APRILIA RS 125 Manuale del Proprietario

www.serviceaprilia.comworkshopmanualRS 125 1300 600/2006-038104976UK

GENERAL INFORMATION1-3RS125 1.1. GENERAL INFORMATION 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, e

CHASSIS 5 - 2 RS125SUMMARY 5.1. REMOVING THE OUTER STRUCTURES ...

CHASSIS5-3RS125 5.1. REMOVING THE OUTER STRUCTURES 5.1.1. REMOVING THE SEAT • Insert the key in the seat latch and turn it anticlockwise. • Re

CHASSIS 5 - 4 RS1255.1.2. REMOVING THE PASSENGER SEAT • Remove the seat, see (REMOVING THE SEAT). • Remove the small flap in a downward motion.

CHASSIS5-5RS125 5.1.3. REMOVING THE SIDE FAIRINGS WARNING Allow for the engine and exhaust silencer to cool down completely before working on the

CHASSIS 5 - 6 RS1255.1.4. REMOVING THE LOWER COWL • If you have not removed the side and lower fairings yet, loosen and remove the two screws work

CHASSIS5-7RS125 5.1.5. REMOVING THE LOWER FAIRINGS • Working on either side, loosen and remove the four screws. • Remove the lower fairings in

CHASSIS 5 - 8 RS1255.1.6. REMOVING THE HEADLIGHT FAIRING • Working on either side, loosen and remove the screw. • Working on either side, relea

CHASSIS5-9RS125 • Push the headlight fairing forward. • Disconnect the parking light connector. • Disconnect the high / low beam light connecto

CHASSIS 5 - 10 RS1255.1.7. REMOVING THE TANK FAIRING • Remove the fuel tank, see (REMOVING THE FUEL TANK) and place it on a bench. • Remove the t

CHASSIS5-11RS125 5.1.8. REMOVING THE TAIL GUARD • Remove the passenger seat, see (REMOVING THE PASSENGER SEAT). • Release and remove the four scr

GENERAL INFORMATION 1 - 4 RS1251.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the fo

CHASSIS 5 - 12 RS1255.1.9. REMOVING THE TAIL LIGHT • Remove the passenger seat, see (REMOVING THE PASSENGER SEAT). • Disconnect the tail light co

CHASSIS5-13RS125 5.1.10. REMOVING THE LOWER COVER • Remove the passenger seat, see (REMOVING THE PASSENGER SEAT). • Working on either side, loose

CHASSIS 5 - 14 RS125• Working on either side, loosen and remove the two screws. • Remove the lower cover.

CHASSIS5-15RS125 5.1.11. REMOVING THE NUMBER PLATE HOLDER • Remove the tail guard, see (REMOVING THE TAIL GUARD). • Disconnect the number plate l

CHASSIS 5 - 16 RS125• Unscrew and remove the screw. • Remove the number plate holder pulling in a downward motion.

CHASSIS5-17RS125 5.1.12. REMOVING THE SIDE BODY PANELS NOTE The following information applies to both components. • Lift the fuel tank, see (LIFTI

CHASSIS 5 - 18 RS1255.2. CONTROLS 5.2.1. REMOVING THE THROTTLE CONTROL • Lift the fuel tank, see (LIFTING THE FUEL TANK). • Remove the left side f

CHASSIS5-19RS125 • Loosen and remove the screw located on the inside of the frame on the left side of the vehicle. • Remove the throttle cable spl

CHASSIS 5 - 20 RS1255.3. FRONT FORK 5.3.1. FRONT FORK DIAGRAM Key: 1. Slider cap 2. O-ring 3. Half ring 4. Ring for spring 5. Spacer 6. S

CHASSIS5-21RS125 5.3.2. REMOVING THE FORK LEGS NOTE Position the tall front stand (OPT). NOTE The following information applies to both fork legs.

