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APRILIA RS 125, Manual

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CHASSIS 

7 - 2 

RS 125

SUMMARY 

7.1. CHASSIS .......................................................................................................................................... 4 

7.1.1.  CHASSIS...................................................................................................................................... 4 
7.1.2. RIDER 

SEAT REMOVAL ............................................................................................................. 6 

7.1.3. REMOVING 

THE SIDE FAIRINGS ..............................................................................................7 

7.1.4. AIR 

DAM REMOVAL.................................................................................................................... 9 

7.1.5. FRONT 

FAIRING REMOVAL.....................................................................................................10 

7.1.6. WINDSCREEN REMOVAL ........................................................................................................11 
7.1.7. FUEL 

TANK 

FILLER CAP REMOVAL .......................................................................................12 

7.1.8. FUEL 

TANK 

FAIRING REMOVAL .............................................................................................13 

7.1.9. SEAT 

SUBFRAME COVER REMOVAL.....................................................................................14 

7.1.10. TAIL REMOVAL .....................................................................................................................15 
7.1.11. REMOVING 

THE FRONT MUDGUARD................................................................................16 

7.1.12. REMOVING 

THE REAR MUDGUARD ..................................................................................17 

7.1.13. REMOVING 

THE SEAT END COVER ..................................................................................18 

7.1.14. 

REMOVING THE NUMBER PLATE BRACKET ....................................................................20 

7.1.15. CHAIN 

GUARD REMOVAL ...................................................................................................21 

7.1.16. UPPER 

CHAIN 

SLIDER REMOVAL......................................................................................22 

7.1.17. LOWER 

CHAIN 

SLIDER REMOVAL .....................................................................................23 

7.1.18. AIR 

SCOOP REMOVAL.........................................................................................................24 

7.2. ELECTRIC COMPONENTS ...........................................................................................................25 

7.2.1. BATTERY REMOVAL ................................................................................................................25 
7.2.2.  REMOVING THE ENGINE CONTROL UNIT.............................................................................26 
7.2.3. VOLTAGE 

RECTIFIER REMOVAL............................................................................................27 

7.2.4.  REMOVING THE RIGHT-HAND LIGHT DIP SWITCH ..............................................................28 
7.2.5.  REMOVING THE LEFT-HAND LIGHT DIP SWITCH ................................................................29 
7.2.6.  REMOVING THE IGNITION SWITCH/STEERING LOCK .........................................................30 
7.2.7. REMOVING 

THE INSTRUMENT PANEL ..................................................................................31 

7.2.8. HEADLIGHT REMOVAL ............................................................................................................33 
7.2.9.  REMOVING THE FRONT DIRECTION INDICATORS ..............................................................34 
7.2.10. 

REMOVING THE REAR DIRECTION INDICATORS ............................................................35 

7.2.11. WARNING 

HORN REMOVAL ...............................................................................................36 

7.2.12. REMOVING 

THE TAIL LIGHT ...............................................................................................37 

7.3. CONTROLS....................................................................................................................................38 

7.3.1. REMOVING 

THE 

THROTTLE CONTROL.................................................................................38 

7.3.2.  REMOVING THE THROTTLE CABLE FROM INTERMEDIATE PULLEY TO OIL PUMP........39 
7.3.3. REMOVING 

THE 

FRONT BRAKE CONTROL ..........................................................................40 

7.3.4. REMOVING 

THE 

FRONT BRAKE CONTROL ..........................................................................41 

7.3.5. REMOVING 

THE CLUTCH CABLE ...........................................................................................42 

7.3.6. COMPLETE 

REMOVAL 

OF THE GEAR SHIFT LEVER ...........................................................43 

7.3.7. REMOVING 

THE REAR BRAKE LEVER...................................................................................44 

7.4. CHASSIS ........................................................................................................................................45 

7.4.1. REMOVING 

THE HANDLEBARS ..............................................................................................45 

7.4.2.  REMOVING THE INSTRUMENT PANEL SUBFRAME .............................................................46 
7.4.3. REMOVING 

THE SEAT LATCH ................................................................................................47 

7.4.4.  REMOVING THE RIGHT-HAND RIDER FOOTPEG BRACKET...............................................48 
7.4.5.  REMOVING THE LEFT-HAND RIDER FOOTPEG BRACKET .................................................49 
7.4.6. REMOVING 

THE RIDER FOOTPEG.........................................................................................50 

7.4.7.  REMOVING THE PASSENGER FOOTPEG BRACKETS .........................................................51 
7.4.8. PASSENGER 

FOOTPEG REMOVAL........................................................................................52 

7.4.9. SIDE 

STAND REMOVAL ...........................................................................................................53 

7.4.10. SEAT 

SUBFRAME REMOVAL ..............................................................................................54 

7.4.11. FRAME REMOVAL ................................................................................................................55 
7.4.12. FRAME 

