APRILIA SR MAX 125 ie Service Station Manual
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APRILIA SR MAX 125 ie Service Station Manual

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SERVICE STATION MANUAL
677506 EN
SR MAX 125 ie

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Wayne Wright
April 8, 2025

I have a white plug and don’t know were it goes on my aprillia sr125 max

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1 comments:
Mr. Anderson
April 9, 2025

The white plug connects to the +Live (White-Black) and to the electric control management device (Grey) on the Aprilia SR Max 125 ie.

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Wayne Wright
April 9, 2025

How to bypass my immobiliser unit because I can’t get it off do you know how to do this mate

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Summary of Contents for APRILIA SR MAX 125 ie

  • Page 1 SERVICE STATION MANUAL 677506 EN SR MAX 125 ie...
  • Page 2 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.
  • Page 3 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.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    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.

  • Page 8: Vehicle Identification

    SR MAX 125 ie Characteristics 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...
  • Page 9 SR MAX 125 ie Characteristics Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity 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 Specification Desc./Quantity...
  • Page 10 SR MAX 125 ie Characteristics Specification Desc./Quantity 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 Specification Desc./Quantity...

  • Page 11: Wheels And Tyres

    SR MAX 125 ie Characteristics Brakes BRAKES Specification Desc./Quantity 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.
  • Page 12 SR MAX 125 ie Characteristics ENGINE COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder 56.997 to 57.004 56.945 - 56.952 0.045 - 0.059 Cylinder 57.004 to 57.011 56.952 - 56.959 0.045 - 0.059 Piston 57.011 to 57.018 56.959 - 56.966 0.045 - 0.059...
  • Page 13 SR MAX 125 ie Characteristics - 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).
  • Page 14 SR MAX 125 ie Characteristics 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.
  • Page 15 SR MAX 125 ie Characteristics 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 D = 0.20 ÷ 0.50 shaft Flywheel-side halfshaft 16.6 +0-0.05 D = 0.20 ÷ 0.50 Connecting rod 18 -0.10 -0.15...

  • Page 16: Cylinder Head

    SR MAX 125 ie Characteristics 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.
  • Page 17 SR MAX 125 ie Characteristics - 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.
  • Page 18 SR MAX 125 ie Characteristics - In case of excessive wear or damage, replace the head. STANDARD VALVE LENGTH Specification Desc./Quantity Intake 84.5 mm Exhaust 94.5 mm - Measure the diameter of the valve stems in the three positions indicated in the diagram.
  • Page 19 SR MAX 125 ie Characteristics - 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.
  • Page 20 SR MAX 125 ie Characteristics - 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.
  • Page 21 SR MAX 125 ie Characteristics -Using a gauge, measure the cam height. STANDARD HEIGHT Specification Desc./Quantity intake 17.382 mm Exhaust 16.563 mm ADMISSIBLE LIMITS Specification Desc./Quantity intake 17.130 mm Exhaust 16.310 mm standard axial clearance 0.11 - 0.41 mm maximum admissible axial clearance 0.42 mm...
  • Page 22 SR MAX 125 ie Characteristics - 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»...
  • Page 23 SR MAX 125 ie Characteristics (0.3) ODELS WITH METAL HEAD GASKET 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...
  • Page 24 INDEX OF TOPICS TOOL OOLING...
  • Page 25 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...
  • Page 26 SR MAX 125 ie Tooling Stores code Description 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...
  • Page 27 SR MAX 125 ie Tooling Stores code Description 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...
  • Page 28 SR MAX 125 ie Tooling Stores code Description 020648Y Single battery charger 020335Y Magnetic mounting for dial gauge 020357Y 32x35-mm Adaptor 020359Y 42 x 47-mm adaptor 020360Y 52x55-mm Adaptor 020363Y 20-mm guide TOOL - 28...
  • Page 29 SR MAX 125 ie Tooling Stores code Description 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...
  • Page 30 SR MAX 125 ie Tooling Stores code Description 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...
  • Page 31 SR MAX 125 ie Tooling Stores code Description 020456Y Ø 24 mm adaptor 020477Y 37 mm adaptor 020483Y 30 mm guide 020489Y Hub cover support stud bolt kit 020428Y Piston position check mounting 020680Y Diagnosis Tool TOOL - 31...
  • Page 32 SR MAX 125 ie Tooling Stores code Description 020621Y HV cable extraction adaptor 001467Y035 Bell for 47-mm outside diameter bearings 020626Y Driving pulley lock wrench 020626Y008 Driving pulley lock wrench 001467Y013 Calliper to extract ø 15-mm bearings 020627Y Flywheel lock wrench...
  • Page 33 SR MAX 125 ie Tooling Stores code Description 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...
  • Page 34 SR MAX 125 ie Tooling Stores code Description 020469Y Reprogramming kit for vehicle diagnostic tester 001467Y017 Driver for OD 36 mm bearings 020234y extractor 020441Y 26 x 28 mm adaptor 020362Y 12 mm guide 020358Y 37x40-mm Adaptor 001467Y002 Driver for OD 73 mm bearing...
  • Page 35 SR MAX 125 ie Tooling Stores code Description 020688Y Dial gauge support TOOL - 35...
  • Page 36 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 37: Maintenance Chart