GENERAL INFORMATION1-5RS125 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the

CHASSIS 5 - 22 RS125• Working on either side, loosen and remove the two screws. • Remove the front mudguard. • Remove the front wheel, see (R

CHASSIS5-23RS125 5.3.3. REMOVING THE FORK LEGS NOTE The procedures described below apply to both stanchion-and-slider assemblies. • Remove the st

CHASSIS 5 - 24 RS125• Hold the slider and pull firmly until separating it from the stanchion tube. NOTE Proceed carefully when removing t

CHASSIS5-25RS125 5.3.4. CHANGING FLUID Fluid quantity: 440 ± 2,5 cm³ (26.85 ± 0.15 cuin) Fluid type, see (LUBRICANT CHART). NOTE The procedures des

CHASSIS 5 - 26 RS125FILLING THE FORK • Place the slider in a vertical position in a vice with soft jaws. • Pour fork fluid into the slider. • Fi

CHASSIS5-27RS125 5.3.5. REFITTING THE FORK LEGS • Check fork components, see (CHECKING FORK COMPONENTS). WARNING Make sure no dirt or foreign ob

CHASSIS 5 - 28 RS1255.3.6. CHECKING FORK COMPONENTS STANCHION TUBE • Inspect the sliding surface for scoring and/or scratching. Eliminate minor s

CHASSIS5-29RS125 5.3.7. INSTALLING THE FORK LEGS • Slide the complete slider-and-stanchion assembly through the bottom and top yokes. • Insert th

CHASSIS 5 - 30 RS125• Working on either side, tighten the two screws. • Position the front brake calliper and tighten the two retaining screws.

CHASSIS5-31RS125 5.4. STEERING BEARINGS 5.4.1. DIAGRAM Key 1. Steering tube cap 2. Front fork top yoke 3. Front fork lower ring nut 4. Seal 5.

GENERAL INFORMATION 1 - 6 RS125 DANGER Take care not to spill coolant onto hot engine parts and exhaust system. It may ignite and produce invisible

CHASSIS 5 - 32 RS1255.4.2. CHECKING BEARING PLAY • Position the vehicle on the front stand. • Shake the fork in the direction of travel. • Adjust

CHASSIS5-33RS125 5.4.3. ADJUSTING BEARING PLAY • Partially loosen the two screws that retain the top yoke. • Loosen and remove the top bush.

CHASSIS 5 - 34 RS125• Refit the top yoke and position it fully home. • Lubricate the thread and contact face of the bush with oil. • Tighten the

CHASSIS5-35RS125 5.5. REAR SHOCK ABSORBER 5.5.1. REMOVING THE SHOCK ABSORBER • Place the vehicle on the front support stand (OPT). • Place the ve

CHASSIS 5 - 36 RS125• Remove the shock absorber pulling it downward.

CHASSIS5-37RS125 5.5.2. FITTING THE SHOCK ABSORBER • Insert the shock absorber from the bottom up. • Insert the upper shock absorber screw with it

CHASSIS 5 - 38 RS1255.5.3. REMOVING THE REAR SUSPENSION CONNECTING RODS • Working on the right side, loosen and remove the nut (1). • Slide out t

CHASSIS5-39RS125 5.5.4. DISASSEMBLING THE CONNECTING RODS • Remove the complete connecting rods assembly of the suspension, see (REMOVING THE REAR

CHASSIS 5 - 40 RS1255.5.5. CHECKING THE COMPONENTS NOTE Check all components for distortion, breakage, cracks and/or denting. Replace any damaged c

CHASSIS5-41RS125 5.5.6. ADJUSTING THE REAR SHOCK ABSORBER Factory setting is designed for any riding condition, low or high speed, with reduced or

GENERAL INFORMATION1-7RS125 DISASSEMBLING THE COMPONENTS - Never use pliers or similar tools to slacken and/or tighten nuts and bolts. Always use t

CHASSIS 5 - 42 RS1255.6. SWINGING ARM 5.6.1. REMOVAL NOTE Support the front end of the vehicle using the front stand (OPT); support the rear end usi

CHASSIS5-43RS125 • Loosen and remove the screw and remove the speed sensor. • Loosen the screw retaining the engine (4) to the frame to facilita

CHASSIS 5 - 44 RS1255.6.2. REMOVAL AND REASSEMBLY REMOVAL • Remove the swinging arm, see (REMOVAL). • Place the swinging arm on a bench. • Clean

CHASSIS5-45RS125 5.6.3. CHECKING THE REAR SWINGING ARM COMPONENTS NOTE Check all components for distortion, breakage, cracks and/or denting. Replac

CHASSIS 5 - 46 RS1255.6.4. INSTALLATION WARNING The tail end is heavy. Have someone assist you with the next operations. • Position the swinging

CHASSIS5-47RS125 • Tighten the screw retaining the engine (4) to the frame. • Fit the connecting rods to the swinging arm. • Insert the screw f

CHASSIS 5 - 48 RS125• Fit the speed sensor.

