SR Max 300

SERVICE STATION MANUAL
677514 EN
SR MAX 300 i.e. (2011)

SERVICE STATION
MANUAL
SR MAX 300 i.e. (2011)
THE VALUE OF SERVICE

As a result of continuous updates and specific technical training programmes for Aprilia products, only
Aprilia Official Network mechanics know this vehicle fully and have the specific tools necessary to carry
out maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding
it, its regular maintenance and the use of original Aprilia spare parts only are essential factors!
For information on the nearest Official Dealer and/or Service Centre consult our website:
www.aprilia.com
Only by requesting aprilia original spare parts can you be sure of purchasing products that were
developed and tested during the actual vehicle design stage. All aprilia original spare parts undergo
quality control procedures to guarantee reliability and durability.
The descriptions and images in this publication are given for illustrative purposes only and are not binding.
While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &
C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand,
to make any changes to components, parts or accessories, which it considers necessary to improve the
product or which are required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of individual
models should be confirmed with the official aprilia sales network.
The Aprilia trademark is the property of Piaggio & C. S.p.A.
© Copyright 2012 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com
SERVICE STATION MANUAL
SR MAX 300 i.e. (2011)
This manual provides the main information to carry out regular maintenance operations on your vehicle.
This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been
deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, Piaggio & C. S.p.a. commits itself
to continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all Aprilia Sales Outlets and its International
Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of
need or further queries on repair and check procedures, consult Aprilia CUSTOMER DEPARTMENT,
which will be prepared to provide any information on the subject and any further communications on
updates and technical changes related to the vehicle.
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee
INDEX OF TOPICS
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
INJECTION INJEC
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
TIME TIME
INDEX OF TOPICS
CHARACTERISTICS CHAR
SR MAX 300 i.e. (2011) Characteristics
This section describes the general specifications of the vehicle.
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well-
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original APRILIA spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spare parts may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. Using unsuitable
coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.
CHAR - 7
Characteristics SR MAX 300 i.e. (2011)
Vehicle identification
To read the chassis prefix, remove the lid «A» in

the helmet compartment.
The engine prefix «B» is stamped near the left

shock absorber lower support.
VEHICLE IDENTIFICATION
Specification Desc./Quantity
Chassis prefix ZAPM35600123456789
Engine prefix M356M
Dimensions and mass
WEIGHTS AND DIMENSIONS

Kerb weight 174 ± 5 kg
Maximum weight allowed 370 Kg
CHAR - 8
Engine
ENGINE TECHNICAL DATA

Type Single-cylinder, 4-stroke
Engine capacity 278 cm³
Bore x Stroke 75x63 mm
Compression ratio 11 ± 0.5 : 1
Idle speed 1700 ± 100 rpm
Timing system 4 valves, single overhead camshaft, chain-driven.
Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm
Max. power 16.1 kW at 7,250 rpm
MAX. torque 23 Nm at 6,000 rpm
Main drive Automatic expandable pulley variator with torque server, V-
belt, automatic self-ventilating centrifugal dry clutch
Final reduction gear Gear reduction unit in oil bath.
Lubrication Engine lubrication with lobe pump (inside crankcase), chain-
driven, with double filter: mesh and paper.
Cooling Forced coolant circulation system.
Electric start-up Oil-coated freewheel and torque limiter.
Ignition Electronic inductive discharge ignition, high efficiency, with
separate HV coil.
Ignition advance α/N three-dimensional map managed by control unit
Spark plug NGK CR8EKB
Fuel system Electronic injection with electric fuel pump
Fuel Unleaded petrol (95 RON)
Exhaust silencer Absorption-type exhaust muffler with catalytic converter.
Emissions compliance EURO 3
CHAR - 9
Transmission
TRANSMISSION
Main drive Automatic expandable pulley variator with torque server, V-
belt, automatic self-ventilating centrifugal dry clutch
Capacities
CAPACITY
Engine oil 1.3 l
Transmission oil 250 cm³
Cooling system fluid ~ 1.8 l
Fuel tank (reserve) approx.15.00 l (approx. 2.80 l)
Electrical system
ELECTRICAL COMPONENTS
Starter Electric
Ignition Electronic inductive discharge ignition, high efficiency, with
separate HV coil.
Ignition advance α/N three-dimensional map managed by control unit
Spark plug NGK CR8EKB
Battery 12V/14 Ah, sealed battery
Frame and suspensions
FRAME AND SUSPENSIONS

Chassis Tubular and steel sheets.
Front suspension Hydraulic telescopic fork with Ø 35-mm stem
Rear suspension Two double-acting shock absorbers, adjustable to four posi-
tions at preloading.
Brakes
BRAKES
Front brake Ø 260mm disc brake with hydraulic control activated by han-
dlebar right-side lever.
Rear brake Ø 240-mm disc brake with hydraulic control operated by the
handlebar left-side lever.
Wheels and tyres
WHEELS AND TYRES

Wheel rim type Light alloy wheel rims.
Front tyre Tubeless, 120/70 - 15'' 56P
CHAR - 10
Rear tyre Tubeless, 140/60 - 14'' 64P
Front rim 15'' x 3.00
Rear rim 14'' x 3.50
TYRE PRESSURE
Front tyre pressure (with passenger) 2.3 bar (2.3)
Rear tyre pressure (with passenger) 2.3 bar (2.5)
NOTE
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-
LATE PRESSURE ACCORDING TO THE WEIGHT OF BOTH RIDER AND ACCESSORIES
Overhaul data
Assembly clearances
Cylinder - piston assy.
CYLINDER - PISTON
Plunger diameter 74.967 +0.014 -0.014 mm
Cylinder diameter 75 +0.038 +0.01 mm
COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
cylinder-piston M 75.01 ÷ 75.017 74.953 ÷ 74.960 0.050 ÷ 0.064
cylinder-piston N 75.017 ÷ 75.024 74.960 ÷ 74.967 0.050 ÷ 0.064
cylinder-piston O 75.024 ÷ 75.031 74.967 ÷ 74.974 0.050 ÷ 0.064
cylinder-piston P 75.031 ÷ 75.038 74.974 ÷ 74.981 0.050 ÷ 0.064
NOTE
CHAR - 11
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.
- Measure the outer diameter of the gudgeon pin.
Characteristic
Pin outside diameter
16 +0 -0.004 mm
- Measure the diameter of the bearings on the pis-

ton.
Characteristic
Standard diameter
16 +0.006 +0.001 mm
- Calculate the piston pin coupling clearance.

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

- Measure the coupling clearance between the
sealing rings and the piston grooves using suitable
sensors, as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
NOTE
MEASURE THE CLEARANCE BY INSERTING THE BLADE
OF THE FEELER GAUGE FROM THE SECOND SEAL RING
SIDE.
Fitting clearance
Top piston ring - standard coupling clearance
0.015 - 0.06 mm Top piston ring - maximum clear-
ance allowed after use 0.07 mm Middle piston
ring - standard coupling clearance 0.015 - 0.06 mm
Middle piston ring - maximum clearance al-
lowed after use 0.07 mm oil scraper ring - stand-
CHAR - 12
ard coupling clearance 0.015 - 0.06 mm oil scraper

ring - maximum clearance allowed after use
0.07 mm
- Check that the head coupling surface is not worn

or misshapen.
- Pistons and cylinders are classified according to
their diameter. The coupling must be made with
those of the same type (M-M, N-N, O-O, P-P).
Characteristic
Maximum allowable run-out:
0.05 mm
Crankcase - crankshaft - connecting rod
CRANKSHAFT
Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Crankshaft Axial clearance between
crankshaft and connecting rod
Axial clearance between crankshaft and connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity
Transmissionside half- 16.6 +0-0.05 A D = 0.20 ÷ 0.50
shaft
Flywheel-side halfshaft 16.6 +0-0.05 B D = 0.20 ÷ 0.50
Connecting rod 18 -0.10 -0.15 C D = 0.20 ÷ 0.50
Spacer tool 51.4 +0.05 E D = 0.20 ÷ 0.50
Diameter of crankshaft bearings.

Measure the bearings on both axes x-y.
CHAR - 13
CRANKSHAFT
Crankshaft bearings: Standard diameter: Cat. 1 28.998 ÷ 29.004 mm
Crankshaft bearings: Standard diameter: Cat. 2 29.004 ÷ 29.010 mm
CHAR - 14
MAX. ADMISSIBLE DISPLACEMENT

A= 0.15 mm
B= 0.010 mm
C= 0.010 mm
D= 0.10 mm
CHAR - 15
Characteristic
Crankshaft-crankcase axial clearance (H)
0.15 ÷ 0.43 mm
- Using a bore gauge, measure the connecting rod

small end diameter.
NOTE
IF THE CONNECTING ROD SMALL END DIAMETER EX-
CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR
OVERHEATING, PROCEED TO REPLACE THE CRANK-
SHAFT AS DESCRIBED IN THE CRANKCASE AND
CRANKSHAFT CHAPTER.
Characteristic
Standard diameter
16 +0.025 +0.015 mm
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and
a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply
channels.
- The main bushings are comprised of two half-bearings, one with holes and channels for lubrication
whereas the other is solid.
- The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is
arranged opposite the cylinder.
- To prevent shutters in the oil feeding channels, the matching surface of the two half-bearings must be
perfectly orthogonal to the cylinder axis, as shown in the figure.
- The oil feeding channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
- Check the inside diameter of the main bushings in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing half. see diagram.
- There are three crankcase versions: with BLUE bushings, with YELLOW bushings and with GREEN
bushings.
- There is only one type of main bushing housing hole in the crankcase. The standard bushing diameter
after driving is variable on the basis of a coupling selection.
- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like
those for the crankshaft.
- The main bushings are available in three thickness categories, identified by colour markings, as shown
in the table below.
BUSHINGS
TYPE IDENTIFICATION CRANKSHAFT HALF-BEARING
B BLUE 1.973 to 1.976
C YELLOW 1.976 to 1.979
E GREEN 1.979 to 1.982
CHAR - 16
COUPLINGS
BUSHING CATEGORY CRANKCASE BUSHING INSIDE DIAMETER AFTER FITTING
HALVES CATEGORY
B 2 29.024 ÷ 29.054
C 1 29.024 ÷ 29.054
2 29.018 ÷ 29.048
E 1 29.018 ÷ 29.048
Combine the shaft with two category 1 crankwebs with the category 1 crankcase (or cat. 2 with cat. 2).
Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories. The spare
crankshaft has half-shafts of the same category.
CATEGORIES
CRANKCASE HALVES ENGINE HALF-SHAFT BUSHING
Cat. 1 Cat. 1 E
Cat. 2 Cat. 2 B
Cat. 1 Cat. 2 C
Cat. 2 Cat. 1 C
NOTE
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-
SHELL COUPLING SURFACE SINCE THE ENDS ARE RE-
LIEVED TO ALLOW BENDING DURING THE DRIVING
OPERATION.
NOTE
CRANKCASES FOR REPLACEMENTS ARE SELECTED
WITH CRANKCASE HALVES OF THE SAME CATEGORY
AND ARE FITTED WITH CATEGORY C BUSHINGS (YEL-
LOW)
Characteristic
Crankshaft-bushing maximum clearance ad-
mitted:
0.08 mm
Diameter of crankcase without bushing
CAT. 1: 32.959 ÷ 32.965 mm
CAT. 2: 32.953 ÷ 32.959 mm
Cylinder head
Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of
the springs and the valves so as not to change the original position during refitting
- Using a trued bar and a feeler gauge check that

the cylinder head surface is not worn or distorted.
Characteristic
Maximum allowable run-out:
0.1 mm
- In case of faults, replace the head.
CHAR - 17
- Check the sealing surfaces for the intake and exhaust manifold.
- Check that the camshaft and the rocking lever pin capacities exhibit no wear.
- Check that the head cover surface is not worn.
- Check that the coolant seal plug exhibits no oxidation.
- Insert the valves into the cylinder head.

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

lever support pins with a bore meter
HEAD BEARINGS
bearing «A» Ø 12.000 - 12.018 mm
bearing «B» Ø 20.000 ÷ 20.021 mm
bearing «C» Ø 37.000 - 37.025 mm
CHAR - 18
Measure the unloaded spring length
Characteristic
Standard length
40.2 mm
Allowable limit after use:
38.2 mm
- Clean the valve seats of any carbon residues.

- Using the Prussian blue, check the width of the
impression on the valve seat "V".
Characteristic
Standard value:
1 - 1.3 mm
Admissible limit:
1.6 mm
- If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°
mill and then grind.
- In case of excessive wear or damage, replace the head.
STANDARD VALVE LENGTH

Valve check Standard length Intake: 94.6 mm
Valve check Standard length Exhaust: 94.4 mm
CHAR - 19
- Measure the diameter of the valve stems in the

three positions indicated in the diagram.
STANDARD DIAMETER
Intake: 4.987 - 4.972 mm
Exhaust: 4.975 - 4.960 mm
MINIMUM ADMISSIBLE DIAMETER

Intake: 4.96 mm
Exhaust: 4.945 mm
- Calculate the clearance between valve and valve guide.
- Check the deviation of the valve stem by resting

it on a «V» shaped abutment and measuring the
extent of the deformation with a dial gauge.
Characteristic
Limit values admitted:
0.1 mm
- 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
CHAR - 20
Measure the valve guide.
Characteristic
Valve guide:
5 +0.012 mm
- After measuring the valve guide diameter and the

valve stem diameter, check clearance between
guide and stem.
INTAKE
Standard clearance: 0.013 - 0.04 mm
Admissible limit: 0.08 mm
EXHAUST
Standard clearance: 0.025 to 0.052 mm
Admissible limit: 0.09 mm
- Check that there are no signs of wear on the faying surface with the articulated set screw terminal.
CHAR - 21
- If no faults are found during the above checks,

you can use the same valves. To obtain better
sealing performance, grind the valve seats. Grind
the valves gently with a fine-grained lapping com-
pound. During the grinding, keep the cylinder head
with the valve axes in a horizontal position. This
will prevent the lapping compound residues from
penetrating between the valve stem and the guide
(see figure).
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO
LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES
WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
- Check that the camshaft bearings exhibit no scores or abnormal wear.
- Using a micrometer, measure the camshaft bearings.
STANDARD DIAMETER
Camshaft check: Standard diameter Bearing A Ø: 36.95 ÷ 36.975 mm
Camshaft check: Standard diameter Bearing B diameter: 19.959 ÷ 19.98 mm
MINIMUM ADMISSIBLE DIAMETER

Camshaft check: Minimum admissible diameter Bearing A Ø: 36.94 mm
Camshaft check: Minimum admissible diameter Bearing B diameter: 19.950 mm
-Using a gauge, measure the cam height.
STANDARD HEIGHT
Camshaft check: Standard height Intake: 30.285 mm
Camshaft check: Standard height Exhaust: 29.209 mm
CHAR - 22
Check the axial clearance of the camshaft
CAMSHAFT AXIAL CLEARANCE

Camshaft check: Standard axial clearance: 0.11 - 0.41 mm
Camshaft check: Maximum admissible axial clearance 0.42 mm
- Measure the outside diameter of the rocking lever pins

- Check the rocking lever pins do not show signs of wear or scoring.
- Measure the internal diameter of each rocker.
Check there are no signs of wear on the slider from contact with the cam and on the jointed adjustment
plate.
ROCKING LEVERS AND PIN DIAMETER:

Rocking lever inside diameter: Standard diameter Diameter 12.000 - 12.011 mm
Rocking lever pin diameter: Standard diameter Diameter 11.977 - 11.985 mm
CHAR - 23
Slot packing system
Characteristic
Compression ratio
10.5 ÷ 11.5 : 1
Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed
by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls
inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice
versa.
NOTE
MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK-
CASE AND CYLINDER AND AFTER RESETTING THE DIAL GAUGE, EQUIPPED WITH A SUP-
PORT, ON A GROUND PLANE
ENGINE 300 SHIMMING

Name Measure A Thickness
SHIMMING 3.70 - 3.60 0.4 ± 0.05
SHIMMING 3.60 - 3.40 0.6 ± 0.05
SHIMMING 3.40 - 3.30 0.8 ± 0.05
CHAR - 24
Products
RECOMMENDED PRODUCTS TABLE

Product Description Specifications
AGIP GEAR SAE 80W-90 Lubricant for gearboxes and transmis- API GL-4
sions.
eni i-Ride PG 5W-40 Synthetic based lubricant for high-per- JASO MA, MA2 - API SL - ACEA A3
formance four-stroke engines.
AGIP GP 330 Water repellent springy calcium spray R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 -
grease. I.A.T.A. 2 - I.M.D.G. class 2 UN 1950 Pag.
9022 EM 25-89
eni i-Ride PG 5W-40 Synthetic based lubricant for high-per- JASO MA, MA2 - API SL - ACEA A3
formance four-stroke engines.
AGIP BRAKE 4 Brake fluid. Synthetic fluid SAE J 1703 -FMVSS 116
- DOT 3/4 - ISO 4925 - CUNA NC 956
DOT 4
AGIP PERMANENT SPECIAL Ethylene glycol-based antifreeze fluid ASTM D 3306 - ASTM D 4656 - ASTM D
with organic inhibition additives. Red, 4985 - CUNA NC 956-16
ready to use.
AUTOSOL METAL POLISH Silencer cleaning paste special product for cleaning and polishing
stainless steel silencer
AGIP GREASE PV2 Ivory smooth-textured, slightly-stringy TL 9150 066, symbol NATO G 460
anhydrous calcium-base grease.
AGIP GREASE SM 2 Gray black smooth-textured lithium -
grease, containing molybdenum disul-
phide.
CHAR - 25
INDEX OF TOPICS
TOOLING TOOL
SR MAX 300 i.e. (2011) 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
020459Y Punch for fitting bearing on steering tube
020004Y Punch for removing steering bearings

from headstock
020055Y Wrench for steering tube ring nut
TOOL - 27
Tooling SR MAX 300 i.e. (2011)

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 - 28

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 - 29

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

020359Y 42 x 47-mm adaptor
020363Y 20-mm guide
TOOL - 30

020375Y 28 x 30 mm adaptor
020376Y Adapter handle
020382Y Valve cotters equipped with part 012 re-

moval tool
020382Y011 adapter for valve removal tool
020393Y Piston assembly band
020412Y 15-mm guide
TOOL - 31

020423Y Driven pulley lock wrench
020424Y Driven pulley roller casing fitting punch
020426Y Piston fitting fork
020431Y Valve oil seal extractor
020434Y Oil pressure check fitting
020444Y Tool for fitting/ removing the driven pulley

clutch
TOOL - 32

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 - 33

020621Y HV cable extraction adaptor
020481Y Control unit interface wiring
001467Y035 Bell for 47-mm outside diameter bearings
020626Y Driving pulley lock wrench
020627Y Flywheel lock wrench
TOOL - 34

020454Y Pin lock fitting tool
020467Y Flywheel extractor
020622Y Transmission-side oil seal punch
020480Y Petrol pressure check kit
020244Y 15-mm diameter punch
020115Y Ø 18 punch
TOOL - 35

020271Y Tool for removing-fitting silent bloc
020469Y Reprogramming kit for vehicle diagnostic

tester
020487Y Fork oil seal extractor
TOOL - 36
INDEX OF TOPICS
MAINTENANCE MAIN
Maintenance SR MAX 300 i.e. (2011)
Maintenance chart
SCHEDULED MAINTENANCE TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
Clean the SAS air filter every 2 years
* Replace every 2 years
km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60
Safety fasteners I I I I I
Spark plug R R R R R R
Driving belt R R R R
Throttle control A A A A A A A
Air filter C C C C C C
Belt compartment air filter I I I I I I
Oil filter R R R R R R R
Oil filter (mesh) C
Valve clearance A A A
Electrical system and battery I I I I I I I
Brake fluid * I I I I I I I
Coolant * I I I I I I I
Engine oil R I R I R I R I R I R I R
Hub oil R I R I R I R
Brake pads I I I I I I I I I I I I I
Sliding shoes / CVT rollers R R R R R R
Tyre pressure and wear I I I I I I I
Vehicle road test I I I I I I I
Suspension I I I I I I
Steering A A A A A A A
Centre stand L L
Checking the spark advance
The ignition advance is determined electronically

on the basis of parameters known by the control
unit. For this reason it is not possible to interpret
the reference values based on the engine rpm.
The ignition advance value is detectable at any
time using the diagnostic tester. It is possible to
check whether the ignition advance determined by
the injection system matches the value actually
activated on the engine, by means of the strobo-
scopic light.
Proceed as follows:
- Remove the spark plug.
- Remove the transmission crankcase.
- Rotate the driving pulley fan until the reference
marks between the flywheel and flywheel cover
coincide as shown in the photograph.
MAIN - 38
SR MAX 300 i.e. (2011) Maintenance
- Bring the reference mark onto the transmission

side between the fan and the transmission cover
as shown in the picture.
- Refit the spark plug.
- Refit the plastic cap on the flywheel cover.
- Adjust the spark gap to the contact position (no
reference mark visible) and install it on the engine
between the spark plug and spark plug cap
- Connect the induction clamp on the spark gap
cable respecting the proper polarity (the arrow on
the clamp must be pointing at the spark plug).
- Connect the diagnostic tester.
- Start the engine.
- Select the «Parameters» function in this menu.
- Set the stroboscopic light control to the traditional
four-stroke engine position (1 spark, 2 revs).
- Check that the real values of rpm and ignition
advance match those measured using the diag-
nostic tester.
If the values do not correspond, check:
- distribution timing
- revolution timing sensor
- injection control unit
Specific tooling
020330Y Stroboscopic light to check timing
020621Y HV cable extraction adaptor
Spark plug
Proceed as follows:
1. Remove the right side cover unscrewing the 3
«A» screws;
2. Disconnect the spark plug HV wire hood «B» ;
3. Unscrew the spark plug using the wrench sup-
plied. ;
MAIN - 39
4. When refitting, place the spark plug in the hole

at the due inclination and tighten it by hand until it
is finger tight;
5. Only use the wrench to lock it in place;
6. Push hood «B» fully over the spark plug.
WARNING
THE USE OF SPARK PLUGS OTHER THAN THOSE REC-
OMMENDED OR A SHIELDLESS SPARK PLUG CAP
COULD CAUSE DISTURBANCES TO THE SYSTEM.
WARNING
THE SPARK PLUG MUST BE REMOVED WHEN THE EN-

GINE IS COLD. REPLACE THE SPARK PLUG AS INDICA-
TED IN THE SCHEDULED MAINTENANCE TABLE. THE
USE OF ELECTRONIC CENTRAL UNITS AND OF NON-
COMPLIANT ELECTRONIC IGNITIONS OR SPARK PLUGS
OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY
DAMAGE THE ENGINE.
Characteristic
Spark plug
NGK CR8EKB
Electric characteristic
Electrode gap
0.7 to 0.8 mm
Locking torques (N*m)

Spark plug 12 ÷ 14
Hub oil
Check
-Place the vehicle on the centre stand on flat

ground;
- Remove the oil dipstick «A», dry it with a clean
cloth and put it back into its hole tightening it
completely;
Remove the dipstick and check that the oil level is
slightly over the second notch starting from the
lower end; if the level is under the MAX. mark, it
needs to be filled with the right amount of hub oil.
-Screw up the oil dipstick again and make sure it
is locked properly into place.
MAIN - 40
Replacement
-Remove the oil filler cap «A».

