APRILIA M192M Manuel d'instructions
www.serviceaprilia.com
workshopmanual
engines M192M/M191M
M245M/M234M/M282M/M281M
1111 2
11/2003-01
8140684 UK
FOREWORD
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ines M192M / M191M / M245M / M234M / M282M / M281M
FOREWORD 0
GENERAL INFORMATION 1
SPECIAL TOOLS 2
ENGINE 3
UPDATING ENGINES M192M / M191M 4
FOREWORD
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ines M192M / M191M / M245M / M234M / M282M / M281M
SUMMARY
0.1. FOREWORD ................................................................................................................................................... 3
0.1.1. FOREWORD.......................................................................................................................................... 3
0.1.2. REFERENCE MANUALS....................................................................................................................... 4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..................................................................................... 5
FOREWORD
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/
M234M / M282M / M281M
0.1. FOREWORD
0.1.1. FOREWORD
- This manual provides all information necessary for vehicle servicing.
- This manual is intended for use by aprilia Dealers and their qualified mechanics. Some information has been omit-
ted intentionally as considered unnecessary. For this reason, people who are using this manual must have a good
background on mechanics and procedures for motorcycle servicing. Motorcycles serviced or inspected by incompe-
tent operators might be inefficient or unsafe to ride. As not all servicing and inspection procedures are described in
details, proceed with utmost care so to avoid injuries to people and damages to vehicle parts. aprilia s.p.a.'s mis-
sion is to enhance the riding pleasure by ever improving products and technical literature. All aprilia Points of Sale
and Subsidiaries worldwide are kept updated on major engineering changes and modifications to repair proce-
dures. All changes and modifications are then included in the next release of the relevant manual. When in doubt
about some inspection or repair procedure, please contact aprilia CONSUMER SERVICE (A.C.S.) DEPARTMENT
staff, who will be glad to provide full information on servicing procedures and technical aspects.
aprilia s.p.a. reserves the right to make changes to its products at any time, being understood that main features as
herein described and shown remain unchanged.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
Any reference to products or services provided by third parties is for information only and by no means binding.
aprilia s.p.a. disclaims all responsibility for their performance or use.
Refer to 0.1.2 for further information.
First edition: November 2003
Produced and printed by:
DECA s.r.l.
via Risorgimento, 23/1 - 48022 Lugo (RA) - Italia
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
www.decaweb.it
for:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - Italia
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 29 190
www.aprilia.com
www.serviceaprilia.com
FOREWORD
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0.1.2. REFERENCE MANUALS
ENGINE WORKSHOP MANUALS
aprilia part # (description)
8140680
8140681
8140682
8140683
8140684
PARTS CATALOGUES
aprilia part # (description)
6642
SPECIAL TOOLS MANUALS
aprilia part # (description)
H001
FOREWORD
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0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS
#= number
<= is less than
>= is more than
≤= is less than or equal to
≥= is more than or equal to
~= approximately
∞= infinite
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = plus or minus
a.c = alternated current
A=ampere
Ah =ampere per hour
API = American Petroleum Institute
HT = High Tension
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement (1 bar =100 kPa)
DC = Direct Current
cu cm = cubic centimeters
CO = carbon oxide
CPU = Central Processing Unit
DIN = German industrial standards (Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Electronic Control Unit
rpm = revolutions per minute
HC = unburnt hydrocarbons
ISC = Idle Speed Control
ISO = International Standardization Organization
kg = kilograms
kgm = kilograms per meter (1 kgm =10 Nm)
km = kilometers
km/h = kilometers per hour
kΩ= kiloOhm
kPa = kiloPascal (1 kPa =0.01 bar)
KS = clutch side (from the German "Kupplungseite")
kW = kiloWatt
l= liters
LAP = racetrack lap
LED = Light Emitting Diode
LEFT
SIDE =left side
m/s = meters per second
max = maximum
mbar = millibar (1 mbar =0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German "Magnetseite")
MΩ= megaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton per meter (1 Nm =0.1 kgm)
Ω= ohm
PICK-UP
BDC = Bottom Dead Center
TDC = Top Dead Center
PPC = Pneumatic Power Clutch
RIGHT
SIDE = right side
SAE = Society of Automotive Engineers
TEST = diagnostic check
T.B.E.I. = crowned-head Allen screw
T.C.E.I. = cheese-headed Allen screw
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T.E. = hexagonal head
T.P. = flat head screw
TSI = Twin Spark Ignition
UPSIDE-
DOWN = inverted fork
V= volt
W= watt
Ø= Diameter
GENERAL INFORMATION
1 - 1
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ines M192M / M191M / M245M / M234M / M282M / M281M
GENERAL INFORMATION 1
GENERAL INFORMATION
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ines M192M / M191M / M245M / M234M / M282M / M281M
SUMMARY
1.1. MANUAL LAYOUT ........................................................................................................................... 3
1.1.1. CONVENTIONS USED IN THE MANUAL .............................................................................. 3
1.1.2. SAFETY INFORMATION......................................................................................................... 4
1.2. GENERAL RULES ........................................................................................................................... 5
1.2.1. BASIC SAFETY RULES .......................................................................................................... 5
1.3. DANGEROUS ELEMENTS.............................................................................................................. 8
1.3.1. WARNINGS CONCERNING FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENT
PARTS..................................................................................................................................... 8
1.4. RUNNING-IN .................................................................................................................................... 9
1.4.1. RUNNING-IN RECOMMENDATIONS..................................................................................... 9
1.5. USING TOOLS AND SPARE PARTS............................................................................................ 10
1.5.1. SPARE PARTS...................................................................................................................... 10
1.6. SPECIFICATIONS.......................................................................................................................... 11
1.6.1. TECHNICAL DATA - 125CC 4T-4V-H2O ENGINE............................................................... 11
1.6.2. TECHNICAL DATA - 200CC 4T-4V-H2O ENGINE............................................................... 12
1.7. USE OF PRODUCTS..................................................................................................................... 13
1.7.1. USE OF PRODUCTS ............................................................................................................ 13
1.8. TIGHTENING ................................................................................................................................. 14
1.8.1. GENERAL TIGHTENING TORQUE SETTINGS................................................................... 14
GENERAL INFORMATION
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1.1. MANUAL LAYOUT
1.1.1. CONVENTIONS USED IN THE MANUAL
• This manual is divided in sections and subsections, each covering a set of the most significant components. For
quick reference, see the sections index.
• Unless expressly specified otherwise, reassemble/install by following disassembly/removal procedure in the re-
verse order.
• The terms “left” and “right” are referred to the motorcycle when viewed from the riding position.
In this manual any variants are identified with the following symbols:
option
catalyzed version
- all versions
11KW 11 kw derated version
80km 80km/h version
f.p full-power version
MP National homologation
SF European homologations (EURO 1 limits)
VERSION:
Italy Greece Malaysia
United Kin-
gdom Netherlands Chile
Austria Switzerland Croatia
Portugal Denmark Australia
Finland Japan United Sta-
tes of Amer-
ica
Belgium Singapore Brazil
Germany Slovenia Republic of
South Africa
France Israel New Zea-
land
Spain South Ko-
rea Canada
Ce manuel convient aux modèles suivants
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