    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 Roller bearing - Driven pulley...
  • Page 38 SR MAX 125 ie Maintenance 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.
  • Page 39 SR MAX 125 ie Maintenance 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.

  • Page 40: Engine Oil

    SR MAX 125 ie Maintenance • 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.
  • Page 41 SR MAX 125 ie Maintenance Recommended products eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines. JASO MA, MA2 - API SL - ACEA A3 Locking torques (N*m) Engine oil drainage plug 24 to 30 Check This operation must be carried out with the engine cold and following the procedure below: 1.

  • Page 42: Engine Oil Filter

    SR MAX 125 ie Maintenance 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.

  • Page 43: Cooling System

    SR MAX 125 ie Maintenance 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.
  • Page 44 SR MAX 125 ie Maintenance 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.

  • Page 45: Headlight Adjustment

    SR MAX 125 ie Maintenance 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;...
  • Page 46 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 47 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...
  • Page 48 SR MAX 125 ie Troubleshooting Possible Cause Operation 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...
  • Page 49 SR MAX 125 ie Troubleshooting Suspension oil leakage IL LEAKAGE FROM SUSPENSION Possible Cause Operation Faulty or broken seals Replace the shock absorber Check the condition of wear of the steering covers and the adjustments. TROUBL - 49...
  • Page 50 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 51 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 8. Fusibile N.02 - 15A 9. Fusibile N.03 - 15A 10.
  • Page 52 SR MAX 125 ie Electrical system 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.
  • Page 53 SR MAX 125 ie Electrical system 58. Sensore giri motore 59. Decoder 60. Antenna 61. Pompa acqua 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.
  • Page 54 SR MAX 125 ie Electrical system 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...
  • Page 55 SR MAX 125 ie Electrical system 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.
  • Page 56 SR MAX 125 ie Electrical system 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.
  • Page 57 SR MAX 125 ie Electrical system 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.
  • Page 58 SR MAX 125 ie Electrical system 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...
  • Page 59 SR MAX 125 ie Electrical system LEGENDA 1. Batteria 12v - 14 Ah 6. Massa motore 8. Fusibile N.02 - 15A 11. Fusibile N.05 - 10A 17. Fusibile N.11 - 7,5A 28. Contatto del commutatore a chiave 32. Gruppo strumenti 40.
  • Page 60 SR MAX 125 ie Electrical system 3. Volano magnete 4. Teleruttore d'avviamento 5. Motorino d'avviamento 6. Massa motore 7. Fusibile N.01 - 30A 8. Fusibile N.02 - 15A 10. Fusibile N.04 - 15A 14. Fusibile N.08 - 7,5A 22. Pulsante avviamento 23.
  • Page 61 SR MAX 125 ie Electrical system 10. Fusibile N.04 - 15A 15. Fusibile N.09 - 7,5A 16. Fusibile N.10 - 7,5A 17. Fusibile N.11 - 7,5A 28. Contatto del commutatore a chiave 32. Gruppo strumenti 34. Contagiri analogico 35. Sensore pressione olio 38.
  • Page 62 SR MAX 125 ie Electrical system LEGENDA 1. Batteria 12v - 14 Ah 6. Massa motore 8. Fusibile N.02 - 15A 9. Fusibile N.03 - 15A 10. Fusibile N.04 - 15A 14. Fusibile N.08 - 7,5A 16. Fusibile N.10 - 7,5A 17.
  • Page 63 SR MAX 125 ie Electrical system Lights and turn indicators LEGENDA 1. Batteria 12v - 14 Ah 6. Massa motore 8. Fusibile N.02 - 15A 10. Fusibile N.04 - 15A 12. Fusibile N.06 - 7,5A 13. Fusibile N.07 - 7,5A 14.