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

Hub oil drainage screw 15 to 17 Nm
Air filter
Proceed as follows:
1. Unscrew the 9 fixing screws «A»;
2. Remove the air filter«B»
CAUTION
IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NEC-

ESSARY TO CARRY OUT MAINTENANCE CHECKS OF
THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE
ENGINE.
MAIN - 41
1. Wash the sponge with water and neutral soap.

2. Dry it with a clean cloth and small blasts of compressed air.
3. Soak the sponge with a mixture of 50% petrol and 50% specified oil.
4. Gently squeeze the filter element without twisting it, let it drip and then refit it.
CAUTION
IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE

CHECKS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.
AGIP FILTER OIL Special product for the treatment of foam filters.
-
Engine oil
In four stroke engines, the engine oil is used to lubricate the distribution elements, the bench bearings
and the thermal group. An insufficient quantity of oil can cause serious damage to the engine.
In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should
be considered normal, especially if during the run-in period. Consumption levels in particular can be
influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".
Replacement
Change oil and replace filter as indicated in the

scheduled maintenance table. Empty the engine
by draining the oil through drainage plug «B».
MAIN - 42
To facilitate oil drainage, loosen the cap/dipstick

«A».
Once all the oil has drained through the drainage

hole, unscrew and remove the oil cartridge filter
«C ».
Make sure the pre-filter and drainage plug O-rings

are in good conditions.
Lubricate them and refit the mesh filter and oil
drainage plug, screwing them up to the specified
torque.
Refit the new cartridge filter being careful to lubri-
cate the O-ring before fitting it.
Change the engine oil.
Since a certain quantity of oil still remains in the
circuit, engine oil must be added through plug
«A». Then start the scooter, leave it running for a
few minutes and switch it off: after five minutes
check the level and if necessary top up without
exceeding the MAX level. The cartridge filter must
be replaced every time the oil is changed. Use new
oil of the recommended type for topping up and
changing purposes.
NOTE
THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.
eni i-Ride PG 5W-40 Synthetic based lubricant
for high-performance four-stroke engines.
MAIN - 43
JASO MA, MA2 - API SL - ACEA A3

Oil filter 4 to 6 Engine oil drainage plug 24 to 30
Check
This operation must be carried out with the engine

cold and following the procedure below:
- Place the vehicle on its centre stand and on flat
ground.
- Unscrew the cap/dipstick «A», dry it with a clean
cloth and reinsert it, screwing it all the way
down.
- Remove the cap/dipstick again and check that
the level is between the min and max reference
marks; top-up, if required.
If the check is carried out after the vehicle has
been used, and therefore with a hot engine, the
level line will be lower; in order to carry out a cor-
rect check, wait at least 10 minutes after the en-
gine has been stopped so as to get the correct
level.
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.
Restoring the level from the MIN to the MAX marks
requires approx. 400 m³ of oil.
Engine oil filter
The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended
type for topping up and changing purposes.
Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the
mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge
filter being careful to lubricate the O-ring before fitting it. Change the engine oil.
MAIN - 44
eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance four-stroke engines.
JASO MA, MA2 - API SL - ACEA A3
Oil pressure warning light
Warning light (low oil pressure)

The vehicle is equipped with a warning light on the
instrument panel that lights up when the key is
turned to the «ON» position. However, this light
should switch off once the engine has been star-
ted.
If the light comes on during braking, at idling
speed or while turning, it is necessary to first
switch off the engine and then to check the oil
level and the lubrication system
Checking the ignition timing
- Remove the plastic cap on the flywheel cover

-Turn the flywheel until the reference mark «T» on
the rotor matches the reference mark on the fly-
wheel cover as shown in the figure (TDC). Make
sure that the 4V reference point on the camshaft
control pulley is aligned with the reference point on
the head as shown in the second figure. If the ref-
erence is opposite the indicator on the head, turn
the crankshaft once more.
For the use of this reference mark, remove the
spark plug and turn the engine in the direction that
is the reverse of the normal direction using a cal-
liper spanner applied to the camshaft command
pulley casing.
Cooling system
If noise or liquid leaks through the drain bore of the water pump is detected, it will be necessary to
replace the pump as described in the «Flywheel cover» Chapter.
Proceed to carry out a few preliminary operations as described below:
MAIN - 45
- Place the vehicle on its centre stand and on flat ground.

- Empty the cooling system by removing the couplings on the pump cover and the filler plug on the
expansion tank.
CAUTION
THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.
- Remove the water pump cover as indicated in the
figure by loosening the 3 fixing screws.
- Proceeding as described in chapter «Engine»,
partially drain the system and overhaul the pump.
- Refill and drain the system again once after hav-
ing repaired the damaged and reinstalled all the
components.
NOTE
FOR CHANGING THE COOLANT AND BLEEDING THE
SYSTEM, SEE CHAPTER "COOLING SYSTEM".
Characteristic
Cooling system
approx. 1.8 litres
Level check
Check coolant level when the engine is cold and

as indicated in the scheduled maintenance table,
following the steps below:
- Place the vehicle on its centre stand and on flat
ground.
- Remove the expansion tank cap.
- To check the level, it is necessary to look inside
the expansion tank:
Reference «C» shows the adequate coolant level.
-The coolant consists of an ethylene glycol and corrosion inhibitor based 50% de-ionised water- anti-
freeze solution mix.
CAUTION
DO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO AS TO AVOID THE COOLANT ESCAPING
FROM THE EXPANSION TANK WHEN THE VEHICLE IS IN USE.
NOTE
THE COOLANT CONSISTS OF A MIXTURE OF DE-IONISED WATER AND FLUID FOR SEALED
CIRCUITS. THE MIXTURE THUS OBTAINED LOWERS THE FREEZING POINT OF THE COOLANT
TO - 40°C. THE MIXTURE IN COMBINATION WITH THE PRESSURE OF 0.9 BAR RAISES THE
BOILING POINT TO APPROX. 125°C. THE RECOMMENDED LIQUID ALSO PROVIDES PROTEC-
TIVE FUNCTIONS FOR THE ALUMINIUM ALLOYS. THIS CHARACTERISTIC MAY DECREASE
OVER THE COURSE OF TIME; THIS IS WHY A PERIODIC REPLACEMENT OF THE COOLANT IS
INDISPENSABLE.
MAIN - 46
NOTE
FOR THE REPLACEMENT OF THE COOLANT AND THE FLUSHING OF THE SYSTEM, SEE
CHAPTER COOLING SYSTEM.
Braking system
Level check
- Position the vehicle on a flat surface and on the

centre stand.
- Check the brake fluid level via the special indi-
cator located on the pump.
NOTE
THE LEVEL TENDS TO DROP AS THE BRAKE PADS GET WORN, A MINIMUM LEVEL SHOULD
NOT BE REACHED. IF THE LEVEL IS TOO LOW, CHECK AND FIX THE SYSTEM SEALS, IF RE-
QUIRED. TOP UP THE PUMP RESERVOIR, IF REQUIRED, CONSIDERING THAT THE "MAX."
LEVEL MUST ONLY BE OBTAINED WITH NEW PADS.
Top-up
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.
Proceed as follows:
- Position the vehicle on a flat surface and on the
centre stand.
- Remove the tank cap by removing the two
screws, remove the gasket and top up using only
the liquid specified without exceeding the maxi-
mum level.
MAIN - 47
CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE
OF ACCIDENTAL CONTACT, WASH WITH WATER.
WARNING
BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; DO NOT LET IT COME INTO CONTACT WITH
THE PAINTED PARTS.
WARNING
THE BRAKE FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS MOISTURE FROM THE SUR-
ROUNDING AIR. IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, IT
WILL LEAD TO INEFFICIENT BRAKING; FOR THIS REASON, NEVER USE BRAKING FLUID
FROM CONTAINERS THAT HAVE ALREADY BEEN OPENED, OR PARTIALLY USED.
AGIP BRAKE 4 Brake fluid.
Synthetic fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO 4925 - CUNA NC 956 DOT 4
Under standard climatic conditions, replace coolant as indicated in the scheduled maintenance table.
NOTE
SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID
AND THE BLEEDING OF AIR FROM THE CIRCUITS.
Headlight adjustment
- Place the vehicle in use conditions, with tyres inflated to the prescribed pressure on flat ground at 10
m from a white screen placed in dim light.
- Make sure that the scooter axle is perpendicular to the screen.
- Turn the headlight on and check that the limit of the light beam projected onto the screen does not
exceed 9/10 of the headlight centre height from the ground and that it is not less than 7/10.
MAIN - 48
- Otherwise, adjust the right headlight by the screw

shown in the figure, which can be accessed by re-
moving the front shield connecting member.
NOTE
THE ABOVE PROCEDURE COMPLIES WITH THE EURO-
PEAN STANDARDS REGARDING MAXIMUM AND MINI-
MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-
TORY REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE VEHICLE IS USED.
MAIN - 49
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
SR MAX 300 i.e. (2011) 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
Poor performance
POOR PERFORMANCE
Possible Cause Operation
Fuel pump Check the injection load relay
Excess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves
Incorrect timing or worn timing system elements Time the system again or replace the worn parts
Obstructed muffler Replace
Filtro aria otturato o sporco Smontare la spugna, lavare con acqua e shampoo, quindi im-
pregnarla con una miscela al 50% di benzina e olio specifico,
successivamente spremerla tra le mani senza strizzarla, las-
ciarla sgocciolare e rimontarla.
Oil level exceeds maximum Check for causes and fill to reach the correct level
Lack of compression: parts, cylinder and valves worn Replace the worn parts
Drive belt worn Replace
Inefficient automatic transmission Check the rollers, the pulley movement and make sure the
drive belt is in good conditions; replace the damaged parts and
lubricate the moveable driven pulley with specific grease.
Clutch slipping Check the clutch system and/or the bell and replace if neces-
sary
Overheated valves Remove the head and the valves, grind or replace the valves
Wrong valve adjustment Adjust the valve clearance properly
Valve seat distorted Replace the head unit
Excessive oil consumption/Exhaust smoke
EXCESSIVE CONSUMPTION
Wrong valve adjustment Adjust the valve clearance properly
Overheated valves Remove the head and the valves, grind or replace the valves
Misshapen/worn valve seats Replace the head unit
Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings
Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings
fitted properly
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal
Worn valve oil seal Replace the valve oil seal
Worn valve guides Check and replace the head unit if required
Insufficient lubrication pressure
LOW LUBRICATION PRESSURE

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Oil pump with excessive clearance Perform the dimensional checks on the oil pump components
Oil filter too dirty Replace the cartridge filter
Oil level too low Restore the level adding the recommended oil type
TROUBL - 51
Troubleshooting SR MAX 300 i.e. (2011)
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

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

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are
not worn, scored or warped. Check the correct level of fluid in
the pumps and change brake fluid if necessary. Check there is
no air in the circuits; if necessary, bleed the air. Check that the
front brake calliper moves in axis with the disc.
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace
Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift
of the disc with a dial gauge and with wheel mounted on the
vehicle.
Brakes overheating
BRAKE OVERHEAT
Defective plunger sliding Replace the calliper.
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Clogged compensation holes on the pump Clean carefully and blast with compressed air
Swollen or stuck rubber gaskets Replace the calliper.
Steering and suspensions
Heavy steering
STEERING HARDENING
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the rotation seats and the steering
fifth wheels.
TROUBL - 52
SR MAX 300 i.e. (2011) Troubleshooting
Excessive steering play
EXCESSIVE STEERING CLEARANCE

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the rotation seats and the steering
fifth wheels.
Noisy suspension
NOISY SUSPENSION
Faults in the suspension system If the front suspension is noisy, check: tightening torques,
headstock components, inspect forks.
Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION

Faulty or broken seals Replace the shock absorber
TROUBL - 53
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

SR MAX 300 i.e. (2011) Electrical system
KEY
1. Battery 12V - 14Ah
2. Voltage regulator
3. Magneto flywheel
4. Starter solenoid
5. Starter motor
6. Engine ground
7. Fuses No. 01 - 30A
8. Fuses No. 02 - 15A
9. N. 03 - 15A Fuse
10. Fuses No. 04 - 15A
11. Fuses No. 05 - 10A
12. Fuses No. 06 - 7.5A
13. Fuses No. 07 - 7.5A
14. Fuses No. 08 - 7.5A
15. Fuses No. 09 - 7.5A
16. Fuses No. 10 - 7.5A
17. Fuses No. 11 - 7.5A
18. Light switch
19. High-beam light solenoid
ELE SYS - 55
Electrical system SR MAX 300 i.e. (2011)
20. High beam bulb 12v-55w

21. High beam warning light 12v-1.2w
22. Starter button
23. N.2 stop buttons
24. Stop light bulb 12v-21/5w
25. Horn 12v c.c.
26. Horn button
27. Pre-installation for anti-theft device
28. Ignition key contact
29. Max 12v-180w socket
30. Helmet compartment light switch
31. Helmet compartment lighting bulb 12v-5w
32. Instrument panel
33. Bulbs 12V-10W for turn indicators
34. Analogue rpm indicator
35. Oil pressure sensor
36. Remote mode button
37. Turn indicator switch
38. Fuel level transmitter
39. Electrical control device
40. Electronic control unit remote control switch
41. Rear daylight running light bulb 12v-21/5w
42. Bulb 12v-5w for license plate lamp
43. 2 bulbs 12v-5w for front daylight running light
44. Bulb 12v-1.2w for daylight running warning light
45. Radiator electric fan remote control
46. Radiator electric fan
47. Wheel speed sensor
48. Injection ECU
49. Diagnosis
50. Coolant temperature sensor for c.d.i.
51. Coolant sensor for instrument
52. Stand button
53. Engine stop switch
54. Fuel pump
55. Fuel injector
56. Lambda sensor
57. HV coil
ELE SYS - 56
58. Engine speed sensor

59. Decoder
60. Aerial
61. Fuses No. 12 - 7.5A
KEY
Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr: Grey Ma: Brown Ne: Black Ro: Pink Rs:
Red Ve: Green Vi: Purple
Components arrangement
ELE SYS - 57
1. Remote controls
Remove the legshield to reach it.
A. Electric fan remote control
B. High-beam light remote control
C. Injection load remote control

Remove the legshield to reach it.
3. Main fuses
To reach it, remove the battery cover placed in the helmet compartment.
ELE SYS - 58
4. Injection ECU
To reach it, remove the inspection compartment
placed in the helmet compartment.
5. Auxiliary fuses
Located in the helmet compartment.
6. Starter motor
Remove the helmet compartment to reach it.
7. Starter remote control

Remove the central chassis cover to reach it.
8. Stand button
Remove the left footrest to reach them.
ELE SYS - 59
9. Horn
To reach it, remove the lower cover.
10-11. Key switch/Immobilizer aerial

Remove the shield back plate to reach it.
12. Battery
To reach it, remove the battery cover placed in the helmet compartment.
13. HV coil
Remove the right side fairing to reach it.
14. Magneto flywheel

The connector is located near the fuel pump. To
reach it, remove the central chassis cover.
ELE SYS - 60

On the engine, on the right-hand side of the vehi-
cle.

To reach it, remove the central chassis cover. The
transmitter is integrated to the fuel pump.

To reach it, remove the lower cover.
18.Wheel turning sensor

In the front wheel, on the right-hand side.
ELE SYS - 61
Ground points
A. Ground points on the chassis

To reach them, remove the right footrest.
B. Ground point on the engine

To reach it, remove the inspection compartment
placed in the helmet compartment.
Conceptual diagrams
ELE SYS - 62
Ignition
KEY
6. Engine ground
8. Fuses No. 02 - 15A
11. Fuses No. 05 - 10A
17. Fuses No. 11 - 7.5A
48. Injection ECU
54. Fuel pump
55. Fuel injector
57. HV coil
ELE SYS - 63
Battery recharge and starting
KEY
3. Magneto flywheel
4. Starter solenoid
5. Starter motor
6. Engine ground
7. Fuses No. 01 - 30A
8. Fuses No. 02 - 15A
10. Fuses No. 04 - 15A
14. Fuses No. 08 - 7.5A
22. Starter button
48. Injection ECU
ELE SYS - 64
Level indicators and enable signals section
KEY
6. Engine ground
8. Fuses No. 02 - 15A
10. Fuses No. 04 - 15A
15. Fuses No. 09 - 7.5A
16. Fuses No. 10 - 7.5A
17. Fuses No. 11 - 7.5A
34. Analogue rpm indicator
47. Wheel speed sensor
48. Injection ECU
ELE SYS - 65
52. Stand button

59. Decoder
60. Aerial
Devices and accessories
KEY
6. Engine ground
8. Fuses No. 02 - 15A
9. N. 03 - 15A Fuse
10. Fuses No. 04 - 15A
14. Fuses No. 08 - 7.5A
16. Fuses No. 10 - 7.5A
17. Fuses No. 11 - 7.5A
25. Horn 12v c.c.
26. Horn button
27. Pre-installation for anti-theft device
29. Max 12v-180w socket
ELE SYS - 66

36. Remote mode button
48. Injection ECU
Lights and turn indicators
KEY
6. Engine ground
8. Fuses No. 02 - 15A
10. Fuses No. 04 - 15A
12. Fuses No. 06 - 7.5A
13. Fuses No. 07 - 7.5A
14. Fuses No. 08 - 7.5A
15. Fuses No. 09 - 7.5A
16. Fuses No. 10 - 7.5A
17. Fuses No. 11 - 7.5A
ELE SYS - 67
18. Light switch

19. High-beam light solenoid
20. High beam bulb 12v-55w
21. High beam warning light 12v-1.2w
31. Helmet compartment lighting bulb 12v-5w
33. Bulbs 12V-10W for turn indicators
37. Turn indicator switch
41. Rear daylight running light bulb 12v-21/5w
42. Bulb 12v-5w for license plate lamp
43. 2 bulbs 12v-5w for front daylight running light
44. Bulb 12v-1.2w for daylight running warning light
Injection
KEY
ELE SYS - 68
6. Engine ground
8. Fuses No. 02 - 15A
11. Fuses No. 05 - 10A
17. Fuses No. 11 - 7.5A
48. Injection ECU
49. Diagnosis
54. Fuel pump
55. Fuel injector
56. Lambda sensor
61. Fuses No. 12 - 7.5A
Checks and inspections
This section is dedicated to the checks on the electrical system components.
Immobiliser
The electronic ignition system is controlled by the control unit with the integrated Immobilizer system.
The immobiliser is an antitheft system which allows the vehicle to function only if it is activated by means
of the coded keys that the control unit recognises. The code is integrated in a transponder in the key
block. This allows the driver clear operation without having to do anything other than just turning the
key. The Immobilizer system consists of the following components:
- an electronic control unit
- immobilizer aerial
- master key with incorporated transponder (red key)
- service key with incorporated transponder (black key)
- HV coil
- diagnosis LED
The diagnosis LED also works as a theft-deterrent blinker. This function is activated every time the
ignition switch is turned to the "OFF" position, or the emergency stop switch is turned to the "OFF"
position. It remains activated for 48 hours in order not to affect the battery charge. When the ignition
switch is turned to the "ON" position, the theft-deterrent blinker function is deactivated. Subsequently,
a flash confirms the switching to the "ON" status. The duration of the flash depends on the programming
of the electronic control unit If the LED is off regardless of the position of the ignition-key switch and/or
the instrument panel is not initiated, check if:
ELE SYS - 69
• there is battery voltage

• fuses 2, 5, 10, 11 are in working order
• there is power to the control unit as specified below:
Remove the connector mounting bracket shown in the photograph and disconnect the connector from
the control unit. Check the following conditions:
With the key switch set to OFF:
• if there is battery voltage between ter-

minals 6-26 and terminal 6-chassis
ground (fixed power supply). If there is
no voltage check that fuse 12 and its
cable are in working order.
With the key switch in the ON position:
• there is battery voltage between termi-

nals 5-26 and terminal 5-frame earth
(fixed power supply). If there is no volt-
age, check the ignition switch contacts
and that fuses No. 2, 11 and their ca-
bles are in working order.
• There is continuity between terminals