INSTALLATION........................................................................................................58 

7.5. FRONT WHEEL..............................................................................................................................61 

7.5.1. FRONT 

WHEEL DIAGRAM .......................................................................................................61 

7.5.2.  REMOVING THE COMPLETE FRONT WHEEL .......................................................................62 
7.5.3. FRONT 

WHEEL DISASSEMBLY...............................................................................................64 

7.5.4.  FRONT WHEEL COMPONENT INSPECTION..........................................................................65 
7.5.5. REFITTING 

THE 

COMPLETE FRONT WHEEL ........................................................................66 

7.6. REAR WHEEL ................................................................................................................................68 

7.6.1. REAR 

WHEEL DIAGRAM..........................................................................................................68 

Summary of Contents for RS 125

Page 1: ...FORMATION 1 ROUTINE MAINTENANCE 2 LUBRICATION 3 FUEL SYSTEM 4 COOLING SYSTEM 5 ENGINE 6 CHASSIS 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING INFORMATION 9 0 1 SI QUIERE CONSEGUIR MAS INFORMACIÓN DE MOTOS Y MANUALES HAGA CLICK AQUI www infomoto es ...

Page 2: ...FOREWORD RS 125 SUMMARY 0 1 FOREWORD 3 0 1 1 FOREWORD 3 0 1 2 REFERENCE MANUALS 4 0 1 3 ABBREVIATIONS SYMBOLS CONVENTIONS 5 0 2 ...

Page 3: ...ons to repair procedures Such changes and modifications are then reflected in the next release of the relevant manual When in doubt about an inspection or repair procedure please contact the aprilia CONSUMER SERVICE A C S DEPARTMENT who will be glad to provide full information on the procedure in question as well as on any updates or engineering changes affecting the motorcycle under consideration...

Page 4: ...scription Model years 1993 8102260 Model years 1994 8102260 8102319 Model years 1995 8102476 8102530 8102543 Model years 1996 8102685 8102682 8102530 8102683 8102543 Model years 1997 8102685 8102682 8102683 8102530 8102543 8102752 8102753 Model years 1998 8102685 8102682 8102683 8102849 8102934 Model years 1999 8102821 8102937 8102938 8102939 Model years 2001 8202248 8102821 8102937 8102938 810293...

Page 5: ...ute HC unburnt hydrocarbons ISC Idle Speed Control ISO International Standardization Organization kg kilograms kgm kilograms per metre 1 kgm 10 Nm km kilometres km h kilometres per hour kΩ kiloOhm kPa kiloPascal 1 kPa 0 01 bar KS clutch side from the German Kupplungseite kW kiloWatt l litres LAP racetrack lap LED Light Emitting Diode LEFT SIDE left side m s metres per second max maximum mbar milli...

Page 6: ...FOREWORD RS 125 T E hexagonal head TEST diagnostic check T P flat head screw TSI Twin Spark Ignition UPSIDE DOWN inverted fork V volt W watt Ø Diameter 0 6 ...

Page 7: ...GENERAL INFORMATION RS 125 GENERAL INFORMATION 1 1 1 ...

Page 8: ...1 4 1 RUNNING IN RECOMMENDATIONS 11 1 5 VEHICLE IDENTIFICATION DATA 12 1 5 1 SERIAL NUMBERS LOCATION 12 1 6 USING TOOLS AND SPARE PARTS 13 1 6 1 SPARE PARTS 13 1 6 2 USE OF PRODUCTS 14 1 6 3 SPECIAL TOOLS 15 1 6 4 GENERAL TIGHTENING TORQUE SETTINGS 16 1 6 5 TECHNICAL DATA 17 1 7 STANDS 19 1 7 1 POSITIONING THE VEHICLE ON THE FRONT SERVICE STAND OPT 19 1 7 2 POSITIONING THE VEHICLE ON THE REAR SERV...

Page 9: ...otorcycle operation and basic maintenance are covered in the OWNER S MANUAL In this manual any variants are identified with these symbols frame ZD4DW starting from Model Year 2001 option Catalysed version All versions 11Kw 11 Kw derated version 80Km 80Km h speed f p Full power version MP National homologation SF European homologations EURO 1 limits VERSION Italy Greece Malaysia United Kingdom Neth...

Page 10: ...d to the motorcycle use utmost care to avoid the risk of injury Disregarding the instructions identified by this symbol may put your safety as well as that of other persons or of the motorcycle at risk DANGER Disregarding these indications may lead to severe injury or death WARNING Disregarding these indications may lead to minor injury or motorcycle damage NOTE The term NOTE in this manual preced...

Page 11: ... parts wear insulating gloves or wait for the engine and the exhaust system to cool completely down USED GEARBOX AND FORK OILS DANGER In case any maintenance operation should be required it is advisable to use latex gloves Gear oil may cause serious damage to the skin if handled daily and for long periods Wash your hands carefully after use Put it in a sealed container and take it to the filling s...