  • Page 64 SR MAX 125 ie Electrical system 30. Pulsante illuminazione vano casco 31. Lampada illuminazione vano casco 12v-5w 32. Gruppo strumenti 33. Lampade 12v-10w per lampeggiatori 37. Commutatore lampeggiatori 39. Dispositivo gestione comandi elettrici 41. Lampada luce posizione posteriore 12v-21/5w 42. Lampada 12v-5w per luce targa 43.
  • Page 65 SR MAX 125 ie Electrical system 48. Centralina elettronica per iniezione 49. Diagnostica 54. Pompa della benzina 55. Iniettore carburante 56. Sonda lambda 58. Sensore giri motore 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.
  • Page 66 SR MAX 125 ie Electrical system 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...
  • Page 67 SR MAX 125 ie Electrical system 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.
  • Page 68 SR MAX 125 ie Electrical system Electric characteristic 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.
  • Page 69 SR MAX 125 ie Electrical system 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.
  • Page 70 SR MAX 125 ie Electrical system - 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.
  • Page 71 SR MAX 125 ie Electrical system 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.
  • Page 72 SR MAX 125 ie Electrical system 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.
  • Page 73 SR MAX 125 ie Electrical system 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.
  • Page 74 SR MAX 125 ie Electrical system 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.
  • Page 75 SR MAX 125 ie Electrical system Specification Desc./Quantity Power: 12V - 10 W Quantity: 1 RHS + 1 LHS Front turn indicator bulb Type: Incandescent (W2.1x9.5d) Power: 12V - 5 W Quantity: 2 RHS + 2 LHS Tail light and stop light bulb Type: Incandescent (W2.1x9.5d)
  • Page 76 SR MAX 125 ie Electrical system Specification Desc./Quantity Fuse no. 2 Capacity: 15 A Protected circuits: Lines protected by fuses No.10 and 11 (live), plug socket, helmet compartment lighting. Fuse no. 3 Capacity: 15 A Protected circuits: Electric fan (via solenoid) Fuse no.
  • Page 77 SR MAX 125 ie Electrical system • 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"...

  • Page 78: Battery Installation

    SR MAX 125 ie Electrical system 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,...
  • Page 79 SR MAX 125 ie Electrical system 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.
  • Page 80 SR MAX 125 ie Electrical system 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.
  • Page 81 SR MAX 125 ie Electrical system 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...
  • Page 82 SR MAX 125 ie Electrical system 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.
  • Page 83 SR MAX 125 ie Electrical system 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.
  • Page 84 SR MAX 125 ie Electrical system VOLTAGE REGULATOR CONNECTOR 1. Battery positive terminal (Red-White) 2. Ground lead (Black) 3. Battery positive terminal (Red-White) 4. Ground lead (Black) ELE SYS - 84...
  • Page 85 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 86 SR MAX 125 ie Engine from vehicle 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.
  • Page 87 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.
  • Page 88 SR MAX 125 ie Engine from vehicle - 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.
  • Page 89 SR MAX 125 ie Engine from vehicle - 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.
  • Page 90 SR MAX 125 ie Engine from vehicle - Remove the central tunnel. - 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.
  • Page 91 SR MAX 125 ie Engine from vehicle - 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.
  • Page 92 INDEX OF TOPICS NGINE...