CHASSIS5-49RS125 5.7. FRONT WHEEL 5.7.1. DIAGRAM Key: 1. Front tyre 2. Wheel shaft special screw 3. Washer 4. Flanged screw 5. Front brake disc

CHASSIS 5 - 50 RS1255.7.2. REMOVING THE FRONT WHEEL WARNING When removing, pay utmost attention not to damage the brake lines, discs and pads. •

CHASSIS5-51RS125 • Working from the right side, loosen and remove the plug and collect the washer. • Place a support under the tyre so the wheel

GENERAL INFORMATION 1 - 8 RS1251.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS FUEL DANGER The fuel used to operate engines is highly flammable and become

CHASSIS 5 - 52 RS1255.7.3. CHECKING THE FRONT WHEEL COMPONENTS WARNING Ensure that all components are intact and especially the following ones. B

CHASSIS5-53RS125 5.7.4. INSTALLING THE FRONT WHEEL • Smear some grease all along the wheel shaft. WARNING When refitting, pay utmost attention n

CHASSIS 5 - 54 RS125• Tighten the two screws of the wheel shaft clamp. • Fit the front mudguard. • Working on either side, tighten the two sc

CHASSIS5-55RS125 5.8. REAR WHEEL 5.8.1. DIAGRAM Key: 1. Wheel RH ext. spacer 2. Wheel LH ext. spacer 3. Comp. chain, master link 4. Tubeless v

CHASSIS 5 - 56 RS1255.8.2. REMOVING THE REAR WHEEL WARNING Before carrying out the following operations, let the engine and the silencer cool down

CHASSIS5-57RS125 NOTE Note the position of the right (3) and left (4) chain tensioners to refit them to their original positions later on. • Take t

CHASSIS 5 - 58 RS1255.8.3. REMOVING THE FINAL DRIVE ASSEMBLY REMOVAL • Remove the rear wheel, see (REMOVING THE REAR WHEEL). NOTE If you only ne

CHASSIS5-59RS125 5.8.4. CHECKING THE REAR WHEEL COMPONENTS WARNING Ensure that all components are intact and especially the following ones. BEARI

CHASSIS 5 - 60 RS125TREAD CONDITION WARNING Inspect tyre surface condition and check for wear, as worn tyres lead to poor road holding and handlin

CHASSIS5-61RS125 5.8.5. INSTALLING THE REAR WHEEL WARNING Before carrying out the following operations, let the engine and the silencer cool down

GENERAL INFORMATION1-9RS125 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independe

CHASSIS 5 - 62 RS125• Fit the washer and tighten the nut (6) manually. • Check chain tension, see (DRIVE CHAIN ADJUSTMENT). • Tighten the nut (6)

CHASSIS5-63RS125 5.9. DRIVE CHAIN 5.9.1. REMOVING THE DRIVE CHAIN • Slacken the chain, see (DRIVE CHAIN ADJUSTMENT). • Turn the rear wheel until

CHASSIS 5 - 64 RS1255.9.2. CHECKING CHAIN AND CHAIN SPROCKETS FOR WEAR Check the following components and inspect chain and chain sprockets for: -

CHASSIS5-65RS125 5.9.3. REFITTING THE DRIVE CHAIN • Check that the chain is correctly positioned on the sprockets. • Bring the two open ends of t

CHASSIS 5 - 66 RS1255.9.4. REMOVING THE DRIVE CHAIN SLIDER NOTE Break the chain to facilitate access to affected components, see (REMOVING THE DRIVE

COOLING SYSTEM6-1RS125 COOLING SYSTEM 6

COOLING SYSTEM 6 - 2 RS125SUMMARY 6.1. COOLING SYSTEM ...

