil sump screws 11 to 13
Characteristics Sr Motard 125 4T
CHAR - 12

14. Name Torque in Nm
Oil pump central screw 12 to 14
Oil pump cover screws 0.7 - 0.9
Minimum oil pressure switch 12 - 14
STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut 30 to 36
Lower steering ring nut 10 - 13 (loosen by 90°)
Handlebar fixing screw 45 to 50
Mirror fastening spacer 25
CHASSIS ASSEMBLY
Name Torque in Nm
Engine arm pin - chassis arm 45.5
Centre stand pivot on engine 42.5
Silent block-swinging arm retaining bolts 42.5
FRONT SUSPENSION
Name Torque in Nm
Piston tightening fork lower screw 25 - 35
Front wheel axle nut 45 - 50
Fork clamp screw 20 to 25
Fork stanchion upper cap 15 ÷ 30
Safety screw on fork leg 6 ÷ 7
FRONT BRAKE
Name Torque in Nm
Brake fluid hose-pump fitting 20 ÷ 25
Brake fluid pipe-calliper fitting 20 to 25
Calliper to fork tightening screw 20 to 25
Disc tightening screw 8 to 12
Oil bleed screw 8 - 12
Pump U bolt screw 8
Brake pad fastening screw 15 to 20
REAR SUSPENSION
Name Torque in Nm
Rear wheel axle 115
Shock absorber nut 22.5
FUEL TANK UNIT
Name Torque in Nm
Fuel tank to chassis fixing screw 10
SADDLE UNIT
Name Torque in Nm
Saddle plate fixing nut 10
BODYWORK UNIT
Name Torque in Nm
Helmet compartment fixing screw 3
Rear grab handle fixing screw 20.5
Battery cover fixing screw 6
Front wheel housing to chassis fixing screw 6
Front wheel housing to leg shield back plate fixing screw 3
Front mudguard fixing screw 6
Footrest fixing screw 6
Screw fixing leg shield back plate to chassis 6
Leg shield back plate to leg shield fixing screw 3
Footrest spoiler fixing screw 6
Sr Motard 125 4T Characteristics
CHAR - 13

15. Name Torque in Nm
Passenger footrest protection fixing screw 3
Passenger footrest to side body panel fixing screw 6
Rear mudguard fixing screw 6
Rear brake adjustment nut 5
Overhaul data
Assembly clearances
Cylinder - piston assy.
125 version
PISTON TO CAST IRON CYLINDER COUPLING (125)
Name Initials Cylinder Piston Play on fitting
Coupling M 56.997 - 57.004 56.944 - 56.951 0.046 - 0.060
Coupling N 57.004 - 57.011 56.951 - 56.958 0.046 - 0.060
Coupling O 57.011 - 57.018 56.958 - 56.965 0.046 - 0.060
Coupling P 57.018 - 57.025 56.965 - 56.972 0.046 - 0.060
coupling 1st oversize M1 57.197 - 57.204 57.144 - 57.151 0.046 - 0.060
coupling 1st oversize N1 57.204 - 57.211 57.151 - 57.158 0.046 - 0.060
coupling 1st oversize O1 57.211 - 57.218 57.158 - 57.165 0.046 - 0.060
coupling 1st oversize P1 57.218 - 57.225 57.165 - 57.172 0.046 - 0.060
Coupling 2nd oversize M2 57.397 - 57.404 57.344 - 57.351 0.046 - 0.060
Coupling 2nd oversize N2 57.404 - 57.411 57.351 - 57.358 0.046 - 0.060
Coupling 2nd oversize O2 57.411 - 57.418 57.358 - 57.365 0.046 - 0.060
Coupling 2nd oversize P2 57.418 - 57.425 57.365 - 57.372 0.046 - 0.060
Coupling 3rd oversize M3 57.597 - 57.604 57.544 - 57.551 0.046 - 0.060
Coupling 3rd oversize N3 57.604 - 57.611 57.551 - 57.558 0.046 - 0.060
Coupling 3rd oversize O3 57.611 - 57.618 57.558 - 57.565 0.046 - 0.060
Coupling 3rd oversize P3 57.618 - 57.625 57.565 - 57.572 0.046 - 0.060
Piston rings
SEALING RINGS (125)
Name Description Dimensions Initials Quantity
Compression ring 57 x 1 A 0.15 - 0.30
Oil scraper ring 57x1 A 0.10 - 0.30
Oil scraper ring 57x2.5 A 0.10 - 0.35
Compression ring 1st
oversize
57.2 x 1 A 0.15 - 0.30
Characteristics Sr Motard 125 4T
CHAR - 14

16. Name Description Dimensions Initials Quantity
Oil scraper ring 1st
oversize
57.2x1 A 0.10 - 0.30
Oil scraper ring 1st
oversize
57.2x2.5 A 0.10 - 0.35
Compression ring 2nd
oversize
57.4x1 A 0.15 - 0.30
Oil scraper ring 2nd
oversize
57.4x1 A 0.10 - 0.30
Oil scraper ring 2nd
oversize
57.4x2.5 A 0.10 - 0.35
Compression ring 3rd
oversize
57.6x1 A 0.15 - 0.30
Oil scraper ring 3rd
oversize
57.6x1 A 0.10 - 0.30
Oil scraper ring 3rd
oversize
57.6x2.5 A 0.10 - 0.35
Maximum clearance after use: 1 mm
Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name Description Dimensions Initials Quantity
Half shaft, transmission
side
16.6 +0-0.05 A D = 0.20 ÷ 0.50
Sr Motard 125 4T Characteristics
CHAR - 15