  • Page 93: Automatic Transmission

    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.
  • Page 94 SR MAX 125 ie Engine - 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.
  • Page 95 SR MAX 125 ie Engine 020376Y Adapter handle 020357Y 32x35-mm Adaptor 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.
  • Page 96 SR MAX 125 ie Engine - 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...

  • Page 97: Removing The Clutch

    SR MAX 125 ie Engine 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.
  • Page 98 SR MAX 125 ie Engine 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.
  • Page 99 SR MAX 125 ie Engine 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.
  • Page 100 SR MAX 125 ie Engine 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.
  • Page 101 SR MAX 125 ie Engine 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.
  • Page 102 SR MAX 125 ie Engine - 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...
  • Page 103 SR MAX 125 ie Engine 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.
  • Page 104 SR MAX 125 ie Engine 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.
  • Page 105 SR MAX 125 ie Engine Specific tooling 020444Y Tool for fitting/ removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 wrench 46 x 55 Locking torques (N*m) Clutch unit nut on driven pulley 45 to 50 Refitting the driven pulley - Fit the clutch housing on the driven pulley paying attention to the position of the washer indicated.
  • Page 106 SR MAX 125 ie Engine 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...
  • Page 107 SR MAX 125 ie Engine - 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.
  • Page 108 SR MAX 125 ie Engine 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- Ø 25.95 mm Roller: Standard diameter Ø 19.5 - 20.1 mm Roller: Minimum admissible weight 5.4 ±...
  • Page 109 SR MAX 125 ie Engine - 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.
  • Page 110 SR MAX 125 ie Engine 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.
  • Page 111 SR MAX 125 ie Engine 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).
  • Page 112 SR MAX 125 ie Engine 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...
  • Page 113 SR MAX 125 ie Engine - Remove the Seeger ring indicated. Specific tooling 020376Y Adapter handle 020375Y 28 x 30 mm adaptor 020363Y 20-mm guide - Remove the driven pulley shaft bearing using the modular punch. Specific tooling 020376Y Adapter handle...
  • Page 114 SR MAX 125 ie Engine 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...
  • Page 115 SR MAX 125 ie Engine ENG - 115...
  • Page 116 SR MAX 125 ie Engine 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.
  • Page 117 SR MAX 125 ie Engine IF THE BEARING HAS AN ASYMMETRICAL BALL RETAINER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SIDE. Specific tooling 020376Y Adapter handle 020359Y 42 x 47-mm adaptor 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.
  • Page 118 SR MAX 125 ie Engine - Fix the breather tube support by means of the lower screw. - Fit the remaining screws and tighten the seven screws to the prescribed torque. Locking torques (N*m) Hub cover fixing screws 24 to 27 Hub oil drain screws 15 to 17...
  • Page 119 SR MAX 125 ie Engine - 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.
  • Page 120 SR MAX 125 ie Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. Locking torques (N*m) Stator fixing screws Pickup fixing 8 to 10...
  • Page 121 SR MAX 125 ie Engine 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.
  • Page 122 SR MAX 125 ie Engine - 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.
  • Page 123 SR MAX 125 ie Engine 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.
  • Page 124 SR MAX 125 ie Engine - 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...
  • Page 125 SR MAX 125 ie Engine Refitting the starter motor - Fit a new O-ring on the starter motor and lubricate - Fit the starter motor on the crankcase and lock the 2 screws to the prescribed torque. Locking torques (N*m) Starter motor screws 11 ÷...
  • Page 126 SR MAX 125 ie Engine 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.
  • Page 127 SR MAX 125 ie Engine 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.