Page 12: ...sure that the electrolyte acid is suitable for the type of battery used GENERAL PRECAUTIONS AND INFORMATION Follow these instructions closely when repairing disassembling or reassembling the motorcycle or its components DANGER Using bare flames is strictly forbidden when working on the motorcycle Before servicing or inspecting the motorcycle stop the engine and remove the key from the ignition swi...

Page 13: ...a damaged thread Lubricate the bearings abundantly before assembly Make a rule to check that all components you have fitted are correctly in place After repairing the motorcycle and after each service inspection perform the preliminary checks and then operate the motorcycle in a private estate area or in a safe area away from traffic Clean all joint surfaces oil seal edges and gaskets before assem...

Page 14: ...and for long periods Wash your hands carefully after use Do not dispose of oil into the environment Take it to the filling station where you usually buy it or to an oil salvage center WARNING When filling the vehicle with this oil take care not to spill it out since it could damage the vehicle paintwork In case of contact with oil the tyres surface will become very slippery thus becoming a serious...

Page 15: ...vers are warning signs of problems with the hydraulic circuits Ensure that the brake discs and brake linings have not become contaminated with oil or grease This is particularly important after servicing or inspections Make sure the brake lines are not twisted or worn Prevent accidental ingress of water or dust into the circuit Wear latex gloves when servicing the hydraulic circuit DISC BRAKES DAN...

Page 16: ... to separate it from the crown itself If you can move the chain apart of the front sprocket for more than 3 mm 0 125 in change chain crown and pinion DANGER If not properly maintained chain can early wear out and lead to the damage of both crown and pinion Perform chain maintenance operations more frequently if the vehicle is used on rainy or dusty areas TYRES WARNING If tyres are excessively infl...

Page 17: ...peed is low both during and after the running in During the first 100 km 62 mi pull the brakes with caution avoiding sharp and prolonged brakings This ensures a correct bedding in of the pads on the brake disc During the first 800 km 497 mi never exceed 5000 rpm see table WARNING After the first 1000 km 621 mi Dealer carry out the checks indicated in the column After running in see 2 1 2 in order ...

Page 18: ...ification numbers if you do not want to incur severe penal and administrative sanctions In particular the alteration of the frame number results in the immediate invalidity of the guarantee FRAME NUMBER The frame number is stamped on the right side of the steering column ENGINE NUMBER The engine number is stamped on the rear part of the engine near the shock absorber 1 12 ...

Page 19: ...be replaced use aprilia Original Spare Parts only aprilia high quality Original Spare Parts have been expressly designed and manufactured for aprilia vehicles WARNING The use of aprilia non original spare parts can impair the vehicle performance or cause serious damage to the vehicle itself 1 13 ...

Page 20: ...bricate All ball bearings sintered discs gears cylinder walls if not otherwise specified Grease Oil seals lips if not otherwise specified Gearbox oil Engine oil SAE 30 0 6 l Engine oil Premium 2 stroke engine oil LOCTITE 221 N ROTAX 899 785 Countershaft bearing locking washer retaining oval headed screw Starter pedal gear washer retaining oval headed screw RX only Coupling gear stopper retaining s...

Page 21: ...ned for this vehicle are listed hereinafter Should you require some special general tools please refer to the special tools manual WARNING Before using any special tool please refer to the documents coming with the tool itself Key Position Tool name and function Part No 1 Front service stand 8146486 2 Tool for chain assembly disassembly 8140192 3 Ø10 mm to Ø 30 mm bearing pulling kit 8140180 4 Rea...

Page 22: ...refer to 2 3 4 If not otherwise specified the tightening torque settings refer to clean dry and ambient temperature threads NOTE In order to avoid any possible deformation and or wrong coupling please tighten screws and bolts as follows Snug all fasteners by hand Apply half of the recommended tightening torque value and tighten the opposite parts A and B C and D Repeat the above operation by tight...

Page 23: ...ng electric Ignition advance 12 2 at 2000 rpm Clutch Multidisc in oil bath with manual control on the left side of the handlebar Gearbox Mechanical 6 gears with foot control on the left side of the engine Gearbox oil 600 cu cm Gearbox oil FP 600 cu cm Gearbox lubrication Splash lubrication Lubrication system Separate lubrication with automatic mixer at variable strength 1 0 1 3 Mixer oil with rese...

Page 24: ...brake Ø 220 mm WHEEL RIMS Type in light alloy Front 3 00 x 17 Rear 4 00 x 17 TYRES Pressure kPa bar Wheel Size Rider only Rider and passenger Front standard 100 80 17 52S 110 70 R 17 54T 100 80 ZR 17 180 1 8 180 10 1 8 0 1 Posteriore di serie 130 70 17 62S 140 60 ZR 17 150 60 ZR 17 200 2 0 230 10 2 3 0 1 SPARK PLUGS Standard NGK R BR10EG Standard FP NGK BR8EG Spark plug gap 0 7 0 8 mm ELECTRIC SYS...