COOLING SYSTEM6-3RS125 6.1. COOLING SYSTEM 6.1.1. DIAGRAM Key: 1. Expansion tank 2. Radiator plug 3. Tube - from union to expansion tank 4. Tub

COOLING SYSTEM 6 - 4 RS1256.1.2. CHANGING COOLANT WARNING Do not ride when coolant is below the minimum level. Check coolant level every 1500 km (9

COOLING SYSTEM6-5RS125 6.1.3. REMOVING THE RADIATOR REMOVAL • Drain all coolant from the cooling circuit, see (CHANGING COOLANT). • Remove the r

GENERAL INFORMATION 1 - 10 RS125COOLANT DANGER Coolant is toxic when ingested, contact with eyes or skin may cause irritation. In the event of con

COOLING SYSTEM 6 - 6 RS1256.1.4. REMOVING THE EXPANSION TANK REMOVAL • Drain all coolant from the cooling circuit, see (CHANGING COOLANT). • Uns

ELECTRIC SYSTEM7-1RS125 ELECTRIC SYSTEM 7

ELECTRIC SYSTEM 7 - 2 RS125SUMMARY 7.1. ELECTRIC SYSTEM ...

ELECTRIC SYSTEM7-3RS125 7.1. ELECTRIC SYSTEM 7.1.1. ELECTRIC PARTS TROUBLESHOOTING CHART

ELECTRIC SYSTEM 7 - 4 RS1251. HEADLIGHT Low beam light (halogen): 12 V - 55 W H11 High beam light (halogen): 12 V - 55 W H11 Parking light: 12

ELECTRIC SYSTEM7-5RS125 4. COIL Coil winding resistance Primary 0.11 – 0.21 Ohm Secondary 4.3 – 8.1 kOhm Check You may use a hand-held tester

ELECTRIC SYSTEM 7 - 6 RS1257. TAIL LIGHT Rear parking light / number plate light / stoplight: 12 V – 5 / 21 W 8. REAR RIGHT TURN INDICATOR Turn

ELECTRIC SYSTEM7-7RS125 10. INSTRUMENT PANEL Pin Service Pin Service 1 +Key 11 +Battery 2 RH indicator input 12 LH indicator input 3 Speed senso

ELECTRIC SYSTEM 7 - 8 RS125 WARNING Cutting the jumper across the grey and red wires of the Rave control unit will set solenoid actuation threshold

ELECTRIC SYSTEM7-9RS125 WARNING On reassembly, make sure to match the connector (4) to the correct component. Use a tester (placed in diode test m

GENERAL INFORMATION1-11RS125 TYRES WARNING If tyres are excessively inflated, the vehicle will be harder, more difficult and uncomfortable to ride

ELECTRIC SYSTEM 7 - 10 RS12515. Rear right turn indicator Turn indicator light: Mini lamps (cannot be replaced) 16. RAVE CONTROL UNIT ( ) • Re

ELECTRIC SYSTEM7-11RS125 18. MIXER OIL LEVEL SENSOR Measure resistance across the two terminals using a tester: - a full tank will give infinit

ELECTRIC SYSTEM 7 - 12 RS125• If display gives the correct readouts, change the thermistor. • Otherwise replace the display. Key: 6) Resistor 7

ELECTRIC SYSTEM7-13RS125 24. PICK-UP SENSOR Pick-up test • Disconnect the pick-up terminal connector. • Measure resistance across the yellow/whi

ELECTRIC SYSTEM 7 - 14 RS12527. FRONT LEFT TURN INDICATOR Turn indicator light: Mini lamps (cannot be replaced) 28. SAFETY DIODE (horn) Use a t

ELECTRIC SYSTEM7-15RS125 7.1.2. IGNITION SYSTEM TROUBLESHOOTING • Check the condition of the 7.5 A and 20 A fuses. NOTE For instructions on how

ELECTRIC SYSTEM 7 - 16 RS1257.1.3. CHARGING SYSTEM AND MAIN POWER SUPPLY Charging system test • Start the engine and rev it up to 6000 rpm. •

ELECTRIC SYSTEM7-17RS125 Test data Flywheel test • Disconnect the alternator wiring connector. • Start the engine and rev it up to 5000 rpm. • U

ELECTRIC SYSTEM 7 - 18 RS1257.1.4. STARTER CIRCUIT TROUBLESHOOTING NOTE For instructions on how to test electric components, see (ELECTRIC PARTS T

ELECTRIC SYSTEM7-19RS125 7.1.5. STOPLIGHT CIRCUIT Key: 1. Front brake switch 2. Rear brake switch 3. Fuse (15 A) 4. Fuse (20 A) 5. Key 6. Bat

GENERAL INFORMATION 1 - 12 RS1251.4. RUNNING-IN 1.4.1. RUNNING-IN Correct engine running-is essential to ensuring proper performance and durability.

ELECTRIC SYSTEM 7 - 20 RS125Switches Use a tester to check the continuity of the switches according to the diagram below. Change the switch assembl

ELECTRIC SYSTEM7-21RS125 7.1.6. RAVE VALVE CIRCUIT The solenoid controlled by the Rave control unit opens the exhaust valve at 8100 rpm. TROUBLES

ELECTRIC SYSTEM 7 - 22 RS1257.1.7. WIRING DIAGRAM

ELECTRIC SYSTEM7-23RS125 Key: 1. Multiple connectors 2. Fuel level sensor 3. Serial diagnosis connector 4. Electronic instrument panel 5. Water

Piaggio & C. S.p.A. via G.Galilei, 130033 Noale (VE) Italytel. +39 041.5829111fax +39 041.5829190www.serviceaprilia.comwww.aprilia.com

INTRODUCTION0-1RS125 INTRODUCTION 0

GENERAL INFORMATION1-13RS125 1.5. VEHICLE IDENTIFICATION 1.5.1. POSITION OF THE SERIAL NUMBERS These numbers are necessary for vehicle registration

TECHNICAL INFORMATION2-1RS125 TECHNICAL INFORMATION 2

TECHNICAL INFORMATION2 - 2 RS125SUMMARY 2.1. TECHNICAL INFORMATION ...

TECHNICAL INFORMATION2-3RS125 2.1. TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA DIMENSIONS Max. length 1955 mm (76.97 in.) Max. width 720 mm (28.

TECHNICAL INFORMATION2 - 4 RS125FRAME Type Twin-spar frame with cast and stamped frame sections Steering head angle 25° 30’ Trail 102 mm (4.01 in

TECHNICAL INFORMATION2-5RS125 2.1.2. SCHEDULED MAINTENANCE CHART Component After running-in [1000 km (621 mi)] Every 4000 km (2485 mi) or 12 month

TECHNICAL INFORMATION2 - 6 RS1252.1.3. LUBRICANT CHART LUBRICANT PRODUCT Gearbox fluid RECOMMENDED: F.C., SAE 75W - 90. As an alternative to recom

TECHNICAL INFORMATION2-7RS125 2.1.4. TIGHTENING TORQUE SETTINGS Check and tighten as required after the first 1000 km (621 mi) and every 4000 km (24

TECHNICAL INFORMATION2 - 8 RS125DESCRIPTION Q.ty Screw / nut Nm Kgm Note ENGINE Head to frame screw 4 Socket-head screw M8x20 22 2.2 Upper

TECHNICAL INFORMATION2-9RS125 DESCRIPTION Q.ty Screw / nut Nm Kgm Note ELECTRICAL COMPONENTS Battery box mount bracket 4 Hex flange screw M5x

INTRODUCTION 0 - 2 RS125SUMMARY 0.1. INTRODUCTION ...

TECHNICAL INFORMATION2 - 10 RS125DESCRIPTION Q.ty Screw / nut Nm Kgm Note CENTRE BODYWORK Upper RH-LH fairing to frame 2 Allen crowned

TECHNICAL INFORMATION2-11RS125 2.1.5. SPECIAL TOOLS In order to perform assembly, reassembly and settings correctly, special tools suitable for the

TECHNICAL INFORMATION2 - 12 RS1252.1.6. LOCATION OF KEY COMPONENTS Key: 1. Instrument panel 2. Left rear-view mirror 3. Ignition switch/steerin

TECHNICAL INFORMATION2-13RS125 Key: 1. Passenger right footrest (snapping, closed/open) 2. Passenger grab strap 3. Rider seat 4. Air filter 5.

TECHNICAL INFORMATION2 - 14 RS1252.1.7. LOCATION OF INSTRUMENTS / CONTROLS Key: 1. Ignition switch / steering lock ( - - ) 2. Choke lever (

TECHNICAL INFORMATION2-15RS125 Key 1. Rev counter 2. Green turn indicator warning light () 3. Blue high beam light () 4. Multifunction digital

TECHNICAL INFORMATION2 - 16 RS1252.1.8. INSTRUMENT PANEL OPERATION CONTROLS 1) MODE button: - press briefly to toggle between functions; - press

TECHNICAL INFORMATION2-17RS125 Description of functions Press the MODE button repeatedly and zone C of the display will cycle through the following

TECHNICAL INFORMATION2 - 18 RS125LAP TIMER When the Clock readout is displayed, press the MODE button briefly to switch to the Lap Timer. Press and

TECHNICAL INFORMATION2-19RS125 BATTERY VOLTAGE When the Clock readout is displayed, a brief press of the MODE button will turn on the battery icon

INTRODUCTION0-3RS125 0.1. INTRODUCTION 0.1.1. FOREWORD This manual provides the information required for normal servicing. This publication is inten

TECHNICAL INFORMATION2 - 20 RS1252.1.9. GEARBOX FLUID INSPECTION • Check gearbox fluid level every 4000 km (2500 mi); change gearbox fluid after t

TECHNICAL INFORMATION2-21RS125 2.1.10. CHANGING GEARBOX FLUID Check gearbox fluid level every 4000 km (2500 mi); change fluid after the first 1000

TECHNICAL INFORMATION2 - 22 RS1252.1.11. CLUTCH ADJUSTMENT Warning signs that the clutch needs adjusting are the engine stalling, or the vehicle mov

TECHNICAL INFORMATION2-23RS125 2.2. SCHEDULED MAINTENANCE 2.2.1. BRAKE FLUID NOTE Check brake fluid after the first 1000 km (621 mi) and every 4000

TECHNICAL INFORMATION2 - 24 RS125• Check the brake pads for wear, see (BRAKE PADS). • If the pads and/or the disc do not need replacing, provide f

TECHNICAL INFORMATION2-25RS125 CHECKING AND TOPPING UP REAR BRAKE FLUID LEVEL • The brake fluid reservoir is on the right side of the vehicle. •

TECHNICAL INFORMATION2 - 26 RS125FRONT BRAKE • Top up the brake fluid reservoir. • Remove the rubber cap (4) of the bleed valve (5). • Insert on

TECHNICAL INFORMATION2-27RS125 • Tighten the bleed valve (7) and remove the tubing. • Top up brake fluid inside the reservoir up to correct level.

TECHNICAL INFORMATION2 - 28 RS1252.2.2. BRAKE PADS NOTE The information provided below applies to both braking systems. • Check the brake pads for

TECHNICAL INFORMATION2-29RS125 2.2.3. LIFTING THE FUEL TANK DANGER Allow for the engine and exhaust silencers to cool down completely before proce

INTRODUCTION 0 - 4 RS1250.1.2. REFERENCE MANUALS SPARE PARTS CATALOGUE aprilia part# (description) 3406 MANUALI ATTREZZI SPECIALI april

TECHNICAL INFORMATION2 - 30 RS1252.2.4. CLEANING THE AIR FILTER • Check the air filter every 4000 km (2485 mi) or 12 months; change it every 8000

TECHNICAL INFORMATION2-31RS125 2.2.5. COOLANT Check • Check coolant level before each ride; change coolant every two years. WARNING Check the co

TECHNICAL INFORMATION2 - 32 RS1252.2.6. REMOVING THE BATTERY NOTE Removing the battery will reset the digital clock. To set time, see (INSTRUMENT

TECHNICAL INFORMATION2-33RS125 2.2.7. IDLING SPEED ADJUSTMENT • Adjust idling speed in the event of erratic idling. • Proceed as follows: • Ride

TECHNICAL INFORMATION2 - 34 RS1252.2.8. CHOKE ADJUSTMENT Choke control play should be about 2 ÷ 3 mm (0.078 ÷ 0.118 in). To adjust play: • Positi

TECHNICAL INFORMATION2-35RS125 2.2.9. DRIVE CHAIN ADJUSTMENT If the chain needs adjusting after the inspection, proceed as follows: • Place the ve

TECHNICAL INFORMATION2 - 36 RS125 WARNING Too much slack will result in noise or cause the chain to rattle, leading to slider and chain guide plate

TECHNICAL INFORMATION2-37RS125 2.2.10. INSPECTING THE DRIVE CHAIN SLIDER • Position the vehicle on the stand. • Check the chain slider (1) for we

FUEL SYSTEM3-1RS125 FUEL SYSTEM 3

FUEL SYSTEM 3 - 2 RS125SUMMARY 3.1. FUEL SYSTEM...

INTRODUCTION0-5RS125 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS # = number < = less than > = greater than ≤ = less than or equal to ≥ = mor

FUEL SYSTEM3-3RS125 3.1. FUEL SYSTEM 3.1.1. FUEL SUPPLY SYSTEM DIAGRAM Key: 1. Fuel tank 2. Fuel sensor 3. Fuel cock 4. Fuel tank cover 5. Oil

FUEL SYSTEM 3 - 4 RS1253.1.2. REMOVING THE FUEL TANK • Remove the seat, see (REMOVING THE SEAT). • Lift the fuel tank, see (LIFTING THE FUEL TANK

FUEL SYSTEM3-5RS125 3.1.3. REMOVING THE OIL TANK • Remove the seat, see (REMOVING THE SEAT). • Remove the small flap in a downward motion. • D

FUEL SYSTEM 3 - 6 RS125• Remove the oil mixer tank in a downward motion.

FUEL SYSTEM3-7RS125 3.2. AIR FILTER 3.2.1. REMOVING THE AIR FILTER • Lift the fuel tank, see (LIFTING THE FUEL TANK). • Unscrew and remove the tw

ENGINE4-1RS125 ENGINE 4

ENGINE 4 - 2 RS125SUMMARY 4.1. EXHAUST...

ENGINE4-3RS125 4.1. EXHAUST 4.1.1. DIAGRAM Key: 1. Muffler 2. Spring 3. Flanged self-locking nut 4. Spacer 5. Silent block 6. Washer 7. Shear

ENGINE 4 - 4 RS1254.1.2. REMOVING THE EXHAUST SYSTEM • Remove the lower fairing, see (REMOVING THE LOWER FAIRING). • Remove the side fairings, se

ENGINE4-5RS125 • Loosen and remove the screw on the left passenger footrest bracket and collect the spacers. • Loosen and remove the screw and c

INTRODUCTION 0 - 6 RS125RIGHT SIDE = right side SAE = Society of Automotive Engineers TEST = diagnostic check T.B.E.I. = crown-head Allen screw

ENGINE 4 - 6 RS1254.2. SECONDARY AIR SYSTEM 4.2.1. SECONDARY AIR SYSTEM The Secondary Air System (SAS) has been developed to reduce carbon oxide an

ENGINE4-7RS125 4.3. REMOVING AND INSTALLING THE ENGINE 4.3.1. REMOVING THE ENGINE FROM THE FRAME WARNING Before beginning the next procedure, pre

ENGINE 4 - 8 RS125• Release the clamp (1). NOTE Place some paper under the union to collect any oil drops. • Disconnect the oil hoses and block of

ENGINE4-9RS125 • Disconnect the spark plug cap. • Disconnect the thermistor electric connector. • Remove the clamp and slide out the hose fro

ENGINE 4 - 10 RS125• Loosen and remove the gearbox fluid filler plug. • Lever the clutch cable out of its housing using a small flat screwdriver

ENGINE4-11RS125 • Remove the circlip. NOTE Slacken the drive chain moderately to facilitate removal of the drive sprocket. • Slide drive sprocket

ENGINE 4 - 12 RS125- Control unit ground. • Release the clamps. • Disconnect the neutral sensor.

ENGINE4-13RS125 • Loosen the clamp. • Loosen and remove the four screws and remove the air box cover. • Remove the clamp and disconnect th

ENGINE 4 - 14 RS125• Slide the intake manifold off the carburettor pushing the air box rearwards. • Loosen and remove the two screws and remove th

ENGINE4-15RS125 • Loosen and remove the screw and disconnect the speed sensor. • Working from the right side with the box wrench for swinging ar

GENERAL INFORMATION1-1RS125 GENERAL INFORMATION 1

ENGINE 4 - 16 RS125• Working from the right side of the vehicle, loosen and remove the nut and collect the washer. • Slide out the screw, on the o

ENGINE4-17RS125 4.3.2. INSTALLING THE ENGINE INTO THE FRAME • Shift the engine in small motions until matching the mounting holes perfectly. • In

ENGINE 4 - 18 RS125• To achieve correct swinging arm pivot play, tighten the ring nut adjusting bush (2) fully home and then tighten one more ¼ of

ENGINE4-19RS125 • Fit the intake manifold to the carburettor pushing the air box forward. • Fit the throttle cable and tighten the two screws.

ENGINE 4 - 20 RS125 • Tighten the clamp. • Connect the following connectors in the order: - system ground, by tightening the screw. - Conn

ENGINE4-21RS125 • Change the clamps. - Control unit ground. - Pick-up.

ENGINE 4 - 22 RS125- Generator. - Starter motor, by releasing the wiring and tightening the screw. • Fit the drive sprocket with the chain to

ENGINE4-23RS125 • Install the battery, see (REMOVING THE BATTERY). • Fit a new clamp and connect the expansion tank hose. • Refit the clutch ca

ENGINE 4 - 24 RS125• Fit a new clamp and fit the hose onto the cylinder head cover. • Connect the thermistor electric connector. • Fit the sp

ENGINE4-25RS125 • Adjust throttle cable tension by turning the nut on the oil pump until the two reference marks are aligned. • Fit the oil p

GENERAL INFORMATION 1 - 2 RS125SUMMARY 1.1. GENERAL INFORMATION...

ENGINE 4 - 26 RS125• Position the gearbox connecting rod and tighten the screw. • Install the radiator, see (REMOVING THE RADIATOR). • Install

ENGINE4-27RS125 4.4. RAVE VALVE 4.4.1. RAVE VALVE GENERAL INFORMATION The exhaust valve is solenoid-actuated via a Bowden cable. The ECU determines

ENGINE 4 - 28 RS1254.4.2. RAVE VALVE CIRCUIT The solenoid controlled by the Rave control unit opens the exhaust valve at 8100 rpm. TROUBLESHOOTI

ENGINE4-29RS125 CONTROL UNIT • Remove the fuel tank, see (REMOVING THE FUEL TANK). • Remove the battery along with its box mount, see (REMOVING T

ENGINE 4 - 30 RS1254.4.3. REMOVING THE EXHAUST VALVE • Remove the fuel tank, see (REMOVING THE FUEL TANK). • Remove the battery along with its bo

ENGINE4-31RS125 • Disconnect the control unit connector from the system. • Loosen and remove both screws (8) of the battery mount frame. • Remo

ENGINE 4 - 32 RS1254.4.4. CHECKING THE COMPONENTS SEALS • Check the valve stem seal (1) and the O-ring (2) located inside the valve housing for w

ENGINE4-33RS125 4.4.5. RAVE VALVE INSTALLATION • Remove the fuel tank, see (REMOVING THE FUEL TANK). • Remove the battery along with its box mount

ENGINE 4 - 34 RS125PARTIAL INSTALLATION • Connect the Bowden cable (3) to the valve stem housing (4). • Rotate the valve stem housing (4) through

CHASSIS5-1RS125 CHASSIS 5