12-18 and the emergency cut-out
switch is set to "RUN" and the side
stand folded up. If there is no continu-
ity, check the contacts of the latter.
ELE SYS - 70
After removing the leg shield back plate, remove

the electrical connection from the aerial as shown
in the picture.
Remove the protective base from the connector.
With the ignition key switch set to ON, check if

there is battery voltage between the White-Black
and Black cables.
With MIU connector disconnected, check the con-

tinuity between the Orange-White cable and pin 7
of the interface wiring.
Specific tooling
ELE SYS - 71
Virgin circuit
When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The
keys can only be recognised if the control unit has been programmed properly. The data storage pro-
cedure for a previously not programmed control unit provides for the recognition of the master as the
first key to be stored to memory: this becomes particularly important because it is the only key that
enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.
The master and service keys must be used to code the system as follows:
- Insert the Master key, turn it to «ON» and keep this position for two seconds (limit values 1 to 3
seconds).
- Insert the service key and turn it to «ON» for 2 seconds.
- If you have copies of the key, repeat the operation with each key.
- Insert the MASTER key again and turn it to «ON» for 2 seconds.
The maximum time to change keys is 10 seconds.
A maximum of 7 service keys can be programmed at one time.
It is essential to adhere to the times and the procedure. If you do not, start again from the beginning.
Once the system has been programmed, the master key transponder is strictly matched with the control
unit. With this link established, it is now possible to encode new service keys, in the event of losses,
replacements, etc. Each new programming deletes the previous one so, in order to add or eliminate
keys, you must repeat the procedure using all the keys you intend to keep using. If a service key be-
comes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In any
case it is advisable to use resistive spark plugs.
Characteristic
MASTER key:
RED KEY
SERVICE key.
BLACK KEY
ELE SYS - 72
Diagnostic codes
The Immobilizer system is tested each time the ig-

nition key is turned from «OFF» to «ON». During
this diagnosis phase a number of control unit sta-
tuses can be identified and various light codes
displayed. Regardless of the code transmitted, if
at the end of the diagnosis the LED remains off
permanently, the ignition is enabled. If, however,
the LED remains on permanently, it means the ig-
nition is inhibited:
1. Previously unused control unit - key inser-
ted: a single 2 second flash is displayed, after
which the LED remains off permanently. The keys
can be stored to memory, the vehicle can be star-
ted but with a limitation imposed on the number of
revs.
2. Previously unused control unit - transpond-
er absent or cannot be used: the LED is on
permanently. In this condition no operations are
possible including the start up of the vehicle.
ELE SYS - 73
3. Programmed control unit - the service key in

(normal condition of use): a single 0.7-second
flash is displayed, after which the LED remains off
steadily. The engine can be started.
4. Programmed control unit - Master key in: a
0.7-sec flash is displayed followed by the LED re-
maining off for 2 sec and then by short 0.46-sec
flashes, the same number of times as there are
keys stored in the memory including the Master
key. When the diagnosis has been completed, the
LED remains permanently OFF. The engine can
be started.
5. Programmed control unit - fault detected: a light code is displayed according to the fault detected,
after which the LED remains on steadily. The engine cannot be started. The codes that can be trans-
mitted are:
• 1-flash code
• 2-flash code
• 3-flash code
Diagnostic code - 1 flash
A one-flash code indicates a system where the se-

rial line is not present or is not detected. Check the
Immobilizer aerial wiring and change it if necessa-
ry.
ELE SYS - 74
Diagnostic code - 2 flashes
A two-flash code shows a system where the con-

trol unit does not show the transponder signal. This
might depend on the inefficiency of the immobiliser
aerial or the transponder.
Turn the switch to ON using several keys: if the
code is repeated even with the Master key, check
the aerial wiring and change it if necessary. If this
is not the case, replace the defective key and/or
reprogram the control unit. Replace the control unit
if the problem continues.
Diagnostic code - 3 flashes
A three-flash code indicates a system where the

control unit does not recognise the key. Turn the
switch to ON using several keys: if the error code
is repeated even with the Master key, replace the
control unit. If this is not the case, reprogram the
decoder.
Ignition circuit
No spark plug
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS
DISCONNECTED.
HV coil primary resistance value:
Disconnect the connector of the HV coil and meas-
ure the resistance between the two terminals.
Characteristic
HV coil resistance primary value:
~ 0.9 Ω
ELE SYS - 75
HV coil secondary resistance value:

1) Disconnect the HV cable from the spark plug
and measure the resistance between the spark
plug cap and the HV coil negative terminal.
2)Disconnect the spark plug cap from the HV cable
and measure the resistance between the HV cable
end and the HV coil negative terminal (see figure).
3) Measure the resistance between the 2 ends of
the spark plug cap.
Characteristic
HV coil secondary resistance value with spark
plug cap
~ 8.4 kΩ
HV coil secondary resistance value:
~ 3.4 kΩ
Spark plug cap resistance value
~ 5 kΩ
Battery recharge circuit
The charging circuit consists of three-phase alternator and a permanent magneto flywheel.
The generator is directly connected to the voltage regulator.
In turn, the voltage regulator is directly connected to the ground connection and to the battery positive
terminal passing through the 30A protection fuse (No. 1).
The three-phase alternator provides good recharge power and at low revs a good compromise is ach-
ieved between generated power and idle stability.
Stator check
Checking the stator windings

WARNING
THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.
1) Remove the central chassis cover.
2) Disconnect the connectors between stator and regulator with the three yellow cables.
3) Measure the resistance between each of the yellow terminals and the other two.
Resistance:
0.2 - 1 Ω
ELE SYS - 76
4) Check that there is insulation between the each

yellow cable and the ground.
5) If values are incorrect, replace the stator.
Recharge system voltage check
Look for any leakage

1) Access the battery by removing its cover under the saddle.
2) Check that the battery does not show signs of losing fluid before checking the output voltage.
3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole
(-) of the battery and the black cable and only then disconnect the black cable from the negative pole
(-) of the battery.
4) With the ignition key always at OFF, the reading indicated by the ammeter must be ≤ 0.5 mA.
Charging current check

WARNING
BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORK-
ING ORDER.
1) Place the vehicle on its centre stand
2) With the battery correctly connected to the circuit, place the multimeter leads between the battery
terminals..
3) Turn on the engine, increase the engine rpm and, at the same time, measure the voltage.
Voltage ranging between 14.0 and 15.0V at 5000 rpm.
Maximum current output check.
- With the engine off and the panel at «ON» with the lights on, allow the battery voltage to stop at 12V.
- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.
- Start the engine and rev it up to a high engine speed while reading the value on the pincer.
With an efficient battery a value must be detected: > 20A
VOLTAGE REGULATOR/RECTIFIER
Type Non-adjustable three-phase transistor
Voltage 14 to 15V at 5000 rpm with lights off
ELE SYS - 77
Start up system check
KEY
1. Battery
2. Fuse No. 4
3. ignition key contacts
4. Fuse No. 8
5. Stop buttons
6. Starter button
7. Starter motor
8. Starter solenoid
A. To the Injection ECU
WARNING
DISCONNECTED.
1) Check fuses No. 4 and 8, and the key switch contacts.
2) Check the contacts of the stop buttons and the starter button.
3) Check the start-up remote control switch.
4) Check wiring continuity between the Green-Blue cable that connects the starter remote control to
the injection electronic control unit (pin 24).
5) Check the starter motor ground connection.
ELE SYS - 78
Horn control
KEY
1. Battery
2. Fuse No. 4
4. Fuse No. 8
5. Horn button
6. Horn
WARNING
DISCONNECTED.
1) Check fuses No. 4 and 8, and the key switch contacts.
2) Check the horn button contacts.
3) Check wiring continuity.
4) Check the horn ground connection.
ELE SYS - 79
Turn signals system check
KEY
1.Battery
2. Fuse No. 2
4.Fuse No. 11
5. Fuse No. 10
6.Turn indicator control device
7.Electrical control device
8.Turn indicator switch
9.Bulbs for turn indicators
WARNING
DISCONNECTED.
1) Check that bulbs operate properly.
2) Check fuses No. 2, 10, 11 and the key switch contacts.
3) Check if there is voltage between the Red-Black cable and the Black cable of the turn indicator control
device or check wiring continuity.
3) With the key switch set to «ON», check again between the White-Black and the Black cables.
4) Check the turn indicator switch contacts.
5) Check continuity between the Red- Black cable (pin 3) and the White-Blue cable (pin 2) of the electric
control device.
ELE SYS - 80
6) Repeat the check between the Blue cable (pin 5) and the Pink cable (pin 4).
7) Use the turn indicator control device to check bulb wiring continuity.
level indicators
WARNING
DISCONNECTED.
If faults are detected:
1) With a multimeter, check resistance values be-
tween the White-Green cable and the Black cable
of the fuel level transmitter under different condi-
tions.
2) If the transmitter operates correctly but the in-
dication on the instrument panel is not exact,
check that the cable harnesses between them are
not interrupted.
Resistance value when the tank is full
<= 7 Ω
Resistance value when the tank is empty
90 +13/-3 Ω
Lights list
BULBS
1 High/low beam light bulb Type: Halogen (H7)
Power: 12V - 55W
Quantity: 2
2 Front headlights bulb Type: Incandescent (W2.1 x 9.5 D)
Power: 12V - 5W
Quantity: 2
3 Rear turn indicator bulbs Type: Incandescent (BAU 155 )
Power: 12V-10W
Quantity: 2
4 Front turn indicator bulbs Type: Incandescent (BAU 155 )
Power: 12V-10W
Quantity: 2
5 Tail light and stop light bulb Type: Incandescent (W2.1 x 9.5 D)
Power: 12V - 21/5W
Quantity: 1
6 License plate light bulb Type: Incandescent (W2.1 x 9.5 D)
Power: 12V - 5W
Quantity: 1
7 Helmet compartment light bulb Type: Incandescent (SV 8.5)
Power: 12V - 5W
Quantity: 1
ELE SYS - 81
Fuses
The electric system is fitted with 2 fuse boxes:
1. Fuse box «A» 6 fuses located in the helmet

compartment near the battery.
2. Fuse box «B» 6 fuses located in the helmet
compartment near the plug socket.
Replace fuses using adequate pliers supplied in

the tool kit.
The chart shows the position and specifications of
the fuses in the vehicle.
CAUTION
BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE

THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY
TO REPLACE THE FUSE WITH ANY OTHER MATERIAL
(E.G., A PIECE OF ELECTRIC WIRE).
FUSES
1 Fuse no. 1 Capacity: 30 A
Protected circuits: Battery recharge circuit.
ELE SYS - 82
Protected circuits: Lines protected by fuses No.10 and
11 (live), plug socket, helmet compartment lighting.
Protected circuits: Electric fan (via solenoid)
Protected circuits: Lines protected by fuses No. 6, 7, 8
and 9.
5 Fuse No. 5 Capacity: 10A
Protected circuits: Injection load solenoid, h.v. coil, fuel
injector, fuel pump.
6 Fuse No. 6 Capacity: 7.5A
Protected circuits (live): Low beam headlight bulb.
Protected circuits (live): High beam bulb, high beam
light relay, high beam warning light.
Protected circuits (live): Engine start up circuit, horn,
stop light bulb.
Protected circuits (live): Analogue rpm indicator, in-
strument panel lighting, daylight running light bulbs, li-
cense plate bulb, bulb for daylight running warning light.
Protected circuits: Pre-installation for antitheft device,
battery-powered instrument panel.
Protected circuits (live): Instrument panel, turn indica-
tor bulbs, radiator electrical fan remote control, electronic
control unit relay, decoder, antenna, immobilizer, ignition
switched live for injection ECU, anti-theft device prepa-
ration.
Protected circuits: Injection ECU battery power.
Dashboard
The digital display has two service symbols:

SERVICE:
The lamp should come on after reaching 1000 km,
then every 10,000 km or 1 year after the last acti-
vation.
BELT:
This lamp should come on and flash every 10,000
km.
• Press buttons "MODE" and "ODO/SET" simultaneously at the moment you turn the key to
"ON" for more than 3 seconds: The "BELT" symbol starts to flash.
ELE SYS - 83
• Pressing the button "MODE" for less than 1 second displays the symbols in turn. The se-
lected symbol remains lit.
• Pressing button "MODE" for longer than 3 seconds resets the kilometre reading for the
symbol selected, in "SERVICE" mode the date is also reset.
NOTE
• AT THE MOMENT THE DATE IS RESET, THE "SERVICE" SYMBOL IS ACTIVATED
AGAIN.
• PERFORM THE RESET PROCEDURE ONLY AT THE MOMENT OF DELIVERY OF THE
SCOOTER TO THE CUSTOMER IN ORDER THAT THIS SYMBOL SIGNALS THE NEED
FOR THE FIRST SERVICE IN RELATION TO THE DISTANCE TRAVELLED AND THE
TIME SINCE THE ACTIVATION.
The scooter has an instrument panel subdivided

into 3 sections: Digital instrument with LCD and
analogue speedometer, analogue rev counter and
warning light group.
• Warning light group
The warning light group includes:
- Warning light preparation
- Tail light and low-beam warning light (green)
- High-beam warning light (blue)
- Warning light preparation
• Digital instrument
The digital section provides the displays of:
- Injection warning light (amber)
- Low fuel warning light (amber)
- Oil pressure warning light (red)
- Turn signal warning light (green)
- Immobilizer LED (red)
The digital section of the instrument panel is com-

pleted by a liquid crystal display and 3 control
buttons (MODE - CLOCK - ODO/SET).
- The LCD panel provides a 5-digit display for the visualisation of:
• Total kilometres
ELE SYS - 84
• Trip kilometres
• Clock
NOTE
IT IS POSSIBLE TO CHANGE THE DISPLAY TO KM OR MILES BY PRESSING THE BUTTONS
"MODE" AND "CLOCK" SIMULTANEOUSLY FOR LONGER THAN 3 SECONDS AT THE MOMENT
YOU TURN THE KEY TO POSITION "ON". THE WORD "SET" WILL BE DISPLAYED.
- Pushing the "MODE" button for less than a second displays the following function sequence:
1. Average speed
The word "MEAN" appears together with km/h or mph.
The value is calculated on the basis of the trip kilometre reading.
2. Maximum speed
The word "MAX" appears together with km/h or mph.
3. Average consumption
The fuel symbol, the word "MEAN" and km/h or mph appear.
4. Momentary consumption
The fuel symbol and km/h or mph appear.
5. Range
The fuel icon appears.
If the range drops below 40 km, the symbol appears automatically and flashes for 60 seconds.
When the low fuel warning light comes on permanently, dashes appear instead of the range value.
6. Battery voltage
The battery symbol appears
Pressing button "MODE" for longer than 3 seconds returns you to function "1" of the sequence (average
speed).
- The display also contains the symbols:
BELT:
Indicates the need to replace the transmission
belt.
This lamp should come on and flash every 10,000
km.
ELE SYS - 85
SERVICE:
Indicates the need to carry out the scheduled
maintenance operations.
The lamp should come on after reaching 1000 km
or 1 year after initial activation, then every 10,000
km or 1 year after the last activation.
WARNING
THE SCOOTER SHOULD BE SERVICED IN ANY CASE AT
THE KILOMETRE INTERVALS INDICATED IN THE OPER-
ATING AND MAINTENANCE MANUAL; DO NOT RELY ON
THE SERVICE DISPLAY THAT APPEARS ON THE INSTRU-
MENT PANEL.
Data check function
Setting the clock.

To set the clock, press the button "CLOCK" for more than 3 seconds.
The figures showing the hours start to flash.
Set the hours with the button "ODO/SET".
Press button "CLOCK" again and the figures showing the minutes start to flash.
Set the minutes with the «ODO/SET» button.
Press the «CLOCK» button again to start the clock moving normally.
During the reset process, not pressing any buttons for 8 seconds ends the process and the display will
automatically show the modified time.
Setting the date.
Set the "DATE" using the "CLOCK".
If the button "CLOCK" is pressed for longer than 3 seconds, the figures showing the days start to flash.
Set the day with the «ODO/SET» button.
Press the "CLOCK" button again; the numbers showing the months start to flash.
Set the month with the "ODO/SET" button.
Press the "CLOCK" button again; the numbers showing the years start to flash.
Set the year with the "ODO/SET" button.
Press the «CLOCK» button again to start the clock moving normally.
During the reset process, not pressing any buttons for 8 seconds ends the process and the display will
automatically show the modified date.
Sealed battery
Commissioning sealed batteries

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
ELE SYS - 86
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if
required, before storing the vehicle and, afterwards, every six months.
INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE
1) Voltage check
Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 ÷ 14.70V
-Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
-Charge current equal to 1/10 of the nominal capacity of the battery
- Charge time: 5 h
Specific tooling
020333Y Single battery charger
020334Y Multiple battery charger
Cleaning the battery

The battery should always be kept clean, especially on its top side, and the terminals should be coated
with Vaseline.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. THE USE OF A
FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE-
HICLE OR EVEN CAUSE A FIRE.
CAUTION
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. FAILURE TO
CHARGE THE BATTERY ADEQUATELY BEFORE BEING PUT INTO OPERATION WILL LEAD TO
A PREMATURE FAILURE OF THE BATTERY.
If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge
the battery.
The battery runs down completely in the course of three months. If it is necessary to refit the battery in
the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked
(-) must be connected to the negative clamp while the other two red wires marked (+) must be con-
nected to the clamp marked with the + positive sign.
ELE SYS - 87
Dry-charge battery
COMMISSIONING A NEW DRY-CHARGED BATTERY
- Remove the battery air pipe stop cap and each single cell cap.
- Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 Bé) with an am-
bient temperature not below 15°C, until it reaches the upper level indicated on the block.
- Tilt the battery slightly to remove any air bubbles formed during filling.
- Place the caps on each single cell filling hole without screwing them and leave the battery to rest.
During this stage, the battery is subject to a gasification phenomenon and temperature increases.
- Let it rest until it reaches ambient temperature (this stage can take up to 60 minutes).
- Tilt the battery slightly to facilitate the elimination of any gas bubbles present inside; restore the level
using the same filling electrolyte
Note: This is the last time that electrolyte can be added. Future top-ups should be done only with distilled
water;
- Before 24 hours elapse, recharge the battery following these steps:
- Connect the battery charger terminals observing the correct polarity;
- Wit the battery charger drw. 020333Y and/or drw. 020334Y operate the battery charger control by
selecting the position corresponding to that capacity;
- Otherwise, charge the battery with direct current equal to 1/10 of rated capacity (e.g. for a battery with
a 9Ah rated capacity, the charging current should be 0.9-1.0A) for approximately a 4-6 hour charge.
Note: Batteries that have been stored for a long time may take a longer charging time. The battery
chargers drw. 020333Y and drw. 020334Y have an automatic protection which interrupts the recharge
after 12 hours to avoid battery harmful heating. In this case, a green LED turns on to indicate the
activation of the safety system and not the end of the charge.
- Let the open circuit battery rest for approximately 4-6 hours; then check the off-load voltage using a
standard tester.
- If the open-circuit voltage is higher or equal to 12.6V, the battery is charged adequately. Slightly shake
or tilt the battery to eliminate any air bubbles formed during recharging.
- Check the electrolyte levels again, fill them with distilled water up to the upper level line if necessary,
clean battery properly, close each single cell cap tightly and install it on the vehicle.
- If the voltage indicated is low, charge the battery another 4-6 hours in the way described above.
Note: With the battery charger drw. 020334Y, it is possible to check the battery charge level with the
Check function. The value indicated on the display must be higher than the value indicated on the chart;
otherwise, recharge the battery again in the same way indicated above.
ELE SYS - 88
Battery installation
To access the battery, proceed as follows:

1. Place the scooter on its centre stand;
2. Open the saddle following above instructions,
see «Saddle» section;
3. Remove the piston ring «A» and take off the
battery cover.
The battery is the electrical device that requires the
most frequent inspections and diligent mainte-
nance. The most relevant maintenance rules to be
observed are as follows:
Battery
12V-14Ah
- Insert the battery by connecting the battery breather tube as shown in the photograph.
NOTE
IN ORDER TO FIT THE CABLES ON THE BATTERY TERMINALS CORRECTLY, REST THE LOW-
ER END OF THE TERMINAL SIDE OF THE BATTERY ON THE EDGE OF THE BATTERY WELL.
- Using the screwdriver, tighten up the battery terminal cables as far as they will go, placing the special
Grover washer between the screw head and the cable terminal.
NOTE
DO NOT USE WRENCHES TO TIGHTEN UP THE SCREWS FOR FIXING THE TERMINALS TO THE
BATTERY TERMINALS
- Refit the battery cover
Make sure that the terminals are connected correctly. When a new battery is installed, the correct time
and date must be reset on the digital instrument panel («Clock» and «MODE button» section).
CAUTION
DO NOT REVERSE THE POLARITY: RISK OF SHORT CIRCUIT AND DAMAGE TO THE ELEC-
TRICAL SYSTEM.
The electrolyte level, which should be checked regularly, must always be at the maximum level. To top
it up to this level, use only distilled water. Should it become necessary to top up the battery with water
ELE SYS - 89
too frequently, check the scooter's electrical system because the battery is being overloaded, causing
it to lose power quickly.
NEVER DISCONNECT THE BATTERY CABLES WHILE THE ENGINE IS RUNNING; THIS CAN
CAUSE PERMANENT DAMAGE TO THE VEHICLE ELECTRONIC CONTROL UNIT.
CAUTION
ELECTROLYTE CONTAINS SULPHURIC ACID: AVOID CONTACT WITH EYES, SKIN AND
CLOTHES. IN CASE OF ACCIDENTAL CONTACT, RINSE WITH ABUNDANT WATER AND CON-
SULT A DOCTOR.
WARNING
USED BATTERIES ARE HARMFUL FOR THE ENVIRONMENT. COLLECTION AND DISPOSAL
SHOULD BE CARRIED OUT IN COMPLIANCE WITH REGULATIONS IN FORCE.
Phonic wheel
- Ensure that the tone wheel is correctly installed on the scooter and connected to the electrical system.
- Turn the key switch to "ON".
- Access the tone wheel connector on the system side.
- Carry out the following measurements using the special tool.
Specific tooling
Check the supply voltage.

Keeping the connector in the position shown in the
photo, check for battery voltage (12 V) with the
polarity shown.
If incorrect values are measured, check the elec-
trical system and the digital instrument.
NOTE
A DROP IN VOLTAGE OF 1 V IN RELATION TO THE BAT-
TERY VOLTAGE CAN BE CONSIDERED NORMAL.
ELE SYS - 90
Check the signal

Move the positive rod to the position shown in the
photo. Turn the front wheel very slowly and check
that the measured voltage is 0 V or battery voltage,
depending on the position taken up.
This condition should be repeated 16 times during
a complete revolution of the wheel.
NOTE
THE DIGITAL MULTIMETER IS NOT ABLE TO DISPLAY
THE VOLTAGE WHEN THE WHEEL IS ROTATED FAST.
If other voltages are measured or there is no alternation, replace the tone wheel.
Connectors
INJECTION ELECTRONIC CONTROL UNIT

1. Injection telltale light (Brown-Black)
2. Rpm indicator (Green)
3. Not connected
4 Lambda probe negative terminal (Sky blue-
Black)
5 Live supply (White-Black)
6. Battery powered (White-Red)
7. Immobilizer aerial (Orange-White)
8. Electric fan remote control negative terminal
(Green-White)
9. Engine temperature (Yellow-Pink)
10. Not connected
11. Lambda probe positive (Sky blue-Yellow)
12. Engine stop switch (Orange)
13. Pick-up positive terminal (Red)
14. Injector negative terminal (Red-Yellow)
15. Pick-up negative terminal (White)
16. K line (Orange-Black)
17. Immobilizer warning light (Grey-Yellow)
18. Stand button (Brown-Red)
19. Not connected
20. Injection load remote control negative terminal
(Black-Purple)
21. Not connected
ELE SYS - 91
22. HV coil negative terminal (Pink-Black)

23. Not connected
24. Start-up enabling switch (Green-Blue)
25. Not connected
26. Ground (Black)
IMMOBILIZER AERIAL CONNECTOR

1. Live supply (White-Black)
2. Ground (Black)
3. Injection ECU (Orange-White)
ANTITHEFT DEVICE PRE-INSTALLATION

CONNECTOR
1. LHS Turn indicator bulbs (Pink)
2. RHS Turn indicator bulbs (White-Blue)
3. Ground (Black)
4. Battery powered (Red-Black)
5 Live supply (White-Black)
6. Helmet compartment light bulb (Blue-Yellow)
7. Not connected
8. Not connected
LAMBDA PROBE CONNECTOR

1. Positive from injection ECU (Sky blue-Yellow)
2. Negative from injection ECU (Sky blue-Black)
ELE SYS - 92
PICK-UP CONNECTOR
1. Positive from injection ECU (Red)
2. Negative from injection ECU (White)
3. Not connected
CONNECTOR FOR ELECTRICAL CONTROL

MANAGEMENT DEVICE
2. Right turn indicator switch (White-Blue)
3. LHS turn indicator signal (Blue)
4. LHS turn indicator switch (Pink)
5. RHS turn indicator signal (Pink-Black)
6. MODE button remote (Sky blue-Red)
7. MODE button remote signal (Grey)
8. Oil pressure sensor (Pink-White)
9. Oil pressure sensor signal (White)
10. Not connected
11. Not connected
12. Not connected
FUEL INJECTOR CONNECTOR

1. Positive from remote control (Black-Green)
2. Negative from injection ECU (Red-Yellow)
ELE SYS - 93
ENGINE TEMPERATURE SENSOR CONNEC-

TOR
1. Injection ECU temperature signal (Yellow-Pink)
2. Indicator temperature signal (Orange)
3. Ground (Sky blue-Green)
4. Indicator temperature signal (Sky blue-Black)
ELECTRIC FAN CONNECTOR

1. Ground (Black)
2. Positive from remote control (Red-Black)
STAND BUTTON CONNECTOR

1. Ground (Sky blue-Green)
2. Injection ECU signal (Brown-Red)
HV COIL CONNECTOR
2. Negative from injection ECU (Pink-Black)
ELE SYS - 94
FUEL PUMP CONNECTOR AND FUEL LEVEL

TRANSMITTER
1. Not connected
2. Ground (Black)
3. Ground (Black)
4. Fuel level indicator (White-Green)
DIAGNOSIS CONNECTOR
1. Not connected
2. Ground (Black)
3. K line (Orange-Black)
VOLTAGE REGULATOR CONNECTOR

1. Battery positive terminal (Red-White)
2. Ground lead (Black)
3. Battery positive terminal (Red-White)
4. Ground lead (Black)
WHEEL TURNING SENSOR CONNECTOR

1. Indicator signal (Sky blue)
2. Indicator signal (Grey-Black)
3. Indicator signal (Red)
ELE SYS - 95
INSTRUMENT PANEL CONNECTOR

1. Wheel turning sensor signal (Red)
2. Wheel turning sensor signal (Sky blue)
3. Wheel turning sensor signal (Grey-Black)
4. Instrument panel lighting (Yellow-Black)
5. Rpm indicator (Green)
6. Engine temperature signal (Orange)
7. Engine temperature signal (Sky blue-Black)
8. Oil pressure sensor signal (White)
9. RHS Turn indicator bulbs (White-Blue)
10. LHS Turn indicator bulbs (Pink)
11. Battery powered (Red-Black)
12. Immobilizer warning light (Grey-Yellow)
14. MODE button remote signal (Grey)
15. Fuel level indicator (White-Green)
16. Ground (Black)
17. Injection telltale light (Brown-Black)
18. LHS turn indicator signal (Blue)
19. RHS turn indicator signal (Pink-Black)
20. Not connected
WARNING LIGHT UNIT CONNECTOR

1. Not connected
2. Not connected
3. High-beam warning light (Purple)
4. Ground (Black)
5. Headlight warning light (Yellow-Black)
6. Not connected
7. Not connected
8. Not connected
ELE SYS - 96
INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Engine from vehicle SR MAX 300 i.e. (2011)
Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo.
Exhaust assy. Removal
- Remove the Lambda probe from its support and

disconnect it.
- Remove the retainer clamp.
- Undo the two exhaust manifold fixings on the

head. To unscrew the nuts that fix the silencer
flange to the head properly, use a jointed wrench
that allows, according to the travel direction, to get
also at the right nut. That is difficult to do with a
traditional straight wrench.
- Undo the three screws that fix the silencer to the

supporting arm.
- Remove the full silencer unit.
Remove the lambda probe from the manifold.
ENG VE - 98
SR MAX 300 i.e. (2011) 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
SUPPORT THE VEHICLE ADEQUATELY.

Disconnect the battery.
- Remove the side fairings.
- Remove the helmet compartment.
Remove the full muffler unit.
- Remove the air filter.
- Release the blow-by return pipe from the clamp
and disconnect it from the head.
CAUTION
THIS OPERATION MUST BE CARRIED OUT WHEN THE

ENGINE IS COLD.
- Remove the rear brake calliper and release the

rear brake piping from the four clamps of the en-
gine.
- Get a + 2 l container in order to collect the coolant

and place it under the vehicle.
- Remove the pipe that feeds coolant into the pump
as shown in the picture and then empty the sys-
tem.
- Remove the engine coolant outlet pipe as indi-
cated.
ENG VE - 99
- Disconnect:
- fuel piping and retainer clamp.
- injector connector.
- control unit connector.
- Remove the coolant outlet pipe from the engine

as indicated.
- Remove the spark plug cap.

- Remove the coolant temperature sensor con-
nector indicated in the picture.
- Remove the throttle cables from the throttle body

by undoing the nuts indicated in the photograph.
- Remove the throttle cable retainer clamp on the
manifold.
ENG VE - 100
SR MAX 300 i.e. (2011) Engine from vehicle
- Remove the positive and negative wiring from the

starter motor as shown in the picture.
- Disconnect the flywheel wiring connector.

- Remove the clamp indicated.
- Remove the cables from the retainer clamps on

the flywheel cover.
- Remove the lower screws of the right and left

shock absorber.
ENG VE - 101
When refitting the engine onto the vehicle, carry

out the removal operations but in reverse order
and respect the tightening torques shown in the
Specifications Chapter.
- Check the engine oil level and if necessary, top
it up with the recommended type.
- Fill and bleed the cooling circuit.
- Check accelerator and electric devices for correct
functioning.
CAUTION
PAY PARTICULAR ATTENTION TO POSITIONING THE
THROTTLE CONTROL TRANSMISSION PROPERLY.
Upon refitting the engine to the vehicle, carry out

the removal operations but in reverse order, and
respect the tightening torque shown in the «Spec-
ifications» Chapter.
- Check that there is a small clearance when the
valve is in abutment against the set screw.
- Check the engine oil level and if necessary, top
it up with the recommended type.
- Fill and bleed the cooling circuit.
- Check accelerator and electric devices for correct
functioning.
- Pay particular attention to the sleeve, be careful
to position the throttle body reference marks as in-
dicated in the picture.
CAUTION
PAY PARTICULAR ATTENTION TO POSITIONING THE
THROTTLE CONTROL TRANSMISSION PROPERLY.
ENG VE - 102
INDEX OF TOPICS
ENGINE ENG
Engine SR MAX 300 i.e. (2011)
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
- To remove the transmission cover it is necessary

to remove the plastic cover first, by inserting a
screwdriver in the slotted holes. Using the clutch
housing lock wrench shown in the figure, remove
the driven pulley shaft locking nut and washer.
Specific tooling
- Remove the cap/dipstick from the engine oil filling

hole.
- Remove the ten screws.
- Remove the transmission cover.
NOTE
WHEN YOU ARE REMOVING THE TRANSMISSION COVER
YOU MUST BE CAREFUL NOT TO DROP THE CLUTCH
HOUSING.
Air duct
- Remove the transmission compartment air intake

cover shown in the picture.
ENG - 104
SR MAX 300 i.e. (2011) Engine
- Remove the 5 screws, found on two different lev-

els, as well as the small casing.
Removing the driven pulley shaft bearing
- Remove the clip from the inside of the cover.

- Remove the bearing from the crankcase by
means of:
Specific tooling
020412Y 15-mm guide
Refitting the driven pulley shaft bearing
- Slightly heat the crankcase from the inside so as

not to damage the painted surface.
- Insert the bearing in its seat.
- Refit the Seeger ring.
CAUTION
USE AN APPROPRIATE REST SURFACE TO AVOID DAM-
AGING THE COVER PAINT.
NOTE
ALWAYS REPLACE THE BEARING WITH A NEW ONE
UPON REFITTING.
Specific tooling
020412Y 15-mm guide
Baffle roller
ENG - 105
Plastic roller
- Check that the roller does not show signs of wear

and that it turns freely.
- Remove the special clamping screws as indica-
ted in the photograph
- Check the outer diameter of the roller does not have defects that could jeopardise belt functioning
- For refitting, place the roller with the belt containment edge on the engine crankcase side
- Tighten the wrench to the prescribed torque.

Anti-flapping roller 12 - 16
Removing the driven pulley
- Remove the clutch housing and the driven pulley

assembly.
NOTE
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
PULLEY MOUNTED.
ENG - 106
Inspecting the clutch drum
- Check that the clutch bell is not worn or damaged.

- Measure the clutch bell inside diameter.
Characteristic
Max. value clutch bell
Max. value: Ø 134.5 mm
clutch housing standard value
Standard value: Ø 134 - 134.2 mm
Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2 bearings (inside diameter: 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft unit on the support to check the crankshaft alignment.
- Using a feeler dial gauge and the magnetic base, measure the bell eccentricity.
- Repeat the measurement in 3 positions (Central, internal, external).
- If faults are found, replace the bell.
Specific tooling
020074Y Support base for checking crankshaft alignment
Characteristic
clutch bell inspection: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm
ENG - 107
Inspecting the clutch
- Check the thickness of the clutch mass friction material.

- The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals.
NOTE
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST
NOT BE DIFFERENT FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN
SPRING LOAD.
Characteristic
Check minimum thickness
1 mm
ENG - 108
Removing the clutch
Fit the driven pulley spring compressor specific

tool with medium length pins screwed in position
«C» on the tool internal side.
- Introduce the adapter ring 11 with the chamfering
facing the inside of the tool.
- Fit the driven pulley unit on the tool with the in-
sertion of the 3 pins in the ventilation holes in the
mass holder support.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to loosen/tight-
en the clutch nut.
- Use the special 46x55 wrench component 9 to
remove the nut fixing the clutch in place.
- Dismantle the driven pulley components (Clutch
and spring with its plastic holder)
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND
THE CENTRAL SCREW MUST BE BROUGHT INTO CON-
TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE
THE SPECIFIC TOOL TO BUCKLE.
Specific tooling
020444Y011 adapter ring
020444Y009 wrench 46 x 55
020444Y Tool for fitting/ removing the driven
pulley clutch
Pin retaining collar
- Simultaneously turn and pull the collar manually to remove it.

NOTE
USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICULTY.
NOTE
BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT
COULD COMPROMISE THE O-RING SEAL.
ENG - 109
- Remove the 4 torque server pins and pull the pulley halves apart.
Removing the driven half-pulley bearing
- Check there are no signs of wear and/or noisiness; - Replace with a new one if there are.
- Remove the retainer ring using two flat blade screwdrivers.
- Support the pulley bushing adequately from the threaded side using a wooden surface.
- Using a hammer and pin, knock the ball bearing out as shown in the figure.
ENG - 110
- Support the pulley properly using the bell as shown in the figure.
Specific tooling
001467Y035 Bell for 47-mm outside diameter bearings
- Remove the roller bearing using the modular punch.
Specific tooling
020363Y 20-mm guide
Inspecting the driven fixed half-pulley
- 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.
ENG - 111
- Check evenness of the belt contact surface.
Characteristic
Half-pulley minimum diameter
Minimum admissible diameter: Ø 40.96 mm
Half-pulley standard diameter
Standard diameter: Ø 40.985 mm
Wear limit
0.3 mm
ENG - 112
Inspecting the driven sliding half-pulley
- Remove the two seal rings and the two O-rings.

- Measure the movable half-pulley bushing inside
diameter.
- Check the faying surface with the belt to make
sure there are no flaws.
- Check the riveted joints are functional.
- Check the evenness of the belt contact surface.
MOVABLE DRIVEN HALF-PULLEY DIMENSIONS

Wear limit 0.3 mm
standard diameter Ø 41.000 - 41.035 mm
maximum allowable diameter Ø 41.08 mm
Refitting the driven half-pulley bearing
- Support the pulley bushing adequately from the threaded side using a wooden surface.
- Fit a new roller bearing as shown in the figure.
- For the fitting of the new ball bearing, follow the example in the figure using a modular punch.
Fit the retainer ring
WARNING
NOTE
FIT THE BALL BEARING WITH THE VISIBLE SHIELDING
Specific tooling
020424Y Driven pulley roller casing fitting punch
ENG - 113
Refitting the driven pulley
- Insert the new oil seals and O-rings on the mov-

able half-pulley.
- Lightly grease the O-rings «A» shown in the fig-
ure.
- Fit the half-pulley over the bushing using the spe-
cific tool.
- Check that the pins are not worn and proceed to
refitting them in their slots.
- Refit the torque server closure collar.
- Using a curved-spout grease gun, lubricate the
driven pulley unit with approximately 6 grams of
grease. Apply grease through one of the holes in
ENG - 114
the bushing until it comes out through the hole on

the opposite side. This operation is necessary to
avoid the presence of grease beyond the O-rings.
NOTE
THE TORQUE SERVER CAN BE GREASED WHETHER
WITH BEARINGS FITTED OR WHEN THEY ARE BEING RE-
PLACED; UNDERTAKING THE OPERATION WHEN THE
BEARINGS ARE BEING SERVICED MIGHT BE EASIER.
Specific tooling
020263Y Driven pulley assembly sheath
AGIP GREASE SM 2 Gray black smooth-tex-
tured lithium grease, containing molybdenum
disulphide.
-
Inspecting the clutch spring
- Measure the length of the spring when it is re-

laxed.
Characteristic
Standard length
123 mm
Acceptable limit after use:
118 mm
Refitting the clutch
- Support the driven pulley spring compressor spe-

cific tool with the control screw in vertical axis.
- Arrange the tool with the medium length pins
screwed in position "C" on the inside.
- Introduce the adapter ring No. 11 with the cham-
fering facing upwards.
- Insert the clutch on the adapter ring.
- Lubricate the end of the spring that abuts against
the torque server closing collar.
ENG - 115
- Insert the spring with its plastic holder in contact

with the clutch.
- Insert the drive belt into the pulley unit according
to their direction of rotation.
- Insert the pulley unit with the belt into the tool.
- Slightly preload the spring.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to tighten the
clutch nut.
- Place the tool in the clamp with the control screw
on the horizontal axis.
- Fully preload the spring.
- Apply the clutch fixing nut and tighten it to the
prescribed torque using the special 46x55 wrench.
- Loosen the tool clamp and insert the belt accord-
ing to its direction of rotation.
- Lock the driven pulley again using the specific
tool.
- Preload the clutch return spring with a traction/
rotation combined action and place the belt in the
smaller diameter rolling position.
- Remove the driven pulley /belt unit from the tool.
NOTE
DURING THE SPRING PRELOADING PHASE, BE CARE-
FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND
THE BUSHING THREADING.
NOTE
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-
METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-
TED IN CONTACT WITH THE CLUTCH.
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
020444Y011 adapter ring
020444Y009 wrench 46 x 55

Clutch unit nut on driven pulley 45 to 50
ENG - 116
Refitting the driven pulley
- Refit the clutch bell.
Drive-belt
- Check that the driving belt is not damaged.

- Check the width of the belt.
Characteristic
Driving belt - minimum width
19.5 mm
Driving belt - standard width
21.3 ± 0.2 mm
During the wear checks in foreseen in the sched-

uled maintenance program, you are advised to
check that the rim bottom of the toothing does not
show signs of incisions or cracking (see figure):
The rim bottom of the tooth must not have incisions
or cracking; if it does, change the belt.
ENG - 117
Removing the driving pulley
- Turn the crankshaft until the ropes of the pulley

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

in the hole shown in the picture
- Insert the tool in the hollows and apply the reten-

tion ring
- Bring in the ring's clamping screws while keeping
the tool to support the pulley
Specific tooling
- Remove the fixing nut and the washer

- Remove the stationary drive pulley half.
ENG - 118
Inspecting the rollers case
- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inner
diameter A.
- Measure outer diameter B of the pulley sliding
bushing shown in the figure.
- Check that the rollers are not damaged or worn.
- Check the guide shoes for the variator back-plate
are not worn.
- Check the wear of the roller housings and of the
belt faying surfaces on both pulley halves.
- Check that stationary driving pulley does not
show signs of abnormal wear on the grooved edge
and on the surface in contact with the belt.
- Check that the O-ring is not pushed out of shape.
CAUTION
DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS
Characteristic
movable driving half-pulley bushing: Standard
Diameter
26.000 - 26.021 mm
movable driving half-pulley bushing: Maxi-
mum allowable diameter
Ø 26.12 mm
Sliding bushing: Standard Diameter
Ø 25.959 ÷ 25.98 mm
Sliding bushing: Minimum admissible diame-
ter
Ø 25.95 mm
Roller: Standard Diameter
Diameter 20.5 - 20.7 mm
Roller: Minimum diameter permitted
Ø 20 mm
ENG - 119
Refitting the driving pulley
- Preassemble the movable half-pulley with the

roller contrast plate by putting the rollers in their
housings with the larger support surface touching
the pulley according to the direction of rotation.
- Check that the roller contact plate does not have
flaws and is not damaged on the grooved edge.
- Mount the complete bushing unit on the crank-
shaft.
- Fit the driven pulley/Clutch/belt unit on the en-
gine.
- Fit the steel shim in contact with the bushing and

the stationary drive pulley.
- Install the appropriate tool as described in the re-
moval phase.
-Tighten the nut with washer to the prescribed tor-
que.
Specific tooling
ENG - 120
Drive pulley nut 75 - 83
Refitting the transmission cover
- Check that there are 2 alignment dowels and that

the sealing gasket for the oil sump on the trans-
mission cover is adequately fitted.
- Replace the cover and tighten the 10 screws to
the specified torque.
- Refit the oil loading cap/bar.
- Refit the steel washer and the driven pulley nut.
- Tighten the nut to the prescribed torque using the
lock wrench and the torque wrench tools.
- Refit the plastic cover.
Specific tooling

Transmission cover screws 11 to 13 Driven pul-
ley shaft nut 54 ÷ 60
End gear
Removing the hub cover
- Empty the rear hub through the oil drainage plug.

- Remove the 7 flanged screws indicated in the figure.
- Remove the hub cover and its gasket.
ENG - 121
Removing the wheel axle
- Remove the wheel axis complete with gear.

- Remove the intermediate gear.
Removing the hub bearings
- Check the state of the bearings being examined (wear, clearance and noisiness). If faults are detected,
do the following.
- Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).
Specific tooling
ENG - 122
Removing the wheel axle bearings
- Take out the clip on the outside of the hub cover.

- Support the hub cover and expel the bearing.
By means of the appropriate tools, remove the oil guard as in the figure.
Specific tooling
020477Y 37 mm adaptor
020483Y 30 mm guide
020489Y Hub cover support stud bolt kit
ENG - 123
Removing the driven pulley shaft bearing
- As you need to remove the driven pulley shaft, its bearing and oil seal, remove the transmission cover
as described above.
- Extract the driven pulley shaft from its bearing.
- Remove the oil seal using a screwdriver, working from inside the bearing and being careful not to
damage the housing, make it come out of the belt transmission side.
- Remove the Seeger ring shown in the figure
- Remove the driven pulley shaft bearing using the modular punch.
Specific tooling
020363Y 20-mm guide
ENG - 124
Inspecting the hub shaft
- Check the three shafts for wear or distortion of

the toothed surfaces, the bearing housings, and
the oil seal housings.
- If faults are found, replace the damaged compo-
nents.
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted.

- Check the bearing bearings.
- In case of faults, replace the damaged components.
Refitting the wheel axle bearing
- Support the hub cover on a wooden surface.

- Heat the crankcase cover with the specific heat gun.
- Fit the wheel shaft bearing with a modular punch as shown in the figure.
- Fit the Seeger ring.
- Fit the oil guard with seal lip towards the inside of the hub and place it flush with the internal surface
by means of the appropriate tool used from the 52-mm side.
The 52-mm side of the adapter must be turned towards the bearing.
Specific tooling
020483Y 30 mm guide
ENG - 125
ENG - 126
Refitting the hub cover bearings
In order to fit the hub box bearings, the engine crankcase and the cover must be heated with the special
heat gun.
- The three 15-mm bearings must be fitted using the appropriate tools:
- The 42-mm side of the adapter must be turned towards the bearing.
Specific tooling
020150Y Air heater mounting
020151Y Air heater
020412Y 15-mm guide
NOTE
TO FIT THE BEARING ON THE COVER, ADEQUATELY SUPPORT THE COVER WITH THE STUD
BOLT KIT.
- Refit the driven pulley shaft bearing with a modular punch as shown in the figure.
NOTE
ENG - 127
IF THE BEARING HAS AN ASYMMETRICAL BALL RETAINER, PLACE IT SO THAT THE BALLS
ARE VISIBLE FROM THE HUB INNER SIDE.
Specific tooling
020363Y 20-mm guide
NOTE
WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASE
PREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.
- Refit the Seeger ring with the opening facing the bearing and fit a new oil seal flush with the crankcase
from the pulley side.
Refitting the hub bearings

- Install the three shafts in the engine crankcase
as shown in the figure.
Refitting the ub cover

- Fit a new gasket together with the alignment dowels.
- Seal the gasket of the breather pipe using black silicone sealant.
- Fit the gearbox cover, making sure the breather pipe is in the correct position.
- Position the shorter screw that can also be recognised from the different colour as shown in the figure.
ENG - 128
- Fix the breather tube support by means of the lower screw.

- Fit the remaining screws and tighten the seven screws to the prescribed torque.
Flywheel cover
Removing the hub cover
- Remove the clip fixing the sleeve to the cylinder.

- Remove the 10 clamps
- Remove the flywheel cover.
ENG - 129
Removing the stator
- Remove the two pickup screws and the screw

holding the wiring support and the three stator
clamping screws shown in the figure.
- Remove the stator and its wiring.
Refitting the stator
- Refit the stator and flywheel carrying out the re-

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

Stator assembly screws (°) 3 to 4
ENG - 130
Refitting the flywheel cover
- Position the spline clip on the crankshaft and ori-

ent the end as shown in the figure.
- Orient the water pump shaft with reference to the

transmission gear seat as shown in the picture.
- Refit the cover over the engine and tighten the screws to the prescribed torque.
- Carry out the removal steps but in the reverse order.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. MAKE SURE THE CEN-
TRING DOWELS ARE PRESENT.
Flywheel cover screws 11 - 13
Flywheel and starting
Removing the starter motor
- Remove the two screws indicated in the figure

- Take the starter motor out of its seat
ENG - 131
Removing the flywheel magneto
- Remove the water pump shaft and crankshaft

spline clip
- Line up the two holes in the flywheel as shown in

the picture
- Screw in the guide bushing that is part of the

special flywheel stop tool on the flywheel as shown
in the picture
- Insert the special flywheel stop tool on the fly-

wheel as shown in the picture
Specific tooling
ENG - 132
Remove the plate indicated in the picture.
- Remove the flywheel nut with its washer

- Do up the flywheel nut by three or four threads
so that the flywheel does not fall accidentally on
extraction
- Screw the extractor onto the flywheel and extract
it as shown in the picture
Specific tooling
020467Y Flywheel extractor
Inspecting the flywheel components
- Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate.
Refitting the free wheel
- Make sure the freewheel faying surfaces are in good condition.

- Thoroughly clean the free wheel to remove LOCTITE residue.
- Degrease the threading of the holes in the free wheel and the clamping screws.
- Apply the recommended product to the end of the screws.
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock
- Fit the freewheel on the magneto flywheel making

sure that the ground side is in contact with the fly-
wheel itself, i.e. with wheel Seeger ring visible.
- Lock the six clamping screws in criss-cross fash-
ion to the prescribed torque.

Screw fixing freewheel to flywheel 13 - 15
ENG - 133
- Oil the free wheel "rollers".
Refitting the flywheel magneto
- Remove the freewheel retaining plate indicated

in the picture
- Remove the transmission gear and the freewheel
- Insert the free wheel on the flywheel as shown in

the picture
- Then refit the flywheel with free wheel and trans-
mission gear
- Using the special flywheel lock wrench, tighten

up the flywheel fixing nut to the prescribed torque
- Refit the retention plate
Specific tooling

Flywheel nut 94 - 102
ENG - 134
Refitting the starter motor
- Fit a new O-ring on the starter motor and lubricate

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

Starter motor screws 11 ÷ 13
Cylinder assy. and timing system
Removing the intake manifold
Loosen the 3 screws and remove the air intake manifold.

- Upon refitting, secure to the specified torque.
Removing the rocker-arms cover
- Remove the 5 screws indicated in the figure
ENG - 135
Removing the timing system drive
- First remove the parts listed below: transmission

cover, drive pulley with belt, oil sump with spring
and by-pass piston, oil pump pulley cover, O-ring
on the crankshaft and the sprocket wheel separa-
tion washer.
- Remove the tappet cover.
- Remove the central screw fastener and the au-
tomatic valve-lifter retaining cover, as shown in the
figure.
- Remove the return spring of the automatic valve

lifter unit and the automatic valve lifter unit and its
end of stroke washer.
- Loosen the central screw on the tensioner first.

- Remove the two fixings shown in the figure.
- Remove the tensioner with its gasket.
- Remove the internal hex screw and the counter-

weight shown in the figure.
ENG - 136
- Remove the camshaft control pulley with its

washer.
- Remove the control sprocket wheel and the tim-

ing chain.
- Remove the screws indicated in the figure, the
spacer bar and the tensioner slider.
The chain tensioner slider must be removed from
the transmission side. As regards the lower chain
guide slider, it may only be removed after the head
has been removed.
NOTE
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
Removing the cam shaft
- Remove the 2 screws and the camshaft retainer

shown in the diagram.
- Remove the camshaft.
- Remove the pins and the rocking levers from the
flywheel side holes.
NOTE
IF NEEDED, THE HEAD MAY BE REMOVED WITH THE
CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE
HEAD CAN ALSO BE REMOVED WITHOUT REMOVING
THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.
ENG - 137
Removing the cylinder head
- Remove the spark plug.

- Remove the 2 side fixings shown in the figure.
- Loosen the 4 head-cylinder fastening nuts in two
or three stages and in criss-cross fashion.
- Remove the head, the two alignment dowels and
the gasket.
NOTE
IF NEEDED, THE HEAD MAY BE REMOVED WITH THE
CAMSHAFT, ROCKER PINS AND FIXING BRACKET. THE
HEAD CAN ALSO BE REMOVED WITHOUT REMOVING
THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER.
Removing the valves
- Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves.
- Remove the oil guards with the appropriate tool.
- Remove the lower spring supports.
CAUTION
REPLACE THE VALVES IN SUCH A WAY AS TO RECOGNISE THEIR ORIGINAL POSITION ON
THE HEAD.
Specific tooling
020382Y Valve cotters equipped with part 012 removal tool
020431Y Valve oil seal extractor
ENG - 138
Removing the cylinder - piston assy.
Removing cylinder and piston

- Remove the chain guide slider.
- Remove the 4 O-rings on the stud bolts.
- Pull out the cylinder.
- Remove the cylinder base gasket.
- Remove the two stop rings, the wrist pin and the
piston.
- Remove the piston seals.
CAUTION
TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE
REMOVING THE CYLINDER.
NOTE
BE CAREFUL NOT TO DAMAGE THE SEALING RINGS
DURING REMOVAL.
ENG - 139
Inspecting the small end

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

NOTE
TER.
See also
Inspecting the piston

NOTE
TER.
See also
Inspecting the cylinder

NOTE
TER.
See also
Inspecting the piston rings

NOTE
TER.
See also
Interventions rules
ENG - 140
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 wrist pin retainer ring onto the appropriate
tool
- With opening in the position indicated on the tool
S = left
D= right
- Place the wrist pin retainer ring into position using
a punch
- Fit the wrist pin snap ring using the plug as shown
in the figure
NOTE
THE TOOL FOR INSTALLING THE RETAINER RINGS MUST
BE USED MANUALLY.
CAUTION
USING A HAMMER MIGHT DAMAGE THE STOPS' HOUS-
ING.
Specific tooling
020454Y Pin lock fitting tool
Choosing the gasket
- Provisionally fit the piston into the cylinder, without any base gasket.
- Assemble a dial gauge on the specific tool.
Specific tooling
020428Y Piston position check mounting
- Using an abutment plane, reset the dial gauge

with a preload of a few millimetres.
- Finally fix the dial gauge.
- Check the perfect sliding of the feeler pin.
- Install the tool on the cylinder without changing
the dial gauge position.
- Lock the tool using the original head fixing nuts.
- Rotate the crankshaft up to the TDC (the inver-
sion point of the dial gauge rotation)
- Measure the deviation from the reset value.
ENG - 141
- By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to
be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres-
sion ratio.
- Remove the special tool and the cylinder.
NOTE
IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORY
ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEAT
THE TOOL INSTALLATION BY INVERTING ITS POSITION.
See also
Refitting the piston rings
- Place the scraper ring spring on the piston.

- Install the scraper ring keeping the opening op-
posed to the spring junction and with the writing
"top" facing the piston crown. The chamfered side
of the oil scraper ring should always be facing the
piston crown.
- Fit the second lining with the identification letter
or the writing "top" facing the piston crown. In any
case, the step must be facing opposite the piston
crown.
- Install the first compression lining in the direction
imposed by the housing.
- It is advisable to use a fitter to facilitate the in-
stallation of the linings.
NOTE
THE TWO PISTON RINGS ARE MADE WITH A TAPERED
CYLINDRICAL CONTACT CROSS-SECTION. THIS IS TO
ACHIEVE A BETTER BEDDING.
- Misalign the lining openings at 120° as shown in the figure.

- Lubricate the components with engine oil.
- The engine uses the first compression lining with an L section.
ENG - 142
Refitting the cylinder
- Insert the cylinder base gasket with the thickness

determined above.
- Using the fork support and the piston ring retain-
ing band, refit the cylinder as shown in the figure.
NOTE
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW
OUT THE LUBRICATION DUCT AND OIL THE CYLINDER
LINER.
Specific tooling
020426Y Piston fitting fork
020393Y Piston assembly band
Inspecting the cylinder head

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

slider are not worn out.
- Ensure that the camshaft control pulley chain as-
sembly and the sprocket wheel are not worn.
- If you detect wear, replace the parts or, if the
chain, sprocket wheel and pulley are worn, replace
the whole unit.
- Remove the centre screw with the washer and
the tensioner spring. Check that the one-way
mechanism is not worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
unit.
Inspecting the valve sealings

NOTE
ENG - 143
TER.
See also
Inspecting the valves

NOTE
TER.
See also
Inspecting the springs and half-cones
- Check that the upper and lower supporting spring washers, the cotters and the oil seal show exhibit
no signs of abnormal wear. Replace a component when worn.
- Measure the unloaded spring length.

NOTE
TER.
See also
Refitting the valves
- Lubricate the valve guides with engine oil.

- Place the valve spring supports on the head.
- Using the special punch, fit the four valve seal rings.
- Fit the valves, the springs and the caps. Using the appropriate tool with adapter, compress the springs
and insert the cotters in their seats.
NOTE
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REF-
ERENCE COLOUR ON COTTER SIDE (TURNS WITH GREATER PITCH).
Specific tooling
ENG - 144
020306Y Punch for assembling valve seal rings

020382Y Valve cotters equipped with part 012 removal tool
Inspecting the cam shaft

NOTE
TER.
See also
ENG - 145
Refitting the head and timing system components
- Refit the lower timing chain sprocket wheel on the

crankshaft, with the chamfer facing the insertion
side.
- Loop the timing chain around the sprocket on the
crankshaft.
- Fit the chain tensioner slider from the cylinder
head side.
- Fit the spacer and the screw fastener.
- Tighten the screws to the prescribed torque.
- Fit the pins and rocking levers.
- Lubricate the two rocking levers through the
holes at the top.
- Lubricate the 2 bearings and insert the camshaft
in the cylinder head with the cams corresponding
to the rocking levers.
- Insert the retention plate and tighten the two
screws shown in the figure to the prescribed tor-
que.
- Refit the spacer on the camshaft.
- Rotate the engine so that the piston is at top dead
centre, using the reference marks on the flywheel
and the crankcase.
- Holding this position insert the chain on the cam-
shaft control pulley.
- Insert the pulley on the camshaft while keeping
the reference 4V in correspondence with the ref-
erence mark on the head.
- Fit the counterweight and tighten the clamping
screw to the prescribed torque.
-Fit the end-stop ring on the automatic valve-lifter
cam and fit the automatic valve-lifter cam to the
camshaft.
- Fit the automatic valve lifter return spring.
- During this operation the spring must be loaded
by approximately 180°.
ENG - 146
- Fit the automatic valve-lifter retaining dish, using

the counterweight screw fastener as a reference.
- Tighten the clamping screw to the prescribed tor-
que.
- Set the tensioner cursor in the rest position.
- Fit the chain tensioner on the cylinder, using a
new gasket, and tight the two screws to the pre-
scribed torque.
- Insert the chain tensioning screw, together with
the spring and washer, tightening it to the prescri-
bed torque.
- Adjust the valve clearance.
- Fit the spark plug.
Electrode distance 0.8 mm
NOTE
GREASE THE END STOP RING TO PREVENT IT COMING
OUT AND FALLING INTO THE ENGINE.

Timing chain tensioner support screw 11 to 13
Spark plug 12 to 14 Starter ground screw 7 to 8.5
Timing chain tensioner slider screw 10 to 14
Starter counterweight support screw 11 to 15
Timing chain tensioner central screw 5 to 6
Camshaft retention plate screw 4 to 6
ENG - 147
- Fit the timing chain guide slider.

- Insert the centring dowel between the cylinder
head to the cylinder, fit the cylinder head gasket
and the cylinder head.
- Lubricate the stud bolt threading.
- Tighten up the nuts to an initial pre-torque of 7±1
N·m
- Tighten up the nuts to a second pre-torque of 10
±1 N·m
- Rotate by an angle of 270°
- To carry out the operations described above, fol-
low the tightening sequence in the figure.
- Fit the two screws on the outside of the timing
chain side and tighten them to the specified torque.
NOTE
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN USING A COM-
PRESSED AIR JET.

Timing chain tensioner support screw 11 to 13
ENG - 148
Refitting the rocker-arms cover
- Refit the cylinder head cover and tighten the 5

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

Tappet cover screws 6 - 7 Nm
Refitting the intake manifold
- Fit the intake manifold and do up the three

screws.

Intake manifold screws 11 to 13
Crankcase - crankshaft
ENG - 149
Splitting the crankcase halves
- Before opening the crankcase, it is advisable to

check the axial clearance of the crankshaft. To do
this, use a plate and a support with appropriate tool
dial gauge.
- Upper clearances are an indication of wear on
the surfaces of the crankshaft casing support.
- Remove the 10 crankshaft coupling screws.
- Separate the crankcase while keeping the crank-
shaft in one of the two halves of the crankcase.
- Remove the crankshaft.
- Remove the half crankcase coupling gasket.
- Remove the two screws and the internal cover
shown in the diagram.
- Remove the oil guard on the flywheel side.
- Remove the oil filter fitting shown in the diagram.
- Check the axial clearance on the connecting rod.
- Check the radial clearance on the connecting rod.
-Check the surfaces that limit the axial free-play
are not scored and measure the width of the crank-
shaft between these surfaces, as shown in the
diagram.
- If the axial clearance between crankshaft and
crankcase is exceeding and the crankshaft does
not have any defect, the problem must be due to
either excessive wear or wrong machining on the
crankcase.
- Check the diameters of both the bearings of the
crankshaft in accordance with the axes and surfa-
ces shown in the figure. The half-shafts are clas-
sified in two categories Cat. 1 and Cat. 2 as shown
the chart below.
CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH
IS WITHIN THE STANDARD VALUES AND THE SURFACES
SHOW NO SIGNS OF SCORING.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE CRANKSHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-
ENG - 150
INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN

DAMAGE THE MAIN BUSHINGS.
CAUTION
KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES
OF THE CRANKCASE WHEN SEPARATING IT. IF YOU FAIL
TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY
FALL.
NOTE
WHEN MEASURING THE WIDTH OF THE CRANKSHAFT,
MAKE SURE THAT THE MEASUREMENTS ARE NOT
MODIFIED BY THE RADIUSES OF FITTINGS WITH THE
CRANKSHAFT BEARINGS.
NOTE
TO MEASURE WEAR LIMITS AND COUPLING CLEARAN-
CES, SEE THE SPECIFICATIONS CHAPTER.
See also
Inspecting the crankshaft alignment

NOTE
TER.
See also
Inspecting the crankcase halves
- Before proceeding to check the crankcase

halves, thoroughly clean all surfaces and oil ducts.
- On the transmission-side crankcase half, take
particular care when handling the oil pump com-
partment and the oil ducts, the by-pass duct, the
main bushings and the cooling jet on the trans-
mission side (see diagram).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the piston, which regulates the oil pressure.
- On the flywheel side crankcase half, take partic-
ular care cleaning the oil ducts for the main bush-
ings, the oil duct for the jet that lubricates the
cylinder head and the oil drainage duct at the fly-
wheel side oil seal.
- Inspect the coupling surfaces on the crankcase
halves for scratches or deformation, taking partic-
ENG - 151
ular care with the cylinder/crankcase surfaces and

the crankcase halves surfaces.
- Defects in the crankcase coupling gasket be-
tween the crankcase halves or the mating surfaces
shown in the diagram, could cause a drop in the
oil pressure lubricating the main bushings and
connecting rod.
- Check the main bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and di-
mensions.
NOTE
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-
ER OPERATION OF THIS COMPONENT IMPROVES PIS-
TON CROWN COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-
CREASE). FAILURE OR LEAKS CAN CAUSE A CONSID-
ERABLE DROP IN THE LUBRICATION PRESSURE FOR
MAIN BUSHINGS AND CONNECTING ROD.
NOTE
THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH
A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD
LUBRICATION; THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP. THE JET CLOG-
GING IMPAIRS THE HEAD LUBRICATION AND THE TIM-
ING MECHANISMS. A JET FAILURE CAUSES A DE-
CREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
Inspecting the crankshaft plain bearings
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and
a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply
channels.
- The main bushings are comprised of two half-bearings, one with holes and channels for lubrication
whereas the other is solid.
Characteristic
Lubrication pressure
3.5 to 4 bar
ENG - 152
- The solid half-bearing is intended to stand the

thrusts caused by combustion, and for this reason
it is arranged opposed the cylinder.
- To prevent shutters in the oil feeding channels,
the matching surface of the two half-bearings must
be perfectly orthogonal to the cylinder axis, as
shown in the figure.
- The oil feeding channel section is also affected
by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
NOTE
TER.
See also
Refitting the crankcase halves
- Fit the internal shield by locking the two screws

to the prescribed torque.
- Fit the oil filter fitting and tighten it to the prescri-
bed torque.
- Position the oil pre-filter element as shown in the
picture.
- Place a new gasket on one of the crankcase
halves, preferably on the transmission side, to-
gether with the alignment dowels.
- Lubricate the main bushings and insert the crank-
shaft in the transmission side crankcase half.
- Reassemble both crankcase halves.
- Fit the 10 screws and tighten them to the speci-
fied torque.
- Fit a new O-ring on the pre-filter and lubricate it.
- Insert the filter on the engine with the relative cap.
Tighten to the prescribed torque.

Internal engine crankcase bulkhead (transmis-
sion-side half shaft) screws 4 to 6 Engine-crank-
case coupling screws 11 to 13 Oil filter on
crankcase fitting 27 to 33 Engine oil drainage
plug/ mesh filter 24 to 30
ENG - 153
Studs
Check that the stud bolts have not worked loose

from their seat in the crankcase.
Check the depth of stud bolt driving with a gauge,
as indicated in the picture. If it varies significantly
from the driving depth indicated, it means that the
stud bolt has yielded.
In this case, replace it.
ENG - 154
By working on two fitted cylinder head fixing nuts,

nut and lock nut, as shown in the picture, remove
the stud bolt from its seat.
Clean the threaded seat on the carter thoroughly.
Refit a new stud bolt and apply the special product
on the threading crankcase side.
Tighten up to the depth of the driving indicated.
Loctite Quick Set Loctite 270 high strength
threadlock
Loctite 270 high strength threadlock
Lubrication
Conceptual diagrams
LUBRICATION CIRCUIT
ENG - 155
ENG - 156
Oil pressure check
- Remove the electrical minimum oil pressure

switch connection and remove the switch.
- Check that the oil pressure reading is between
0.5 and 1.2 atm with the engine idling at 1650 rpm
and the oil at the required temperature (wait for at
least one electric ventilation).
- Check that the oil pressure is between 3.2 and
4.2 atm with the engine running at 6000 rpm and
the oil at the required temperature.
- Remove the appropriate tools once the meas-
urement is complete, refit the oil pressure switch
and washer, tightening it to the specified torque
and fit the flywheel cover.
- If the oil pressure is not within the specified limits,
in the following order, check: the oil filter, the oil
by-pass valve, the oil pump and the crankshaft
seals.
NOTE
THE CHECK MUST BE CARRIED OUT WITH OIL AT THE
CORRECT LEVEL AND WITH AN OIL FILTER IN PROPER
CONDITION.
Characteristic
Oil pressure
Minimum pressure admitted at 6000 rpm: 3.2 atm.

Minimum oil pressure sensor 12 to 14
Crankshaft oil seals
ENG - 157
Removal
- Remove the transmission cover and the com-

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

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

and extract the oil seal.
Specific tooling
Refitting
- Always use a new oil seal upon refitting

- Prepare the new oil guard by lubricating the seal-
ing lip.
- Preassemble the oil seal with the appropriate tool
by positioning the screws.
- Insert the sheath over the crankshaft.
- Insert the tool with the oil seal on the crankshaft
until it comes into contact with the crankcase.
- Insert the adaptor bushing of the tool in the hole
on the crankcase.
ENG - 158
- Orientate the oil seal by inserting the bracket

which is part of the appropriate tool.
- Tighten the threaded bar onto the crankshaft as
far as it will go.
- Use the nut to move the base of the tool until you
can see the end of the oil seal driving stroke
- Remove all the tool components following the
procedure but in reverse order
CAUTION
DO NOT LUBRICATE THE KEYING SURFACE ONTO THE
ENGINE CRANKCASE.
CAUTION
ORIENT THE OIL SEAL BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. WHEN THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
SEAL. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL SEAL
SHEATH.
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCE-
DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO
THE WRONG TENSIONING OF THE OIL PUMP CONTROL
CHAIN.
Specific tooling
Oil pump
ENG - 159
Removal
- Undo the two clamping screws in the figure and

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

with a screwdriver inserted through one of its two
holes.
- Remove the central screw with Belleville washer,
as shown in the diagram.
- Remove the chain with the crown.
- Remove the control sprocket wheel with relative
O-ring.
- Remove the oil pump by undoing the two screws
in the figure.
- Remove the oil pump seal.
NOTE
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover.

- Remove the circlip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with pet-
rol and compressed air.
- Reassemble the rotors in the pump body, keep-
ing the two reference marks visible Replace the
retainer ring.
ENG - 160
- Check the clearance between the rotors in the

position shown in the diagram using a feeler
gauge.
Measure the distance between the outer rotor and
the pump body (see figure).
- Check the axial clearance of the rotors using a
trued bar as shown in the figure.
Characteristic
Axial rotor clearance
Limit values admitted: 0.09 mm
Distance between the outer rotor and the pump
body
Admissible limit clearance: 0.20 mm
Distance between the rotors
Admissible limit clearance: 0.12 mm
Refitting
- Check there are no signs of wear on the oil pump

shaft or body.
- Check there are no signs of scoring or wear on
the oil pump cover.
- If you detect non-conforming measurements or
scoring, replace the faulty parts or the unit.
- Fit the pump cover in the position that permits the
crankcase clamping screws to be aligned.
ENG - 161
- Make sure the gasket is positioned properly and

refit the pump on the engine crankcase. The pump
can only be fitted in one position. - Tighten the
screws to the prescribed torque.
- Fit the sprocket wheel with a new O-ring.
- Fit the chain.
- Fit the central screw and the cup washer. Tighten
-Fit the oil pump cover, by tightening the two
screws to the prescribed torque.
NOTE
FIT THE CUP WASHER SO THAT ITS OUTER RIM TOUCH-
ES THE PULLEY. MAKE SURE THAT THE PUMP TURNS
FREELY.

Screws fixing oil pump to the crankcase 5 to 6
Oil pump command sprocket screw 10 to 14 Oil
pump cover screws 0.7 - 0.9
Removing the oil sump
- Remove the oil filler plug, the transmission cover,

the complete driving pulley assembly with belt and
the sprocket wheel, as described in the "Trans-
mission" chapter.
- Drain the oil as described above.
- Remove the 7 screws, shown in the diagram, and
the 2 rear brake fluid pipe fixing brackets.
- Remove the screw, the by-pass piston, the gas-
ket and the centring dowels shown in the figure.
ENG - 162
Inspecting the by-pass valve
- Check the unloaded spring length.

- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and
that it guarantees a good seal.
- If not, eliminate any impurities or replace defec-
tive parts.
Characteristic
By-pass check up: Standard length
54.2 mm
Refitting the oil sump
- Refit the by-pass piston in its housing.

- Insert the pressure-regulating spring.
- Fit a new sump seal.
- Refit the two centring dowels.
- Refit the sump, taking care to locate the spring in
the appropriate recess machined into the inside of
the sump.
- Refit the rear brake cable brackets and the
screws in the reverse order from which they were
removed.
- Tighten the screws to the prescribed torque.
- Refit the driving pulley assembly, the drive belt,
the sprocket wheel and the transmission cover, as
described in the "Transmission" chapter.
- When testing the lubrication system, refer to
chapter "Crankcase and Crankshaft", regard-
ing lubrication of the crankshaft and connect-
ing rod

Oil sump screws 10 to 14
ENG - 163
INDEX OF TOPICS
INJECTION INJEC
SR MAX 300 i.e. (2011) Injection
INJECTION COMPONENTS
1 Throttle body and electronic injection control unit (MIU)
2 Fuel injector
3 Diagnostics socket connector
4 Injection load remote control
5 Electric fan
6 Fuel pump
7 Lambda Probe
8 Engine Speed sensor
9 HV coil
10 Water temperature sensor
MIU injection system

This vehicle is fitted with an integrated injection and ignition system.
Injection is indirect in the manifold through an electro-injector.
The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the
crankshaft (24-2 teeth) and pick-up sensor.
Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further
corrections are made according to the following parameters:
- Coolant temperature.
- Intake air temperature
- Lambda probe
The system implements an idle feeding correction with cold engine through a Stepper motor on a by-
pass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening
time, thereby ensuring the idle steadiness and the proper combustion.
INJEC - 165
Injection SR MAX 300 i.e. (2011)
In all conditions of use, mixture preparation is managed by modifying the injector opening time.
The fuel system pressure is kept constant based on the ambient pressure.
The fuel supply circuit consists of:
- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
The pump, the filter and the regulator are placed inside the fuel tank on a single support.
The injector is connected by a pipe with fast-release fitting. The pressure regulator is located at the
beginning of the circuit.
The fuel pump is controlled by the MIU control unit ; this ensures the scooter safety
The ignition circuit consists of:
- HV coil
- HV cable
- Shielded cap
- MIU control unit
- Spark plug
The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only
in the compression phase) at the same time.
The MIU injection-ignition system controls engine functions by means of a pre-set program.
Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to
reach a service station.
Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the
control circuits:
- Fuel pump
- HV coil
- Injector
The control unit is provided with a self-diagnosis
system connected to an indicator light in the in-
strument panel.
Failures are detected and restored by the diagnostic tester.

In any case, when the fault is no longer present, the data storage is automatically cleared after 16 cycles
of use (cold start, running at regular engine temperature, stop).
INJEC - 166
The diagnostic tester is also required to adjust the idle mixture.
Specific tooling
The MIU injection-ignition system carries out

checks on the rpm indicator and the electric fan for
radiator cooling.
The MIU control unit has a decoder for the anti-
theft immobilizer system.
The MIU control unit is connected to a diagnostic
LED on the instrument panel, that also carries out
the deterrent flashing functions.
The MIU control unit power supply is furthermore controlled by the emergency switch; that is to provide
further safety for the vehicle.
Precautions
Troubleshooting hints
1 A MIU failure is more likely to be due to the connections than to the components.
Before troubleshooting the MIU system, carry out the following checks:
A: Electrical power supply
a. Battery voltage
b. Blown fuse
c. Remote controls
d. Connectors
B: Chassis ground
C: Fuel system
a. Broken fuel pump
b. Dirty fuel filter
D: Ignition system
a. Faulty spark plug
b. Broken coil
c. Broken shielded cap
E: Intake circuit
a. Dirty air filter
b. Dirty by-pass circuit
c. Faulty Stepper motor
F: Other
a. Incorrect distribution timing
INJEC - 167
b. Wrong idle mixture

c.Incorrect reset of the throttle valve position sensor
2 MIU system faults may be caused by loose connectors. Make sure that all connections have been
correctly made.
Check the connections as follows:
A check that the terminals are not bent.
B check that the connectors have been properly connected.
C check whether the malfunction can be fixed by shaking the connector slightly.
3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit,
install the original control unit again and check if the fault occurs again.
4 Use a multimeter with an internal resistance of more than 10K Ohm /V when troubleshooting. Instru-
ments that are not suitable might damage the MIU central control unit. Use instruments with definitions
over 0.1V and 0.5 W , the precision must be greater than 2%.
1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not
disconnect the battery before checking for faults.
2. The fuel feed system is pressurised at 250 kPa (2.5 BAR). Before disconnecting the fast-release
fitting of the fuel supply pipe, check that there are no naked flames. Do not smoke. Act with caution to
avoid spraying fuel to your eyes.
3. When fixing electric components, operate with the battery connected only when actually required.
4. When functional checks are performed, check that the battery voltage is over 12V.
5. Before trying to start the vehicle, check to make sure there is at least two litres of fuel in the tank.
Failure to respect this norm will damage the fuel pump.
6. If the vehicle is expected to remain unused for a long time, refill the tank up to a little over half the
level. This will ensure the pump will be covered by fuel.
7. When washing the vehicle, be careful with the electric components and wiring.
8. When an ignition problem is detected, start the checks from the battery and the injection system
connections.
9. Before disconnecting the MIU control unit connector, perform the following steps in the order shown:
- Set the switch to «OFF»
- Disconnect the battery
Failure to respect this norm may damage the control unit.
10. Do not invert the polarity when fitting the battery.
11. To avoid damage, only disconnect and reconnect the MIU system connectors if required. Before
reconnecting, check that the connectors are dry.
12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not
take measurements not specifically foreseen by the manual.
INJEC - 168
13. At the end of every check performed with the diagnostic tester, protect the system connector with
its cap. Failure to observe this precaution may damage the MIU control unit.
14. Before reconnecting the quick couplers of the power supply system, check that the terminals are
perfectly clean.
Terminals setup
TERMINAL LAYOUT
1 Injection telltale light
2 Rpm indicator
3 -
4 - Lambda probe
5 + battery under permanent power supply
6 + Battery
7 Immobilizer aerial
8 Electric fan remote control
10 -
11 + Lambda probe
12 engine stop switch
13 Engine speed sensor (+)
14 Fuel injector
15 Engine speed sensor (-)
16 Diagnostics socket output
17 Immobilizer LED
18 Side stand
19 -
21 -
22 HV coil
23 -
24 Start up enabling
25 -
26 Ground lead
INJEC - 169
EMS circuit diagram
KEY
4. Starter solenoid
5. Starter motor
6. Engine ground
8. Fuses No. 02 - 15A
9. N. 03 - 15A Fuse
11. Fuses No. 05 - 10A
16. Fuses No. 10 - 7.5A
17. Fuses No. 11 - 7.5A
48. Injection ECU
49. Diagnosis
INJEC - 170

52. Stand button
54. Fuel pump
55. Fuel injector
56. Lambda sensor
57. HV coil
59. Decoder
60. Aerial
61. Fuses No. 12 - 7.5A
Troubleshooting procedure
Engine does not start
ENGINE DOES NOT START IF ONLY PULLED

Immobiliser enabling signal System not encoded
System not efficient, repair according to the indications of the
self-diagnosis
Presence of faults detected by the self diagnosis Pump relay
HV coil
Injector
Revolution timing sensor
Fuel system Fuel in the tank
Fuel pump activation
Fuel pressure (low)
Injector capacity (low)
Power to the spark plug Shielded spark plug cap HV coil (secondary insulation)
Parameter reliability Coolant temperature
Distribution timing - injection ignition
Intake air temperature
End of compression pressure End of compression pressure
Starting difficulties
ENGINE STARTER PROBLEMS

HV coil
Injector
Air temperature
Coolant temperature
Starter speed Starter motor and solenoid
Battery
Ground connections
End of compression pressure End of compression pressure
Power to the spark plug Spark plug
Shielded cap
HV coil
INJEC - 171

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

HV coil
Injector
Air temperature
Coolant temperature
Ignition efficiency Spark plug
Ignition timing
Correctness of the parameters Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake system cleaning Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake system sealing (infiltrations) Intake manifold - head
Throttle body - manifold
Intake sleeve
Filter box
Fuel system (low pressure) Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Engine does not rev down
ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGH

HV coil
Injector
Air temperature
Coolant temperature
Ignition efficiency Ignition timing
Stepper
Intake sleeve
Filter box
Pressure regulator
Fuel filter
Injector capacity
INJEC - 172
Exhaust backfires in deceleration
EXHAUST BACKFIRES WHEN DECELERATING

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

Intake system cleaning Air filter
Diffuser and throttle valve
Additional air pipe and Stepper
Intake system sealing Intake sleeve
Filter box
Ignition system Spark plug wear check
Parameter reliability Throttle valve position signal
Coolant temperature indicator
Intake air temperature indicator
Ignition advance
TPS reset successful TPS reset successful
HV coil
Injector
Air temperature
Coolant temperature
Lambda probe
Poor performance at full throttle
POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM-

ANCE ON PICKUP
HV coil
Injector
INJEC - 173

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

HV coil
Injector
Air temperature
Coolant temperature
Lambda probe
Ignition efficiency Spark plug
Ignition advance
Intake system sealing Intake sleeve
Filter box
TPS reset successful TPS reset successful
Fuel system Fuel pressure
Fuel filter
Injector capacity
Fuel quality
Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness
Fuel supply system
The fuel system circuit includes the electric pump, the filter, the pressure regulator, the electro-injector
and the fuel delivery pipes.
The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through
the filter.
The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.
INJEC - 174
Removing the butterfly valve
Remove the helmet compartment.

Remove the fuel piping clamping screw indicated
in the figure.
Remove the fast-release fitting from the injector

support.
INJEC - 175
Remove the injector connector.
Remove the three screws fixing the manifold to the

cylinder head and the clip fixing the throttle body
to the manifold.
Remove the MIU ECU connector.
Remove the clip fixing the throttle body to the air

cleaner bellows.
INJEC - 176
Remove the throttle control retainers as indicated

in the photograph.
Refitting the butterfly valve
For refitting, carry out the removal operations but

in reverse order paying particular attention to po-
sition the reference marks of the air cleaner sleeve
on the throttle body as indicated in the photograph.
Pump supply circuit
INJEC - 177
INJECTION LOADS
1 Battery 12V-14Ah
2 Fuse 15 A
3 Fuse 15 A
4 Ignition key contacts
5 Fuse 7.5 A
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda Probe
When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine
starts, in the presence of rpm timing signal the pump is continuously supplied.
ELECTRICAL DATA
• Pump winding resistance ~ 1.5 Ohm

• Input current during regular operation 1.4 ÷ 1.8 A
• Input current to the closed hydraulic circuit ~ 2 A (to be checked with appropriate tool for
fuel pressure control choking the circuit on the return pipe)
Check that the injection load 15A fuse No. 3 works

properly.
Check that the 7.5A fuse No. 12 for live control unit
power works properly.
INJEC - 178
Check the efficiency of the injection load solenoid.

Check the resistance of the energising coil be-
tween pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the remote control.
Check the power supply line of the injection load

remote control energising coil: After switching to
"ON", make sure there is battery voltage, for two
seconds, between the black/white cable and
black-violet cable of the remote control base. If
there is not, check the continuity of the black/white
cable between fuse block and the remote control
base and of the black/violet cable between pin 20
of the control unit and the remote control base.
NOTE
CONTINUITY TESTS MUST BE CARRIED OUT WITH THE
COMPONENTS DISCONNECTED. (REMOTE CONTROLS,
ELECTRONIC CONTROL UNIT, FUSES, ETC.).
INJEC - 179
INJEC - 180
Check the presence of fixed voltage between the

red/blue cable of the remote control base and
earth. If not, check the continuity of the red/blue
cable between the fuse box (No. 3 15A) and the
remote control base.
NOTE
pump circuit 6
After switching to «ON» and for about 2 seconds,

check that there is battery voltage between the
Black-Green cable of the pump connector and the
ground lead with the pump connector disconnec-
ted. Otherwise, check the continuity of the Black-
Green cable between the pump connector and the
Check the efficiency of the ground line of the fuel
pump by measuring the continuity between the
pump connector black cable, system side, and the
ground.
If, when switching to "ON", the pump continues to
turn after two seconds of activation, check, with the
INJEC - 181
control unit disconnected and the injection load re-

mote control disconnected, that the Black-Purple
cable (pin 20 on the interface wiring) is insulated
from the ground.
Specific tooling
Circuit leak test
Install the specific tool for fuel pressure control,

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

propriate tool between the pump and the injector.
With the battery voltage> 12 V check that the fuel
pressure is 2.5 BAR and that the input current is
1.4 to 1.8 A
With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe
equipped with the pressure gauge of the appropriate tool. Get a graded burette with a flow rate of
approximately 1 L. Rotate the pump using the active diagnoses of the palm top computer. Using a pair
of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 2.5 BAR.
Check that within 15 seconds the pump has a flow rate of approx. 110 cm³.
Specific tooling
INJEC - 182
Fuel filter check
Disconnect the terminals from the electric pump
Remove the screw shown in the picture
Remove the clip fixing the piping to the filter shown

in the picture
Separate the lower part of the pump mounting as

shown in the picture.
INJEC - 183
Remove the filter from the pump mounting
Inspecting the injector circuit
INJECTION LOADS
1 Battery 12V-14Ah
2 Fuse 15 A
3 Fuse 15 A
5 Fuse 7.5 A
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda Probe
Checking the resistance at the injector ends: 14.5 ± 5% Ohm
INJEC - 184

properly.

INJEC - 185

NOTE
INJEC - 186

NOTE
INJEC - 187
With the control unit and the injector disconnected,

check the continuity of the Red-Yellow cable be-
tween pin 14 of the interface wiring and the injector
connector
Switch to «ON» and check if there is voltage, with

injector disconnected and control unit connected,
between the Black-Green cable of the injector con-
nector and the ground lead
With injector disconnected and the injector load

solenoid disconnected, check the continuity of the
Black-Green cable between the injector connector
and solenoid base.
INJEC - 188
Inspecting the injector hydraulics
To carry out the injector check, remove the intake

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

sure and position the manifold over a container
graduated by at least 100 cm³. Connect the injec-
tor with the cable making up part of the supply for
the injection tester. Connect the clamps of the ca-
ble to an auxiliary battery. Activate the fuel pump
with the active diagnosis. Check that, within fifteen
seconds, approximately 40 cm³ of fuel is dis-
pensed with an adjustment pressure of approxi-
mately 2.5 BAR.
Specific tooling
Proceed with the injector seal test.

Dry the injector outlet with a blast of compressed
air. Activate the fuel pump. Wait for one minute,
making sure there are no leaks coming from the
injector. Slight oozing is normal.
Value limit = 1 drop per minute
INJEC - 189
Components location
INJECTION COMPONENTS
1 Throttle body and electronic injection control unit (MIU)
2 Fuel injector
3 Diagnostics socket connector
5 Electric fan
6 Fuel pump
7 Lambda Probe
8 Engine Speed sensor
9 HV coil
Tachometer
INJEC - 190
With wiring disconnected from the control unit and

connected to the system, check that the sensor
resistance between pins 13 - 15 is between 100
and 150 Ohm at an engine temperature of approx-
imately 20°
Disconnect the fuel pipe connector. Start up the

engine and wait for it to stop. With the wiring con-
nected to the control unit and system try to start up
the engine and check that the voltage between
pins 13 and 15 is around 2.8 V
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.
INJEC - 191
With the revolution sensor connector disconnec-

ted and interface wiring disconnected from the
control unit, check that the red and white cables
(pins 13 - 15) are isolated from each other and in-
sulated from the ground connection.
Specific tooling
HT coil
INJECTION LOADS
1 Battery 12V-14Ah
2 Fuse 15 A
3 Fuse 15 A
5 Fuse 7.5 A
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda Probe
The combined ignition/injection system is a high-efficiency induction system.

The control unit manages two significant parameters:
- Ignition advance
INJEC - 192
This is optimised at once according to the engine revs, engine load, temperature and ambient pressure.
With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ± 50 R/1'.
- Magnetisation time
The coil magnetisation time is controlled by the control unit. The power of the ignition is increased during
the engine start-up phase.
The injection system recognises the 4-stroke cycle so ignition is only commanded in the compression
phase.
Specific tooling

properly.

INJEC - 193

NOTE
INJEC - 194

NOTE
INJEC - 195
Check there is voltage between pins 22 and 26 of

the interface wiring for around two seconds when
switching to «ON».
Check the resistance of the primary coil between

pin 22 of the interface wiring and the green black
cable of the injection load solenoid base with the
control unit disconnected and the solenoid discon-
nected.
Resistance of the primary = 0.5 ± 8% Ohm
INJEC - 196
TEMPERATURE SENSOR 1
1 engine stop switch
With the control unit side connector disconnected

and the coolant temperature sensor connector
connected, check the resistance between pins 9
and 26 in relation to the engine temperature.
20° = 2500 ± 100 Ω
80° = 308 ± 6 Ω
With the control unit side connector disconnected
and the coolant temperature connector discon-
INJEC - 197
nected, check the insulation between the two light

blue/green and pink/yellow cables
Zeroing the throttle

Resetting the throttle valve position signal (TPS reset)
The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated.
Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of
air under pre-set reference conditions.
Pre-calibration ensures optimal air flow to control idling.
This regulation must not be tampered with in any way whatsoever.
The injection system will complete the management of the idling through the Stepper motor and the
variation of the ignition advance.
The throttle body after the pre-calibration has an opened valve with an angle that can vary depending
on the tolerances of the machining of the pipe and the valve itself.
The valve position sensor can also assume various fitting positions. For these reasons the mV of the
sensor with the valve at idle can vary from one throttle body to another.
To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to
match the throttle body with the control unit following the procedure known as TPS resetting.
With this operation we inform the control unit, as the starting point, of the mV value corresponding to
the pre-calibrated position.
To reset, proceed as follows.
Connect the diagnostic tester.
Switch to «ON».
Select the functions of the diagnostic tester on «TPS RESET».
INJEC - 198
Specific tooling
Make sure that the throttle valve with the control is

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

- on first fitting.
- if the injection control unit is replaced.
NOTE
THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY
BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE
AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
Given that the TPS resetting is also done when the
control unit is replaced, place the control unit - filter
box bellows at 45° during the refitting operation as
shown in the picture.
INJEC - 199
Lambda probe
INJECTION LOADS
1 Battery 12V-14Ah
2 Fuse 15 A
3 Fuse 15 A
5 Fuse 7.5 A
7 Fuel pump
8 HV coil
9 Fuel injector
10 Lambda Probe
The lambda probe or oxygen sensor is a sensor which provides information about the oxygen content
in the exhaust fumes. The signal generated is not of the proportional but of the ON/OFF type, i.e. whether
there is oxygen or not. The probe is positioned on the exhaust manifold before the catalytic converter
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.
Specific tooling
INJEC - 200

properly.

INJEC - 201

NOTE
INJEC - 202

NOTE
SIGNAL CONTROL
INJEC - 203
Install the electronic control unit interface wiring.

Start the engine and warm up until the electric fan
switches on.
Use an analogue multimeter with a direct voltage
scale measuring down to 2 V.
Place the tips of the multimeter between pins 4 (-)
and 11 (+)
With the engine running at idle speed, check that

the voltage oscillates between 0V and 1V
With the throttle valve completely open, the volt-
age is approx. 1V.
During the closing phase, the voltage is approx.
0V.
If the voltage remains constant, the sensor may be
damaged. Remove the sensor and check that
there are no oil or carbon deposits inside it..
INJEC - 204
INDEX OF TOPICS
SUSPENSIONS SUSP
Suspensions SR MAX 300 i.e. (2011)
This section is dedicated to operations that can be carried out on the suspensions.
Front
Removing the front wheel
- Remove the fixing nut from the wheel axle on the

left side of the vehicle.
- Loosen the two screws fixing the wheel axle
clamp and remove the clamp.
Front wheel hub overhaul
Check that the wheel bearings do not show signs

of wear.
If you have to replace the wheel bearings, proceed
as follows:
- Remove the two bearings on the brake disc side
using pliers 14 and the special bell 9.
- Remove the internal spacer.
SUSP - 206
SR MAX 300 i.e. (2011) 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.
Specific tooling
020412Y 15-mm guide
- Heat the bearing seat on the side opposite the
brake disc with the heat gun.
- Insert the bearing using the punch consisting of

adaptor handle, 40x37 mm adaptor and 15 mm
guide, and take it to the stop.
SUSP - 207
- Reinsert the spacer bushing on the brake disc

side using the appropriate tool and take it to the
stop.
Specific tooling
020412Y 15-mm guide
020201Y Spacer bushing driving tube
- Refit the cap and tighten the five fixing screws.
SUSP - 208
- Turn over the wheel and insert the internal spacer

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

with the heat gun.
2 - Insert the two bearings one at a time using the punch consisting of adaptor handle, 32x35 mm
adaptor and 15 mm guide, and take it to the stop.
Specific tooling
020412Y 15-mm guide
Refitting the front wheel
- When refitting, pay attention in repositioning the

odometer drive correctly.

Wheel axle nut 45 to 50 Wheel axle clamp
screws 6 - 7 Nm
Handlebar
SUSP - 209
Removal
- Remove the two handlebar covers and the upper

part of the shield back plate proceeding as indica-
ted in the «Bodywork» chapter.
- Remove the handlebar wiring retaining straps
and disconnect the electric connectors from the
brake levers.
- Unscrew the fittings, then remove the front and
rear brake pump piping.
- Remove the flexible transmissions of the throttle
grip and remove the throttle control.
- Unscrew the indicated nut, collect the washers

and remove the fixing pin to the steering tube.
- Remove the handlebar by pulling it upwards.
NOTE
IF THE HANDLEBAR IS BEING REMOVED TO REMOVE
THE STEERING, IT IS ONLY NECESSARY TO TILT THE
HANDLEBAR FORWARD ONTO THE FRONT PART OF THE
VEHICLE WITHOUT REMOVING THE PARTS FITTED SO
AS TO AVOID DAMAGING THE SHAFTS.
Refitting
Carry out the removal operations but in the reverse order, observing the prescribed tightening torque.

Handlebar fixing screw 50 ÷ 55
Front fork
Removal
See also
SUSP - 210
Overhaul
- Support the fork in a vice.

- Loosen the two tightening screws of the stem
supporting clamp.
- Unscrew the stem closing cap and slide off the
complete fork leg from the corresponding support.
CAUTION
THE STEM CLOSING CAP KEEPS THE MAIN SPRING PRE-
LOADED. KEEP THE CAP PROPERLY FITTED DURING
THE REMOVAL FINAL STAGE TO AVOID ACCIDENTS.
- Support the fork leg properly, remove the main

spring and drain off the fork leg oil.
- Remove the hydraulic rod fixing screw with the

corresponding sealing gasket:
- With a 19-mm hexagonal spanner, lock hydraulic
rod rotation.
- Undo the fixing screw and collect the copper
washer.
SUSP - 211
- Remove the stem dust guard with a screwdriver.
- Remove the circlip retaining the oil seal.
- Take out the stem.
- Check there are no signs of wear or seizing between the stem and the fork leg. Otherwise, replace
the damaged parts.
Characteristic
Maximum fork leg diameter
35.10 mm
Minimum stem diameter
34.90 mm
SUSP - 212
- 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
- Hold the tie rod manually so that it does not fall

into the fork leg and/or that both half-rings are not
in their position.
- Fit the bell.
- Tighten the nut until it stops.
- Act on the tool until the oil seal is completely re-
moved.
Specific tooling
- Remove the hydraulic rod with the corresponding

sealing gasket, the spring and the stop bushing.
COMPONENT CHECK
CAUTION
CLEAN ALL THE COMPONENTS THOROUGHLY.
SUSP - 213
- Check that the fork leg is not cracked or broken

in the attachments.
- Check that the stem is not scored, dented or dis-
torted.
- Check that the stop bushing for the hydraulic rod
is correctly fixed through caulking.
- Check that hydraulic rod caulkings, the return

spring to the unloaded the end of stroke and the
hydraulic rod sealing ring are in good conditions.
- Check that the main spring exhibits no signs of

yielding or abnormal wear.
SUSP - 214
- Check that the closing cap O-ring of the stem is

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

ing lips of a new oil seal.
- Fit the sealing ring on the stem and keep the
identification words facing upwards.
- Drive the oil seal as far as it will go using the ap-
propriate tool.
Specific tooling
- Pre-fit the stem with the hydraulic rod, the spring
and the stop bushing.
- Fit the pre-assembled components inside the fork
leg.
- Fit the hydraulic rod fixing screw with the copper

sealing washer and tighten to the prescribed tor-
que using the recommended product.
CAUTION
ALWAYS USE NEW COPPER WASHER.

Hydraulic rod fixing screw 25 ÷ 35*
(°) Apply LOCTITE 243 threadlock
SUSP - 215
- Lock hydraulic rod rotation using a 19-mm hex-

agonal spanner.
- Fit the oil seal retaining circlip.
- Grease and fit a new dust guard.
- Fit the fork leg together with the stem on the fork
supporting clamp until it stops.
- Tighten the two screws to the prescribed torque
in the sequence indicated in the picture.

Stem support clamp tightening screws 20 to 25
SUSP - 216
- Refill the fork leg with the recommended product

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

peatedly.
- Fit the spring into the stem.
CAUTION
FIT THE SPRING WITH THE SMALLER PITCH TO THE UP-

PER PART OF THE STEM.
- Lubricate the closing cap O-ring of the stem.

- Preload the spring, fit the closing cap and tighten

Fork locking screws cap 15 ÷ 30
- Repeat the procedure for the other fork leg.

NOTE
IF BOTH FORK LEGS ARE SERVICED AT THE SAME TIME, BE CAREFUL NOT TO INVERT THE
RIGHT FORK LEG WITH THE LEFT ONE.
SUSP - 217
Steering column
Refitting
- Fit the lower steering bearing on the steering

tube.
- Fit the fork together with the lower steering bear-
ing on the headstock and hold it so that it does not
fall.
NOTE
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.
AGIP GREASE PV2 Ivory smooth-textured,
slightly-stringy anhydrous calcium-base
grease.
TL 9150 066, symbol NATO G 460
- Fit the upper steering bearing.

CAUTION
INSERT THE UPPER STEERING BEARING WITH THE
CAGE FACING UPWARDS.
- Fit the steering bearing upper seat.
SUSP - 218
- Fit the cover plate.
- Insert the spacer.
- Insert the lower tightening ring nut, screw until it

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

Steering tube lower ring nut 14 ÷ 17
SUSP - 219
- Fit the spacer between the two ring nuts on the

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

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

Steering tube upper ring nut 40 ÷ 45
Insert the collar shown in the figure and restore the

cable passage as shown in the figure.
- Fit the front wheel.
Steering bearing
SUSP - 220
Removal
- Clean thoroughly and visually inspect if the com-

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

tracks, the headstock and the steering tube exhibit
no scores or abnormal wear. Otherwise, replace
them.
STEERING FIFTH WHEEL TRACK REMOVAL
- Remove the steering fifth wheel tracks on the
chassis with the specific tool, following the indica-
ted procedure.
- Fit the specific tool from the lower part of the
headstock until it makes contact with the upper
track.
- Hit with force the specific tool, placing it at differ-
ent points diametrically opposed so as to remove
the upper track.
Specific tooling
from headstock
SUSP - 221
- Repeat the procedure for the lower steering bearing track.
- Remove the lower steering bearing seat on the

steering tube using the specific tool.
Specific tooling
from headstock
Refitting
STEERING FIFTH WHEEL TRACK FITTING

- Thoroughly clean the track seats on the headstock and the steering tube.
- Fit the new tracks of the headstock with the specific tool.
- Screw the nut until the tracks are fully inserted.
SUSP - 222
NOTE
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH RECOMMENDED GREASE BEFORE
USE.
Specific tooling
001330Y Tool for fitting steering seats
AGIP GREASE PV2 Ivory smooth-textured, slightly-stringy anhydrous calcium-base grease.
SUSP - 223
SUSP - 224
- Fit the lower fifth wheel seat on the steering tube.

- Using the specific tool, fit the lower fifth wheel
seat on the steering tube.
NOTE
LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH
RECOMMENDED GREASE BEFORE USE.
Specific tooling
020459Y Punch for fitting bearing on steering
tube
grease.
Rear
Removing the rear wheel
Remove the full muffler assembly.
- Remove the cotter pin, the cap, the wheel axle

fixing nut and the outer one of the two spacers.
- Remove the two screws fixing the mudguard to the bracket

- Remove the two screws fixing the bracket to the engine
SUSP - 225
- Slide off the wheel axle bracket, using the heat

gun if necessary.
- Remove the 5 bolts of the wheel and remove
Refitting the rear wheel
To fit, follow the removal steps but in the reverse

sequence, being careful to fit the spacers on the
wheel axle as shown in the picture.

Silencer arm clamping screws 27 - 30 Rear
wheel axle nut 104 to 126 Shock absorber-crank-
case attachment bracket 20 to 25 Lower shock
absorber clamping screw 33 - 41 Nm Rear brake
calliper fixing screws 25 - 30 Nm
Swing-arm
SUSP - 226
Removal
- Place the vehicle on its centre stand;

- Remove the swinging arm/engine fitting shown in
the picture
- Move the engine back
- Remove the spring anchoring the swinging arm

to the chassis as shown in the picture
- Remove the two screws fixing the buffer support

bracket to the chassis
- Undo the nut on the LHS shown in the figure and

remove the corresponding bolt from the opposite
side.
- Remove the swinging arm.
SUSP - 227
- Check the entire swinging arm assembly.

- Check all the centring bushing components and
silent block rubber buffers.
- Replace the work components that cause exces-
sive clearance on the rear suspension.
Overhaul
- Check there is no sticking in the movement of the

connection of the swinging arm on the engine side
to the swinging arm on the chassis side.
- Check the axial clearance between the two
swinging arms using a feeler gauge
Characteristic
Standard clearance
0.40 - 0.60 mm
1.5 mm
- In order to check the clearance of the swinging

arm on the frame side, prepare a retainer using the
fixing pin of the swinging arm on the frame and two
rings from the special tool 020229Y. Alternatively,
use two washers with 12-mm inside diameter for
pins, minimum 30-mm outside diameter and 4-mm
thick at least.
- Check there is no sticking in the rotation.

- Check the axial clearance of the swinging arm on
the chassis side
Characteristic
Standard clearance
0.40 - 0.60 mm
1.5 mm
SUSP - 228
- Separate the swinging arm on the engine side

from the vehicle side arm.
- Remove the plastic bushings and the internal
spacer shown in the picture.
- Using a suitable pin remove the roller casings as

shown in the pictures
- Using an appropriate tool plant new roller cas-

ings, being careful to position the bearings with the
seal rings facing outwards
Specific tooling
020244Y 15-mm diameter punch
020115Y Ø 18 punch
Characteristic
Length of the swinging arm tube on the engine
side:
L 175.3 + 0.3 0
Length of the internal swinging arm spacer on
the engine side:
L 183 + 0.3 0
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
SUSP - 229
Length of the swinging arm tube on the chas-

sis side:
283 ± 0.1 mm
- Lubricate roller casings and the plastic bushings

with grease
- Insert the spacers
- Assemble the two arms with the relative bolt in
the position shown in the picture
- Adjust the bolt as shown in the picture
- Position the chassis side swinging arm with the
most protruding part pointing towards the silent
block side as shown in the picture
grease.
- 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
SUSP - 230
- Hold the full silent bloc bracket in the clamp

- Using the appropriate tool, remove the silent bloc
from the bracket from the side corresponding to
the inside of the vehicle. This is to guarantee the
tool is centred properly on the support
- Install a new silent bloc, making sure it aligns

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

shown in the picture
Refitting
- To refit, perform the removal operations in reverse.

- Grease the bearings and the rolling parts with the recommended grease.
SUSP - 231
-Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque.

Engine and vehicle side swinging arm junction bolt 33 ÷ 41 Nm Swinging arm pin - Engine 64 ÷
72 Body shell - Swinging arm pin 76 ÷ 83 Screw fixing the silent-block support plate to the
body 42 ÷ 52
Shock absorbers
Removal
Proceed as follows:
- place the vehicle on its centre stand;
- lift the engine a little with a jack so as to free the
two shock absorbers;
- remove the silencer
- undo the shock absorber spring assembly clamp-
ing screw from the support fixed to the engine on
the one side and from that fixed to the silencer on
the other;
- unscrew the two upper nuts (one on each side)
fixing the shock absorber spring assembly to the
frame and remove the shock absorbers.
Refitting
Carry out the previous operations but in reverse order.

Shock absorber lower clamping 33 to 41 Shock absorber upper clamp 33 to 41
SUSP - 232
Centre-stand
REMOVAL
- Use a jack to support the vehicle properly.
- Remove the two return springs from the centre
stand.
- Undo the nut shown in the figure.
- Remove the pin from the right side.
- Remove the centre stand.
FITTING
- On refitting tighten the nut to the specified torque.

Centre stand bolt 32 to 40
Side stand
REMOVAL
- Uncouple the centre stand return spring;
Remove the screw shown in the photograph
FITTING
To refit, carry out the removal operations in re-
verse order and comply with the specified torque.

Side stand fixing bolt 35 to 40
SUSP - 233
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

SR MAX 300 i.e. (2011) 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.
NOTE
IF IT IS NECESSARY TO REPLACE OR SERVICE THE
BRAKE CALLIPER, BEFORE REMOVING THE FITTINGS
FIXING THE CALLIPER TO THE SUPPORT BRACKET,
FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING
EMPTIED THE SYSTEM OF THE CIRCUIT BEING EXAM-
INED.
Overhaul
- Remove the brake calliper.

- Suitably support the brake calliper in a vice
- Remove the two pad fixing screws.
- Remove the pads being careful with the stop
spring.
- Remove the fixed plate by undoing the screw

shown in the photograph.
BRAK SYS - 235

Braking system SR MAX 300 i.e. (2011)
- Remove the internal parts from the floating body

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

and in good condition;
• that the cylinders of the calliper floating
body do not show signs of scratches or
erosion, otherwise replace the entire
calliper:
• that the guides of the fixed plate are not
scratched or eroded, otherwise re-
place the entire plate;
• that the brake pad check spring works
properly
CAUTION
ALL THE SEALS AND GASKETS MUST BE REPLACED EV-
ERY TIME THE PUMP IS SERVICED.
Refitting
- Insert the O-rings and small pistons the floating
body, lubricating all the components with brake
fluid.
- Fit the fixed plate being careful to grease guide

A and to insert washer B as indicated in the photo.
- Fit the pad retention spring

- Fit the pads and screw up the relative clamping screws to the specified torque
BRAK SYS - 236

- Hold the pads in the correct position and insert the calliper in the brake disc.
- Fix the support calliper by means of the two screws at the specified torque
- Secure the pipe fitting to the calliper at the specified torque.
- Bleed the air from the system.

Rear brake calliper fixing screws 20 to 25 Engine- calliper support plate fixing screws 48 ÷ 52
Front brake calliper
Removal
- Remove the two front brake calliper devices fas-

tening them to the support as shown in the photo-
graph.
NOTE
WHEN A PROCEDURE IS PLANNED INCLUDING THE
SERVICE OR REPLACEMENT OF THE CALLIPER, FIRST
LOOSEN THE FITTING CONNECTING THE PIPE TO THE
BRAKE CALLIPER
Overhaul

- Suitably support the brake calliper in a vice
- Remove the two pad fixing screws.
- Remove the pads being careful with the stop
spring.
- Remove the fixed plate by undoing the screw

shown in the photograph.
BRAK SYS - 237

- Remove the internal parts from the floating body

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

and in good condition;
• that the cylinders of the calliper floating
body do not show signs of scratches or
erosion, otherwise replace the entire
calliper:
• that the guides of the fixed plate are not
scratched or eroded, otherwise re-
place the entire plate;
• that the brake pad check spring works
properly
CAUTION
ALL THE SEALS AND GASKETS MUST BE REPLACED EV-
ERY TIME THE PUMP IS SERVICED.
Refitting
- Insert the O-rings and small pistons the floating
body, lubricating all the components with brake
fluid.
- Fit the fixed plate being careful to grease guide

A and to insert washer B as indicated in the photo.
- Fit the pad retention spring

- Fit the pads and screw up the relative clamping screws to the specified torque
BRAK SYS - 238

- Hold the pads in the correct position and insert the calliper in the brake disc.
- Fix the support calliper by means of the two screws at the specified torque
- Secure the pipe fitting to the calliper at the specified torque.
- Bleed the air from the system.

Screw tightening calliper to support 24 to 27 Pad fastening pin 19.6 ÷ 24.5 Calliper support plate
- fork fixing screws 41 ÷ 51
Rear brake disc
Removal
- Remove the rear wheel.

- Remove the disc from the wheel axle.
- Undo the five screws and remove the disc from

the wheel hub.
Refitting
For fitting, position the disc correctly using the arrow stamped on it as reference.
- Do up the screws to the prescribed torque and apply the recommended product
NOTE
THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED
TOWARDS THE OUTSIDE OF THE VEHICLE.
BRAK SYS - 239

Brake disc screws 8 to 10
Disc Inspection
- Remove the rear brake calliper.

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

- Check the regular nature of the rotation of the brake disc assembly using the appropriate tool fixed
onto the brake calliper as shown in the photo.
- In order to be able to anchor the appropriate tool properly use a metal plate with M8 threaded hole
and fix it to one of the two rear brake calliper attachment points.
- Suitably fix the flange to the wheel axle with the original nut and spacer and a Æ 17 mm bearing.
NOTE
SO AS NOT TO GET A DISTORTED READING, CAUSE THE DRIVEN PULLEY SHAFT TO TURN
IN ORDER TO ROTATE THE DISC.
Specific tooling
Characteristic
Max. deviation allowed:
0.1 mm
- If you detect incorrect values, replace the disc. If

the anomaly persists, replace the hub.
Front brake disc
BRAK SYS - 240

Removal
- Remove the front wheel.

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

Brake disc screws 8 to 10
Disc Inspection
Checking the disc is important; it must be perfectly

clean, with no sign of rust, oil or grease or any oth-
er dirt, and must show no signs of deep scoring.
Characteristic
Standard thickness:
5 +0.2-0.1 mm
Disc thickness at wear limit
4.5 mm
BRAK SYS - 241

• Using the appropriate tool, measure

how much the disc protrudes when the
wheel is fitted properly. The protrusion,
measured near the external edge of
the disc, must be less than 0.1 mm.
• If a value is measured other than the
specified value, remove the front wheel
(Front/Rear Suspension chapter) and
check the protrusion of the disc. Maxi-
mum permissible out of true is 0.1 mm.
If the value measured is greater, re-
place the disc and repeat the check.
• If the problem persists, check and re-
place the wheel hub if necessary.
Specific tooling
Front brake pads
Removal
Proceed as follows:
- Remove the front brake calliper.
- Loosen the two pins shown in the figure that lock

the two pads.
- Remove the pads, being careful with the pad
spring clamp.
- Check the thickness of the pads.
Characteristic
Minimum value
1.5 mm
BRAK SYS - 242

See also
Refitting
To fit, proceed as follows:

- Insert the two pads in the callipers.
- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
NOTE
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT-
TING, GENTLY EXPAND THE PADS.

Screw tightening calliper to support 24 to 27 Pad fastening pin 19.6 ÷ 24.5
Rear brake pads
BRAK SYS - 243

Removal
Proceed as follows:
- Remove the rear brake calliper.
- Loosen the two pins shown in the figure that lock

the two pads.
- Remove the pads, being careful with the pad
spring clamp.
- Check the thickness of the pads.
Characteristic
Minimum value
1.5 mm
See also
Refitting
To fit, proceed as follows:
BRAK SYS - 244

- Insert the two pads in the callipers.

- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
NOTE
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT-
TING, GENTLY EXPAND THE PADS.

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

- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the left-had brake lever, load the system and
bring it up to the required pressure.
- Keeping the left-hand brake lever pulled, loosen
the bleed screw to permit the air in the system to
escape. Then tighten the bleed screw
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.
- Top up the brake fluid to the right level in the reservoir.
If necessary, bleeding can be done using a special vacuum pump
NOTE
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING
AND EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling

System bleed calliper fitting: 12 ÷ 16 Nm
BRAK SYS - 245

Front
- Remove the rubber cap from the bleed screw.

- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the right-hand brake lever, load the system
and bring it up to the required pressure.
- Keeping the right-hand brake lever pulled, loosen
the bleed screw to purge the air. Then tighten the
bleed screw
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.
- Top up the brake fluid to the right level in the reservoir.
If necessary, bleeding can be done using a special vacuum pump
NOTE
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO
CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE
BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE
FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE
PADS. FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING
AND EFFICIENCY OF THE BRAKING SYSTEM
Specific tooling

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

- Remove the front and rear handlebar covers.
- Place a suitable container to collect the oil, dis-
connect the oil pipe from the calliper and operate
the brake lever until no more oil comes out.
- Disconnect the oil pipe «A» from the pump, then
unscrew the two retainers «B» from the U-bolt and
remove the pump.
- Upon refitting, tighten up the fitting to the speci-
fied torque and bleed the system.
CAUTION
BRAK SYS - 246

ALWAYS USE NEW COPPER WASHERS.

Brake fluid pump-hose fitting 16 - 20 Fixing
screws for the handlebar control unit U-bolts 7
to 10
BRAK SYS - 247

INDEX OF TOPICS
COOLING SYSTEM COOL SYS

SR MAX 300 i.e. (2011) Cooling system
Circuit diagram
KEY
A = Expansion tank
B = Radiator
C = Radiator intake pipe
D = Water pump
E = Delivery pipe to cylinder
F = By-Pass pipe
G = Thermostat
H = Radiator delivery pipe
Electric fan check

- Check and, if necessary, restore the correct battery voltage.
COOL SYS - 249

Cooling system SR MAX 300 i.e. (2011)
Characteristic
Battery voltage
12V
- Check that the electric ventilation relay is working

properly.
- If the relay is not working, replace it.

- If the relay is operating, remove it and jump the
red-green and red-black wires (85 - 86); all the
components in proper operating conditions, the
electric ventilation should be able to start.
- In order to check the coolant temperature sensor, see the «Injection» chapter.
See also
System bleed
- Start up the engine until the operating tempera-

ture is reached.
- Remove the rubber hood over the bleed valve
- Obtain a rubber tube that is of the right length to
connect the valve to the expansion tank
- Place one end of the pipe on the bleed valve and
the other in the expansion tank
- Loosen the screw by two turns until the commu-
nication hole is revealed with the head as shown
in the picture
- Wait until only coolant comes out of the rubber
pipe so as to eliminate any air bubbles inside the
circuit.
COOL SYS - 250

SR MAX 300 i.e. (2011) Cooling system
- Tighten the bleed valve respecting the maximum

torque.
- Bring the coolant up to the correct level inside the
expansion tank

Bleed screw 3
Thermostat
Removal
- Remove the helmet compartment inspection cov-

er.
- Place a + 2.0 l container under the vehicle to col-
lect the coolant.
- Undo the two screws indicated, lift the cover and
remove the thermostat.
COOL SYS - 251

Cooling system SR MAX 300 i.e. (2011)
Check
1) Visually inspect that the thermostat is not dam-

aged.
2) Fill a metal container with approx. 1 litre of wa-
ter.
Immerse the thermostat, and keep it in the centre
of the container.
Immerse the multimeter temperature probe, and
keep it close to the thermostat.
Heat up the container using the thermal gun.
Check the temperature at which the thermostat
starts to open:
Heat up until the thermostat is completely open.
3) Replace the thermostat if it is not working prop-
erly.
CAUTION
TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI-
THER THE THERMOSTAT NOR THE THERMOMETER
TOUCHES THE CONTAINER.
Specific tooling
020151Y Air heater
THERMOSTAT
Type Wax-type, with deviator
Starts opening at 85±2°C
Refitting
- Follow the removal steps but in reverse order; be careful to tighten screws to the prescribed torque.

Thermostat cover screws 3 to 4
- Once the cooling circuit is restored, refill using the recommended product and purge the circuit as
expressly indicated in the «Cooling System» chapter.
COOL SYS - 252

INDEX OF TOPICS
CHASSIS CHAS
Chassis SR MAX 300 i.e. (2011)
This section è is dedicated to the operations that can be carried out on the vehicle's bodywork.
Seat
- Remove the two clamping screws on the frame.

- Remove the control button of the undersaddle
light.
Rear handlebar cover
- Release the three retaining tabs of the rear han-

dlebar cover shown in the figure using a screw-
driver and paying attention not to damage the
paintwork.
- Remove the five fixing screws from the rear han-

dlebar cover.
- Remove the rear cover.
NOTE
WHEN INSTALLING, THE CENTRE SCREW IS A METAL
SCREW, THE OTHER 4 ARE PLASTIC.
CHAS - 254
SR MAX 300 i.e. (2011) Chassis
Instrument panel
- Remove the instrument panel.

- Loosen the five fixing nuts of the instrument pan-
el.
Front handlebar cover
- Remove the rear handlebar cover.

- Remove the left and right frames of the brake
pump secured with two retaining fins.
- Loosen the four fixing screws of the front han-

dlebar cover with the handlebar itself.
- Disconnect the warning light unit connector «A».
CHAS - 255
Headlight assy.
- Remove the centre cover of the shield.
- Remove the 4 front retainers of the front light as-
semblies.
- To remove the right-hand light assembly, remove

the screw located near the cover of the expansion
tank.
- To remove the left-hand light assembly, remove

the screw located in the left-hand storage com-
partment.
Remove the light, disconnecting the electric con-

nector from the light and the complete lamp holder
of the position light.
NOTE
THE TWO REAR ADJUSTMENT SCREWS SHOWN IN THE
FIGURE ARE ADJUSTED DURING ASSEMBLY OF THE
LIGHT AND MUST NOT BE ALTERED.
Frame central cover

The chassis central cover has a central tunnel and two side fairings, the procedure is the following:
CENTRAL TUNNEL:
CHAS - 256
- Remove the saddle together with the hinge.
- Open the fuel tank flap.

- Undo the screw indicated in the figure.
- Undo the three screws indicated in the figure.

NOTE
THE OTHER 3 SCREWS HAVE ONLY AN AESTHETIC
FUNCTION
- Undo and remove from both vehicle sides the

screw indicated in the figure.
- Undo the five screws indicated in the figure.

CAUTION
PROVISIONALLY PROTECT THE NECK OF THE FUEL
TANK USING A CLEAN CLOTH TO PREVENT ANY DIRT OR
OBJECTS ACCIDENTALLY FALLING INTO THE TANK.
CHAS - 257
- Working from both sides, undo the screw indica-

ted and release the retaining tongues to remove
the side air deflectors.
- 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 handgrips and top side fairings.
- Remove the right and left footrests (see FOOTREST).
- Working from both sides, undo the screw indica-

ted in the figure.
- Remove the side fairing sliding it from the
tongues.
Legshield
The front shield has a lot of sections. The removal procedure is described below:
CHAS - 258
FRONT LOWER FRAME:

- Using a screwdriver, remove the clip-on badge.
- Undo and remove the screw under the badge.
- Undo and remove the screw «A».
- Taking care not to damage the plastic tongues,

remove the front lower frame sliding it upwards
from bottom to top.
FRONT UPPER FRAME:

- Remove the FRONT LOWER FRAME.
- Remove the windshield together with the supports.
CHAS - 259
- Undo and remove the two screws «B» and the

four screws «C».
- Remove the frame sliding it from the tongues.
FRONT TURN INDICATORS:

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

- Undo and remove the three screws to remove the
bulb holder from the support.
FRONT SHIELD:
- Remove the front lower frame.
- Remove the front upper frame.
- Remove the front headlight assemblies.
- Remove the instrument panel (see SHIELD BACK PLATE).
- Remove the lower shield back plate (see SHIELD BACK PLATE).
CHAS - 260
- Remove the hand guards unscrewing, from both

sides, the two screws «A» collecting the washers
and the screw «B».
- 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.
To refit follow the reverse order paying attention to fasten the cable harness with the relative clamps.
Knee-guard
The shield back plate is made by two sections. The instrument panel, with instrument unit and lower
shield back plate. The procedure for both is described below:
CHAS - 261
INSTRUMENT PANEL:
- Remove the windshield.
- Remove the rear handlebar cover.
- Remove the front handlebar cover.
- Remove the handlebar.
- Undo and remove the two screws «A».
- Working from both vehicle sides, undo and re-

move the screw «B».
- Undo and remove the two screws «C» placed on

and inside the glove compartment.
- Undo and remove the two screws «D» placed on

and inside the coolant loading compartment.
CHAS - 262
- Undo and remove the expansion tank cap and

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

strument panel connector «E» and the instrument
panel lighting connector «F». Remove the instru-
ment panel.
LOWER SHIELD BACK PLATE:

- Remove the central tunnel (see CENTRAL CHASSIS COVER).
- Remove the instrument panel (see SHIELD BACK PLATE).

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

be necessary to use pliers), releasing the catch.
CHAS - 263
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.
- Loosen the 2 hex. socket head screws and re-
move the complete switch.
- From the underside it is possible to loosen the 3

retaining screws and to release the 2 locking tabs
to raise the mounting plate of the steering lock
strut.
- The latter has a retaining tab with cylindrical teeth
that cannot be replaced.
Front wheel housing
To remove the front wheel housing, proceed as

follows:
- Remove the spoiler.
- Remove the front fork.
- Remove the plate supporting bracket for the horn
and voltage regulator by loosening the two fixing
screws shown in the figure in order to release the
two lower retainers of the wheel housing.
- Remove the upper fixing screw of the wheel

housing to permit movement.
CHAS - 264
- In order to remove the wheel housing it is necessary to remove the front brake hose to the tank and
combination with the splitter.
To remove the front wheel housing, proceed as

follows:

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

lows:
- Remove the rear upper central cover.
- Remove the handgrips and the upper side fair-
ings.
- Undo and remove the central screw.
CHAS - 265
- Using a jointed wrench between the helmet com-

partment and the chassis pipes, loosen the two
rear fixing nuts and then disconnect the light stud
bolts from the support extensions.
- Remove the light and disconnect the bulb holder
by turning it through 30° in anticlockwise direction.
To remove the rear light assembly, proceed as fol-

lows:
- Remove the handgrips and the upper side fair-
ings.
- Undo and remove the central screw.
- Using a jointed wrench between the helmet com-

partment and the chassis pipes, loosen the two
rear fixing nuts and then disconnect the light stud
bolts from the support extensions.
- Remove the light and disconnect the bulb holder
by turning it through 30° in anticlockwise direction.
Footrest
The footrest comprises a right and left footrest, a passenger footrest and a rider footrest. The whole
procedure is described below:
PASSENGER FOOTREST:
- Unscrew the nut «A» from both vehicle sides and
release the footrests.
CHAS - 266
RIGHT AND LEFT FOOTREST:

- Working from both vehicle sides, remove the mat.

four screws «C».
- Remove the footrest
RIDER FOOTREST:
To remove the rider footrest, proceed as follows:
- Remove the central cover.
- Remove the shield back plate.
- Remove the right and left footrest (see FOOTREST).
- Undo the screw «D» and the screw «E» and re-
move the rider footrest.
The footrest comprises a right and left footrest, a passenger footrest and a rider footrest. The whole
procedure is described below:
CHAS - 267
PASSENGER FOOTREST:
- Unscrew the nut «A» from both vehicle sides and
release the footrests.
RIGHT AND LEFT FOOTREST:

- Working from both vehicle sides, remove the mat.

four screws «C».
- Remove the footrest
RIDER FOOTREST:
To remove the rider footrest, proceed as follows:
- Remove the central cover.
- Remove the right and left footrest (see FOOTREST).
- Undo the screw «D» and the screw «E» and re-
move the rider footrest.
CHAS - 268
Side fairings
- Remove the rear central cover.

- Remove the passenger handles.
- Remove the lower cover.
- Remove the lower side cover.

- Remove the eight screws shown in the figure
(four on each side).
- Pull out the fairing.
CHAS - 269
- 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.
Rear mudguard
To remove the rear mudguard, proceed as follows:

- From the right side of the vehicle, undo the screw
«A».
CHAS - 270
- From the left side of the vehicle, undo the two

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

- Remove the saddle.
- Remove the battery.
- Remove the handgrips and top side fairings.
- Working from both vehicle sides, undo the three

screws «A» and the screw «B».
- Undo and remove the two screws «C» from the

battery compartment.
- Lift the helmet compartment from the rear side
and remove the saddle lock.
- Disconnect the connectors of the power socket and the under seat light.
- Remove the plug socket due to the interference with the chassis.
- Remove the fuse box releasing the side hook teeth.
- Remove the complete helmet compartment.
CHAS - 271
Front mudguard

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

NOTE
THIS OPERATION SHOULD PREFERABLY BE PERFORMED WITH THE TANK EMPTY.
- Remove the central frame cover.
- Remove the footrest.
- Remove the filler unscrewing the two tank retain-

ing straps.
- Remove the "too full" pipe «A» and the tank ven-
tilation pipe «B».
CHAS - 272
- Remove the horn plate support bracket and the

voltage regulator unscrewing the two nuts shown
in the figure.
- Release the fuel pipe removing the clamp «C».
- Disconnect the fuel probe connector.
- Undo the two tank fixing screws.

- Remove the tank through the front lower part of
the vehicle.
CHAS - 273
Radiator fan


- Prepare a container to collect the coolant.

- Remove the feed and return hoses from the ex-
pansion tank.
- Remove the coolant feed and return hoses from
the radiator.
- Remove the retaining screws of the radiator to
the frame shown in the figure.
- Disengage the complete radiator and the electric
fan.
Flyscreen
- Remove the three hex. socket head screws, then

remove the windshield together with the rubber
rings.
CHAS - 274
To remove the windshield supports, proceed as

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

- Remove the supports.
Pilot lights kit
- Remove the front handlebar cover.

- Remove the three screws shown in the figure,
then slide off the complete unit from the front han-
dlebar cover.
Battery
- Remove the elastic strap and the battery cover.
CHAS - 275
- First disconnect the negative terminal «A», then

the positive terminal «B».
- Remove the battery.
Lower cover
- Remove the two screws of the lower spoiler (long

type).
- Remove the 2 screws located under the footrests.
- Remove the 4 union screws with the front wheel

housing cover.
- Pull the spoiler from the lower part of the scooter.
CHAS - 276
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Pre-delivery SR MAX 300 i.e. (2011)
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
- Visually check that there is a yellow mark on the following clamps:

FRONT WHEEL
• Wheel pin fixing nut

• Safety screws on left fork leg
FRONT BRAKE
• Brake pipe to brake calliper fitting

• Calliper to calliper support fixing screws
• Calliper to fork support fixing screws
SWINGING ARM
• Nut fixing swinging arm pin to engine
COOLING SYSTEM
• Water pump cover - delivery pipe fixing clamp

• Water pump cover - return pipe fixing clamp
REAR WHEEL
• Screws fixing wheel to hub
REAR BRAKE
• Brake pipe - brake calliper fitting

• Calliper - calliper support fixing screws
• Engine - calliper support fixing screws
REAR SUSPENSION
• Left shock absorber lower retainer

• Right shock absorber lower retainer
MUFFLER SUPPORTING ARM
PRE DE - 278
SR MAX 300 i.e. (2011) Pre-delivery
• Muffler- supporting arm fixing screws

• Engine- supporting arm fixing screws
Electrical system
• Main switch
• Lights: high-beam lights, low-beam lights, taillights (front and rear) and relevant warning lights
- Headlight adjustment according to the regulations currently in force
• Front and rear stop light buttons and relative light •Turn indicators and relative telltales
• Instrument lighting
• instruments: fuel and temperature indicator
•Instrument panel lights
• Horn
• Electrical start up
• Engine stopping with emergency stop switch
• electric saddle opening button
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR
ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES,
SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
Level check:
- Hydraulic brake system liquid level.
- Rear hub oil level
- Engine coolant level
PRE DE - 279
- Engine oil level
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
Static test
Static control after the test ride:

• Hot engine restart
• Minimum seal (turning the handlebar)
• Uniform steering rotation
• Possible losses
• electric radiator fan operation
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
Functional inspection
Functional Checks:
• Hydraulic braking system: lever travel
• Clutch: proper functioning check
• Engine: proper general functioning and no abnormal noise check
• Other: papers check, chassis and engine number check, tools and equipment, licence plate fitting,
lock check, tyre pressure check, rear-view mirror and any accessory fitting
PRE DE - 280
Specific operations for the vehicle
Windshield fitting:
- Remove the legshield upper cover.
- Fit the indicated nut in the seat at the back of the
windshield support brackets.
- With the screws supplied fasten the windshield

support brackets to the front frame .
- Fit the legshield upper cover.
- Remove the protection film from the windshield,

fit the rubber buffers in the three holes.
PRE DE - 281
- Fit the three plastic spacers in the three rubber

buffers.
- Fit the central protection.
- Fit the rubber protection on the windshield sup-

port brackets, make sure that the clamps are cor-
rectly snapped in the holes.
NOTE
THE WINDSHIELD CAN BE ADJUSTED TO THREE POSITIONS. HEIGHT MAY VARY DEPENDING
ON THE RETAINER USED.
PRE DE - 282
- Fit the supplied cover caps in order to cover the

holes not used.
- Fit the windshield to the vehicle with the three

screws supplied.
PRE DE - 283
INDEX OF TOPICS
TIME TIME
SR MAX 300 i.e. (2011) Time
Engine
Crankcase
Crankshaft
Cylinder assy.
Cylinder head assy.
Rocker arms support assy.
Cylinder head cover
Oil filter
Flywheel cover
Driven pulley
Oil pump
Final gear assy.
Driving pulley
Transmission cover
Starter motor
Flywheel magneto
Butterfly valve
TIME - 285
Time SR MAX 300 i.e. (2011)
Exhaust pipe
Air cleaner
Frame
Centre-stand
Legshield spoiler
Side fairings
Rear cover
Central cover
Mudguard
Fuel tank
Rear shock-absorber
Handlebar covers
Handlebar components
Swing-arm
Seat
Instrument panel
Turn signal lights
TIME - 286
SR MAX 300 i.e. (2011) Time
Front wheel
Rear wheel
Electric devices
Helmet bay
Front suspension
Cooling system
Braking system
TIME - 287
A
Accessories: 66
Air filter: 41
B
Battery: 64, 76, 86, 88, 89, 275
Brake: 235, 237, 239, 240, 242, 243, 246
Brake calliper: 235, 237
Brake disc: 239, 240
Brake pads: 242, 243
Brake pump: 246
Bulbs:
Bushings:
C
Clutch: 52, 107–109, 115
Coil: 192
Connectors: 91
coolant: 197
Coolant: 197
Crankcase: 13, 149–151, 153, 285
Crankshaft: 13, 149, 151, 152, 157, 285
Cylinder: 11, 17, 135, 138–140, 143, 285
E
Electric fan: 249
Electrical system: 10, 55, 279
Engine oil: 42
Exhaust: 98, 173, 286
F
Fairings: 269, 286
Fork: 210
Front wheel: 206, 209, 264, 287
Fuel: 174, 183, 272, 286
Fuses: 82
H
Handlebar: 209, 254, 255, 286
Head cover: 285
Headlight: 48, 256
Horn: 79
Hub oil: 40
I
Identification: 8
Instrument panel: 255, 286
L
Lambda probe: 200
License plate holder: 270
M
Maintenance: 7, 38
Mudguard: 270, 272, 286
O
Oil filter: 44, 285
Oil sump: 162, 163
R
Radiator: 274
Rear wheel: 225, 226, 287
Recommended products:
S
Scheduled maintenance:
Shock absorbers: 232
Side fairings: 269, 286
Side stand: 233
Spark plug: 39, 75
Stand: 233
Starter motor: 131, 135, 285
T
Tank: 272, 286
Technical data:
Transmission: 10, 52, 104, 121, 285
Turn indicators: 67
Tyre pressure:
Tyres: 10

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SERVICE STATION MANUAL

SR MAX 300 i.e. (2011)

SR MAX 300 i.e. (2011)

THE VALUE OF SERVICE

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

This section describes the general specifications of the vehicle.

To read the chassis prefix, remove the lid «A» in

The engine prefix «B» is stamped near the left

Dimensions and mass

WEIGHTS AND DIMENSIONS

ENGINE TECHNICAL DATA

Frame and suspensions

FRAME AND SUSPENSIONS

Wheels and tyres

WHEELS AND TYRES

Cylinder - piston assy.

- Measure the diameter of the bearings on the pis-

- Calculate the piston pin coupling clearance.

- Carefully clean the seal housings.

ard coupling clearance 0.015 - 0.06 mm oil scraper

- Check that the head coupling surface is not worn

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Diameter of crankshaft bearings.

MAX. ADMISSIBLE DISPLACEMENT

- Using a bore gauge, measure the connecting rod

- Using a trued bar and a feeler gauge check that

- In case of faults, replace the head.

- Insert the valves into the cylinder head.

Measure the camshaft bearing seats and rocking

Measure the unloaded spring length

- Clean the valve seats of any carbon residues.

STANDARD VALVE LENGTH

- Measure the diameter of the valve stems in the

MINIMUM ADMISSIBLE DIAMETER

- Calculate the clearance between valve and valve guide.

- Check the deviation of the valve stem by resting

- Check the concentricity of the valve head by ar-

Measure the valve guide.

- After measuring the valve guide diameter and the

- If no faults are found during the above checks,

MINIMUM ADMISSIBLE DIAMETER

-Using a gauge, measure the cam height.

Check the axial clearance of the camshaft

CAMSHAFT AXIAL CLEARANCE

- Measure the outside diameter of the rocking lever pins

ROCKING LEVERS AND PIN DIAMETER:

Slot packing system

ENGINE 300 SHIMMING

RECOMMENDED PRODUCTS TABLE

001467Y014 Calliper to extract ø 15-mm bearings

005095Y Engine support

002465Y Calliper for circlips

020459Y Punch for fitting bearing on steering tube

020004Y Punch for removing steering bearings

020055Y Wrench for steering tube ring nut