  • Page 128: Removing The Cylinder Head

    SR MAX 125 ie Engine 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.
  • Page 129 SR MAX 125 ie Engine - Use the specific tool to remove the valve oil seal. Specific tooling 020306Y Punch for assembling valve seal rings ENG - 129...
  • Page 130 SR MAX 125 ie Engine - Slide off the valve and remove the lower support. Specific tooling 020382Y Tool to extract valve cotters - 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».
  • Page 131 SR MAX 125 ie Engine - 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...

  • Page 132: Removing The Piston

    SR MAX 125 ie Engine 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...
  • Page 133 SR MAX 125 ie Engine - 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.
  • Page 134 SR MAX 125 ie Engine - 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.
  • Page 135 SR MAX 125 ie Engine Inspecting the cylinder head NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Inspecting the timing system components - Check that the guide slider and the tensioner slider are not worn out.
  • Page 136 SR MAX 125 ie Engine 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...
  • Page 137 SR MAX 125 ie Engine - 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...
  • Page 138 SR MAX 125 ie Engine 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.
  • Page 139 SR MAX 125 ie Engine 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.
  • Page 140 SR MAX 125 ie Engine TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- 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.
  • Page 141 SR MAX 125 ie Engine 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.
  • Page 142 SR MAX 125 ie Engine 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.
  • Page 143 SR MAX 125 ie Engine 020335Y Magnetic mounting for dial gauge 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.
  • Page 144 SR MAX 125 ie Engine - 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.
  • Page 145 SR MAX 125 ie Engine 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-...
  • Page 146 SR MAX 125 ie Engine 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.
  • Page 147 SR MAX 125 ie Engine - 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.
  • Page 148 SR MAX 125 ie Engine - 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.
  • Page 149 SR MAX 125 ie Engine 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»;...

  • Page 150: Oil Pressure Check

    SR MAX 125 ie Engine 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).
  • Page 151 SR MAX 125 ie Engine 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 020622Y Transmission-side oil seal punch - Screw the threaded bar onto the base of the tool and extract the oil seal.

  • Page 152: Oil Pump

    SR MAX 125 ie Engine - 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...
  • Page 153 SR MAX 125 ie Engine 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.
  • Page 154 SR MAX 125 ie Engine - 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.
  • Page 155 SR MAX 125 ie Engine - 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.
  • Page 156 SR MAX 125 ie Engine 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.
  • Page 157 INDEX OF TOPICS INJEC NJECTION...
  • Page 158 SR MAX 125 ie Injection INJEC - 158...
  • Page 159 SR MAX 125 ie Injection TRANSPARENCY Specification Desc./Quantity Throttle body and electronic injection control unit (MIU) Fuel injector Instrument panel Injection load remote control Water temperature sensor Fuel pump HV coil Lambda Probe Engine Speed sensor Battery 12V - 12 Ah...
  • Page 160 SR MAX 125 ie Injection - 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.
  • Page 161 SR MAX 125 ie Injection 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.
  • Page 162 SR MAX 125 ie Injection 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.
  • Page 163 SR MAX 125 ie Injection Terminals setup TERMINAL LAYOUT Specification Desc./Quantity Injection telltale light Rpm indicator - Lambda probe + battery under permanent power supply + Battery Immobilizer aerial Electric fan remote control Water temperature sensor + Lambda probe engine stop switch...
  • Page 164 SR MAX 125 ie Injection EMS circuit diagram LEGENDA 1. Batteria 12v - 14 Ah 4. Teleruttore d'avviamento 5. Motorino d'avviamento 6. Massa motore 8. Fusibile N.02 - 15A 9. Fusibile N.03 - 15A 11. Fusibile N.05 - 10A 16. Fusibile N.10 - 7,5A 17.

  • Page 165: Troubleshooting Procedure

    SR MAX 125 ie Injection 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. 58. Sensore giri motore 59. Decoder 60. Antenna 61.
  • Page 166 SR MAX 125 ie Injection Possible Cause Operation 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;...
  • Page 167 SR MAX 125 ie Injection Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe Correctness of the parameters...
  • Page 168 SR MAX 125 ie Injection Possible Cause Operation 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) Parameter reliability Throttle valve position signal...
  • Page 169 SR MAX 125 ie Injection 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...
  • Page 170 SR MAX 125 ie Injection 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.
  • Page 171 SR MAX 125 ie Injection 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°...
  • Page 172 SR MAX 125 ie Injection INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 15 A Ignition key contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda Probe Electric fan remote control When switched to "ON", the fuel pump starts to rotate for two seconds and then stops.
  • Page 173 SR MAX 125 ie Injection 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.
  • Page 174 SR MAX 125 ie Injection INJEC - 174...
  • Page 175 SR MAX 125 ie Injection 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 CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED.
  • Page 176 SR MAX 125 ie Injection mote control disconnected, that the Black-Purple cable (pin 20 on the interface wiring) is insulated from the ground. Specific tooling 020331Y Digital multimeter Circuit leak test Install the appropriate tool for fuel pressure control with the pipe fitted with the pressure gauge on the delivery pipe..
  • Page 177 SR MAX 125 ie Injection 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.
  • Page 178 SR MAX 125 ie Injection Remove the filter from the pump mounting Inspecting the injector circuit INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 15 A Ignition key contacts Fuse 7.5 A Injection load remote control...
  • Page 179 SR MAX 125 ie Injection Verificare l'efficienza del fusibile N° 5 da 10 A car- ichi iniezione. Verificare l'efficienza del fusibile N° 8 da 7,5 A ali- mentazione centralina da chiave. Check the efficiency of the injection load solenoid. Check the resistance of the energising coil be- tween pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85;...
  • Page 180 SR MAX 125 ie Injection 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...
  • Page 181 SR MAX 125 ie Injection 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 CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED.
  • Page 182 SR MAX 125 ie Injection 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...
  • Page 183 SR MAX 125 ie Injection 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.
  • Page 184 SR MAX 125 ie Injection Components location INJEC - 184...
  • Page 185 SR MAX 125 ie Injection TRANSPARENCY Specification Desc./Quantity Throttle body and electronic injection control unit (MIU) Fuel injector Instrument panel Injection load remote control Water temperature sensor Fuel pump HV coil Lambda Probe Engine Speed sensor Battery 12V - 12 Ah...
  • Page 186 SR MAX 125 ie Injection 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.
  • Page 187 SR MAX 125 ie Injection HT coil INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 15 A Ignition key contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda Probe Electric fan remote control The combined ignition/injection system is a high-efficiency induction system.
  • Page 188 SR MAX 125 ie Injection Verificare l'efficienza del fusibile N° 5 da 10 A car- ichi iniezione. Verificare l'efficienza del fusibile N° 8 da 7,5 A ali- mentazione centralina da chiave. Check the efficiency of the injection load solenoid. Check the resistance of the energising coil be- tween pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85;...
  • Page 189 SR MAX 125 ie Injection 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...
  • Page 190 SR MAX 125 ie Injection 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 CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED.
  • Page 191 SR MAX 125 ie Injection 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...

  • Page 192: Coolant Temperature Sensor

    SR MAX 125 ie Injection Coolant temperature sensor TEMPERATURE SENSOR Specification Desc./Quantity Water temperature sensor 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.
  • Page 193 SR MAX 125 ie Injection 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.
  • Page 194 SR MAX 125 ie Injection 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.
  • Page 195 SR MAX 125 ie Injection 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.
  • Page 196 SR MAX 125 ie Injection 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.
  • Page 197 SR MAX 125 ie Injection 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...
  • Page 198 SR MAX 125 ie Injection 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 CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED.
  • Page 199 SR MAX 125 ie Injection INJEC - 199...
  • Page 200 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 201: Removing The Front Wheel

    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.
  • Page 202 SR MAX 125 ie Suspensions - 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.
  • Page 203 SR MAX 125 ie Suspensions - Reinsert the spacer bushing on the brake disc side using the appropriate tool and take it to the stop. Specific tooling 020376Y Adapter handle 020359Y 42 x 47-mm adaptor 020412Y 15-mm guide 020201Y Spacer bushing driving tube - Refit the cap and tighten the five fixing screws.
  • Page 204 SR MAX 125 ie Suspensions - 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.