17. Name Description Dimensions Initials Quantity
Half shaft, flywheel side 16.6 +0-0.05 B D = 0.20 ÷ 0.50
Connecting rod with PP 18 -0.10 -0.15 C 0.20 to 0.50
Crank pin width 51.400 E
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CRANKSHAFT HALF-BEARINGS
Name Description Dimensions Initials Quantity
Crankshaft Category 1 28.998 to 29.004
Crankshaft Category 2 29.004 to 29.010
Crankcase Category 1 32.953 to 32.959
Crankcase Category 2 32.959 to 32.965
Crankshaft half-bearing Category B - blue 1.973 to 1.976
Crankshaft half-bearing Category C - yellow 1.976 to 1.979
Crankshaft half-bearing Category E - green 1.979 to 1.982
Crankshaft category 1 -
Crankcase category 1
E - E
Crankshaft category 1 -
Crankcase category 2
C - C
Crankshaft category 2 -
Crankcase category 1
C - C
Crankshaft category 2 -
Crankcase category 2
B - B
Crankshaft/crankcase axial clearance: 0.15 ÷ 0.40
Slot packing system
Characteristics Sr Motard 125 4T
CHAR - 16

18. - Provisionally fit the piston into the cylinder, without any base gasket.
- Assemble a dial gauge on the specific tool
- Set the dial gauge to zero at a contrast plane with an average preload, for example 5 mm. Keeping
the zero setting position, fit the tool on the cylinder and lock it with 2 nuts, as shown in the figure.
- Rotate the crankshaft up to the TDC (the inversion point of the dial gauge rotation)
- Calculate the difference between the two measurements: use the chart below to identify the thickness
of the cylinder base gasket to be used for refitting. Correctly identify the cylinder base gasket thickness
to keep the correct compression ratio.
- Remove the special tool and the cylinder.
Characteristic
Compression ratio
10.6: 1
SHIMMING SYSTEM
Specification Desc./Quantity
Value measured 0 - 0.1
Thickness 0.8 ± 0.05
Value measured 0.1 - 0.3
Thickness 0.6 ± 0.05
Value measured 0.3 - 0.4
Thickness 0.4 ± 0.05
Products
RECOMMENDED PRODUCTS TABLE
Product Description Specifications
AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmis-
sions.
API GL-4
eni i-Ride PG 5W-40 Synthetic based lubricant for high-per-
formance four-stroke engines.
JASO MA, MA2 - API SL - ACEA A3
AGIP FILTER OIL Special product for the treatment of foam
filters.
-
eni i-Ride PG 5W-40 Synthetic based lubricant for high-per-
formance four-stroke engines.
JASO MA, MA2 - API SL - ACEA A3
AGIP GREASE MU3 Yellow-brown, lithium-base, medium-fi-
bre multipurpose grease.
ISO L-X-BCHA 3 - DIN 51 825 K3K -20
AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116
- DOT 3/4 - ISO 4925 - CUNA NC 956
DOT 4
Sr Motard 125 4T Characteristics
CHAR - 17

19. Product Description Specifications
AGIP GREASE PV2 Ivory smooth-textured, slightly-stringy
anhydrous calcium-base grease.
TL 9150 066, NATO G 460 symbol
AGIP GP 330 Water repellent stringy calcium spray
grease.
R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 -
I.A.T.A. 2 - I.M.D.G. class 2 UN 1950
Page 9022 EM 25-89
AGIP FORK 7.5 W Oil for fork. -
Characteristics Sr Motard 125 4T
CHAR - 18

20. INDEX OF TOPICS
TOOLING TOOL

21. SPECIFIC TOOLS
Stores code Description
001330Y Tool for fitting steering seats
001467Y009 Bell for OD 42-mm bearings
001467Y013 Pliers to extract ø 15-mm bearings
002465Y Pliers for circlips
005095Y Engine support
006029Y Punch for fitting fifth steering bearing on
steering tube
008564Y Flywheel extractor
Tooling Sr Motard 125 4T
TOOL - 20

22. Stores code Description
020004Y Punch for removing fifth wheels from
headstock
020055Y Wrench for steering tube ring nut
020074Y Support base for checking crankshaft
alignment
020150Y Air heater support
020151Y Air heater
020193Y Gauge for oil pressure check
020201Y Spacer bushing driving tube
Sr Motard 125 4T Tooling
TOOL - 21

23. Stores code Description
020262Y Crankcase splitting plate
020263Y Driven pulley assembly sheath
020271Y Tool for removing-fitting silent bloc
020306Y Punch for assembling valve seal rings
020329Y Vacuum pump Mity-Vac
020330Y Stroboscopic light to check timing
Tooling Sr Motard 125 4T
TOOL - 22

24. Stores code Description
020331Y Digital multimeter
020332Y Digital rpm indicator
020335Y Magnetic mounting for dial gauge
020357Y 32x35-mm Adaptor
020359Y 42x47-mm Adaptor
020360Y 52x55-mm Adaptor
Sr Motard 125 4T Tooling
TOOL - 23

25. CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
• Thank you very much for reading the
preview of the manual.
• You can download the complete
manual from: www.heydownloads.com
by clicking the link below
• Please note: If there is no response to
CLICKING the link, please download
this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL