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M245M
APRILIA M245M User Manual
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ENGINE
3 -
65
En
g
ines M192M / M191M / M245M / M234M / M282M / M281M
•
Remove ceramic seal static side (1) from flyw
heel
cover (2) with a screw
driver.
•
Position flyw
heel cover under a press. Make sure it is
perfectly flat.
•
Use drift (B) of tool 8140663,
in reversed position to
push out the two ball bearings.
88
90
Table of Contents
General Information 1
9
Foreword
2
Reference Manuals
5
Abbreviations/Symbols/Conventions
6
Table of Contents
9
Manual Layout
10
Conventions Used in the Manual
10
Safety Information
11
General Rules
12
Basic Safety Rules
12
Dangerous Elements
15
Warnings Concerning Fuel, Lubricants, Coolant and Other Component Parts
15
Running-In
16
Running-In Recommendations
16
Using Tools and Spare Parts
17
Spare Parts
17
Specifications
18
Technical Data - 200Cc 4T-4V-H2O Engine
19
Use of Products
20
Tightening
21
General Tightening Torque Settings
21
Special Tools
22
Engine 3
26
Transmission
28
Transmission Cover
28
Fan Guard
29
Removing the Intake Vent
30
Driven Pulley Shaft Bearing
31
Installing the Driven Pulley Shaft Bearing
32
Belt Roller (Engines M234M / M282M) (200 CC)
33
Removing the Driving Pulley
34
Removing the Driving Pulley from the Engine
35
Clutch Housing
36
Removing the Clutch
37
Pin Collar
38
Fixed Driven Half Pulley Bearings
39
Fixed Driven Half Pulley
40
Movable Driven Half Pulley
41
Installing Fixed Driven Half Pulley Bearings
42
Assembling the Driven Pulley
43
Spring
44
Clutch Weights
45
Installing the Clutch
46
Drive Belt
47
Movable Driving Half Pulley
48
Installing the Fixed Driving Half Pulley (Engines M234M / M282M) (200 CC)
49
Installing Movable Half Pulley and Bushing
50
Installing the Fixed Driving Half Pulley (Engines M192M / M245M / M281M /M191M) (125 - 150 CC)
51
Installing the Clutch Housing
52
Fitting the Transmission Cover
53
Rear Hub
54
Removing the Wheel Shaft
55
Hub Case Bearings
56
Removing the Wheel Shaft Bearing from the Cover
57
Removing the Driven Pulley Shaft
58
Installing Hub Case Bearings
59
Installing the Driven Pulley Shaft Bearing
60
Checking Hub Cover
61
Installing the Wheel Shaft Bearing in the Cover
62
Checking Hub Shafts
63
Installing Hub Gears
64
Fitting the Hub Cover
65
Flywheel
66
Removing the Complete Flywheel Cover (Engines M245M / M281M / M234M /M282M) (125 - 200 CC)
66
Removing the Flywheel
67
Removing the Stator
68
Checking the Stator
69
Checking the Flywheel
70
Installing the Stator Assembly
71
Installing the Flywheel
72
Fitting the Complete Flywheel Cover (Engines M245M / M281M / M234M /M282M) (125 - 200 CC)
73
Lubrication
74
Checking the Oil Pressure
74
Removing the Oil Sump and the Pressure-Adjusting By-Pass
75
Checking the By-Pass
76
Removal of the Chains Housing Cover (Engines M245M / M281M / M191M) (125 - 150 CC)
77
Disassembly of the Chains Housing Cover (Engines M192M / M234M / M282M) (125 - 200 CC)
78
Removing the Oil Pump
79
Checking the Oil Pump
80
Assembling the Oil Pump
82
Assembly of the Chains Housing Cover (Engines M192M / M234M / M282M) (125 - 200 CC)
83
Assembly of the Chains Housing Cover (Engines M245M / M281M / M191M) (125 - 150 CC)
84
Assembling the By-Pass and the Oil Sump
85
Lubrication Diagram
86
Cooling
88
Removing the Water Pump
88
Checking the Components
90
Assembling the Water Pump
91
Checking the Thermostat
93
Crankcase and Crankshaft
94
Removing the Starter Motor
94
Checking Crankshaft Axial Play
95
Opening the Crankcase
96
Checking Crankcase
99
Checking the Main Bearing
100
Closing the Crankcase
102
Ineassembling the Starter Motor
104
Cylinder Head and Timing System
105
Disassembly of the Tappet Cover
105
Checking the Timing System
106
Checking/Adjusting Valve Clearance
107
Fitting the Tappet Cover
108
Checking End-Of-Compression Pressure
109
Checking Ignition Advance
110
Intake Manifold Disassembly
111
Removing the Thermostat
112
Removing the Timing Gear
113
Camshaft and Rocker Arms Disassembly
115
Head Disassembly
116
Valves Disassembly
117
Cylinder and Piston Disassembly
118
Checking Con-Rod Small End
119
Gudgeon Pin Diameter
120
Piston
122
Piston Rings
123
Assembling Piston
124
Checking Piston Position
125
Assembling Piston Rings
126
Assembling the Cylinder
127
Checking the Head
128
Checking Valves for Wear
129
Checking Valve Seats for Wear
130
Checking Valve Sealing
132
Checking Collets and Spring Plates
133
Assembling Valves
134
Checking the Timing System Parts
135
Checking the Camshaft
136
Assembling Head and Timing System Parts
138
Assembling Timing System Parts
139
Assembling the Thermostat
142
Assembling the Induction Manifold
143
Secondary Air
144
Description
144
Troubleshooting
146
Updating Engines M192M / M191M 4
148
Specifications
149
Technical Data: 125 CC, Four-Stroke, Two-Valve Air
149
Technical Data: 150 CC, Four-Stroke, Two-Valve Air
150
Engine
151
Kick-Start Cover
151
Diassembly of Sector Gear and Pinion
152
Assembly of Sector Gear and Pinion
153
Disassembly of the Clutch
154
Assembly of the Clutch
155
Disassembly Rear Brake Shoes Ganasce
156
Disassembly of the Brake Lever and Cam
157
Rear Hub
158
Removing the Wheel Shaft
159
Assembly of the Hub Gears
160
Reassembly of Hub Cover
161
Assembly of the Brake Lever and Cam
162
Assembly of the Brake Shoes
163
Disassembly of the Fan Muff
164
Disassembly of the Fan Muff
165
Checking the Timing System
166
Disassembly of the Timing Gear
167
Disassembly of the Camshaft and Rocker Arms
169
Head Disassembly
170
Cylinder and Piston Disassembly
171
Assembling Piston
172
Assembling the Cylinder
173
Assembling Head and Timing System Parts
174
Assembling Timing System Parts
175
4
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APRILIA M245M Specifications
General
Brand
APRILIA
Model
M245M
Category
Engine
Language
English
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