  • Page 205: Front Fork

    SR MAX 125 ie Suspensions 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.
  • Page 206 SR MAX 125 ie Suspensions 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.
  • Page 207 SR MAX 125 ie Suspensions - 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.
  • Page 208 SR MAX 125 ie Suspensions - 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...
  • Page 209 SR MAX 125 ie Suspensions - 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.
  • Page 210 SR MAX 125 ie Suspensions - 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.
  • Page 211 SR MAX 125 ie Suspensions - 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.
  • Page 212 SR MAX 125 ie Suspensions - Refill the fork leg with the recommended product to the prescribed amount. Recommended products 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.
  • Page 213 SR MAX 125 ie Suspensions 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.
  • Page 214 SR MAX 125 ie Suspensions 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.
  • Page 215 SR MAX 125 ie Suspensions - 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 020055Y Wrench for steering tube ring nut...
  • Page 216 SR MAX 125 ie Suspensions - 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.
  • Page 217 SR MAX 125 ie Suspensions 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.
  • Page 218 SR MAX 125 ie Suspensions - 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 020004Y Punch for removing steering bearings from headstock...
  • Page 219 SR MAX 125 ie Suspensions NOTE LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH RECOMMENDED GREASE BEFORE USE. Specific tooling 001330Y Tool for fitting steering seats Recommended products AGIP GREASE PV2 Ivory smooth-textured, slightly-stringy anhydrous calcium-base grease. TL 9150 066, symbol NATO G 460...
  • Page 220 SR MAX 125 ie Suspensions SUSP - 220...

  • Page 221: Removing The Rear Wheel

    SR MAX 125 ie Suspensions - 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.
  • Page 222 SR MAX 125 ie Suspensions - 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.
  • Page 223 SR MAX 125 ie Suspensions - Undo the five wheel fixing screws and collect the wheel. Refitting the rear wheel To fit, follow the removal procedure but in reverse order. Locking torques (N*m) Silencer arm clamping screws 27 - 30 Rear wheel axle nut 104 to 126 Shock absorber-crankcase...
  • Page 224 SR MAX 125 ie Suspensions - 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.
  • Page 225 SR MAX 125 ie Suspensions 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...
  • Page 226 SR MAX 125 ie Suspensions - 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...
  • Page 227 SR MAX 125 ie Suspensions - 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 Allowable limit after use: 1.5 mm - Separate the swinging arm on the engine side from the vehicle side arm.

  • Page 228: Shock Absorbers

    SR MAX 125 ie Suspensions 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...
  • Page 229 SR MAX 125 ie Suspensions 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-...

  • Page 230: Side Stand

    SR MAX 125 ie Suspensions 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.
  • Page 231 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 232 SR MAX 125 ie Braking system 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.
  • Page 233 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;...
  • Page 234 SR MAX 125 ie Braking system - 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.
  • Page 235 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;...
  • Page 236 SR MAX 125 ie Braking system - 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.
  • Page 237 SR MAX 125 ie Braking system - 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.
  • Page 238 SR MAX 125 ie Braking system 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...

  • Page 239: Front Brake Pads

    SR MAX 125 ie Braking system • 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. •...

  • Page 240: Rear Brake Pads

    SR MAX 125 ie Braking system 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.
  • Page 241 SR MAX 125 ie Braking system 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.
  • Page 242 SR MAX 125 ie Braking system - 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.
  • Page 243 SR MAX 125 ie Braking system 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.
  • Page 244 SR MAX 125 ie Braking system Locking torques (N*m) Brake fluid pump-hose fitting 16 - 20 BRAK SYS - 244...
  • Page 245 INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 246: Circuit Diagram

    SR MAX 125 ie Cooling system Circuit diagram 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.
  • Page 247 SR MAX 125 ie Cooling system Specification Desc./Quantity Recommended fluid AGIP PERMANENT SPEZIAL (ready for use) Sealing pressure Cap calibrated at 0.9 bar THERMOSTAT Specification Desc./Quantity Type Wax-type, with deviator Starts opening at 85 ± 2°C ELECTRIC VENTILATION Specification Desc./Quantity Electric ventilation starts at 100°...
  • Page 248 SR MAX 125 ie Cooling system Bleed screw COOL SYS - 248...
  • Page 249 INDEX OF TOPICS CHAS HASSIS...
  • Page 250 SR MAX 125 ie Chassis 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.

  • Page 251: Instrument Panel

    SR MAX 125 ie Chassis Instrument panel - Remove the instrument panel. - Loosen the five fixing nuts of the instrument pan- Front handlebar cover - Remove the rear handlebar cover. - Remove the left and right frames of the brake pump secured with two retaining fins.
  • Page 252 SR MAX 125 ie Chassis 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».
  • Page 253 SR MAX 125 ie Chassis - 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.
  • Page 254 SR MAX 125 ie Chassis - Undo from both sides the screw indicated in the figure. - Remove the central tunnel sliding it from the tongues. SIDE FAIRING: - Remove the central tunnel. - Remove the side fairings. - Remove the handgrips and top side fairings.
  • Page 255 SR MAX 125 ie Chassis - 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.
  • Page 256 SR MAX 125 ie Chassis 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.
  • Page 257 SR MAX 125 ie Chassis - Undo the central screw. - Undo the two screws indicated. - 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.
  • Page 258 SR MAX 125 ie Chassis - 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.
  • Page 259 SR MAX 125 ie Chassis - 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.
  • Page 260 SR MAX 125 ie Chassis 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.
  • Page 261 SR MAX 125 ie Chassis - 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.
  • Page 262 SR MAX 125 ie Chassis 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.
  • Page 263 SR MAX 125 ie Chassis 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).
  • Page 264 SR MAX 125 ie Chassis - 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.
  • Page 265 SR MAX 125 ie Chassis - 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.
  • Page 266 SR MAX 125 ie Chassis - 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.
  • Page 267 SR MAX 125 ie Chassis 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»...

  • Page 268: Front Mudguard

    SR MAX 125 ie Chassis Front mudguard - Working from both vehicle sides, undo and re- move the two screws «A». Slide the mudguard to the front part of the vehicle. CAUTION WHEN REFITTING PAY ATTENTION TO THE CORRECT POSITION OF THE PIPE RETAINING STRAPS.
  • Page 269 SR MAX 125 ie Chassis - 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.
  • Page 270 SR MAX 125 ie Chassis Radiator fan - 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.
  • Page 271 SR MAX 125 ie Chassis - Remove it from the retaining seat. Handles and top side fairings - Remove the side fairings. - Remove the rear central cover. - Undo the two screws indicated. - Working from both sides, undo the screw «A».
  • Page 272 SR MAX 125 ie Chassis 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.
  • Page 273 SR MAX 125 ie Chassis 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...
  • Page 274 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 275 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...

  • Page 276: Road Test

    SR MAX 125 ie Pre-delivery •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.
  • Page 277 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.
  • Page 278 Accessories: 61 Air filter: 39, 264 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: Clutch: 47, 95–97, 103, 104 Coil: 187 Connectors: 82 coolant: 192...
  • Page 279 Maintenance: 7, 37 Mudguard: 265, 268 Oil filter: 42 Oil sump: 155, 156 Radiator: 270 Rear wheel: 221, 223 Recommended products: Scheduled maintenance: Shock absorbers: 228 Side fairings: 263, 271 Side stand: 230 Spark plug: 37, 69 Stand: 230 Starter motor: 121, 125 Tank: 268, 270 Transmission: 10, 47, 93, 109 Turn indicators: 63...

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