Page 25: ...ND OPT Position the vehicle on the appropriate rear service stand OPT see 1 7 2 Insert the two ends of the stand 1 in the two holes positioned on the lower ends of the front fork Rest one foot on the front part of the stand Push the stand downwards until it reaches the end of its stroke 1 1 19 ...

Page 26: ...cation on the rear swingarm NOTE Have someone help you keep the vehicle in vertical position with the two wheels on the ground At the same time introduce the two seats on the stand 2 into the two pins 1 on the vehicle 1 2 Rest one foot on the rear part of the stand Push the stand downwards until it reaches the end of its stroke 1 20 ...

Page 27: ...d FORK 20W mix the products as follows SAE 10W F A 5W 67 of the volume F A 20W 33 of the volume FORK 5W 67 del volume FORK 20W 33 del volume SAE 15W F A 5W 33 of the volume F A 20W 67 of the volume FORK 5W 33 del volume FORK 20W 67 del volume Bearings and other lubrication points RECOMMENDED AUTOGREASE MP or GREASE 30 As an alternative to the recommended product use select oil for rolling bearings...

Page 28: ...rotective film 4 completely NOTE The use of a sprayer 2 is recommended In case you are using a sponge apply it on the surface without exerting any pressure in order not to damage the adhesive Wet the adhesive surface with suds Apply the decal 3 on the surface you wish to decorate and position it correctly NOTE Press the spatule with constant movements working from the center towards the edge of th...

Page 29: ...d around 48 hours after the application After having removed the application tape make sure that no blisters are present on the surface Should some blisters be present proceed as follows Using a pin or a cutter 6 cut the blister 7 Use the spatule 1 starting from the side opposite to the cut and press the blister to make the air come out 6 7 The application tape is used to make the makes and letter...

Page 30: ...GENERAL INFORMATION RS 125 1 24 ...

Page 31: ...ROUTINE MAINTENANCE RS 125 ROUTINE MAINTENANCE 2 2 1 ...

Page 32: ...L 26 2 11 CLUTCH 27 2 11 1 ADJUSTING THE CLUTCH 27 2 12 BRAKE FLUID 29 2 12 1 CHECKING AND TOPPING UP THE FRONT BRAKE FLUID LEVEL 29 2 12 2 CHANGING THE BRAKE FLUID 31 2 12 3 CHECKING THE BRAKE PAD WEAR 32 2 12 4 CHECKING AND TOPPING UP THE REAR BRAKE FLUID 33 2 12 5 BLEEDING THE BRAKING SYSTEMS 35 2 13 ADJUSTING THE REAR BRAKE CONTROL LEVER 37 2 13 1 ADJUSTING THE REAR BRAKE CONTROL LEVER 37 2 14...

Page 33: ...ROUTINE MAINTENANCE RS 125 2 21 3 ADJUSTING THE DRIVE CHAIN 54 2 21 4 CHECKING CHAIN AND SPROCKETS FOR WEAR 55 2 21 5 CLEANING AND LUBRICATION 56 2 21 6 CHAIN SLIDER INSPECTION 57 2 3 ...

Page 34: ...n of the vehicle switch off the engine and remove the key wait until the engine and the exhaust system have cooled down and if possible lift the vehicles with the proper equipment onto firm and flat ground Keep away from the red hot parts of the engine and of the exhaust system in order to avoid burns Do not hold any mechanical piece or other parts of the vehicle with your mouth the components are...

Page 35: ...and oil seal every 12000 km 7456 mi 3 Headlamp aim and operation 1 Piston and piston rings every 8000 km 4970 mi 1 every 16000 km 9941 mi 3 Engine idling speed 4 4 Odometer driving gear 1 Wheels Tyres and inflating pressure 1 1 Wheels Tyres and inflating pressure every 1000 km 621 mi 1 Nut bolt screw tightening 1 1 Exhaust silencer catalised version excluded 2 2 Front fork every 500 km 310 mi 1 Mi...

Page 36: ...rease dirt or dust The points to be lubricated are specified in the LUBRICATING CHART LUBRICATING CHART 1 Steering bearing 2 Clutch lever pin 3 Rider right footpeg pin 4 Rider left footpeg pin 5 Passenger left footpeg pin 6 Rear wheel shaft and bearings 7 Drive chain 8 Rear suspension levers 9 Side stand spindle 10 Passenger right footpeg pin 11 Front wheel shaft and bearings 12 Rear swingarm spin...

Page 37: ...coolant temperature By pressing once the function key the coolant temperature 1 is shown in the upper part of the display in degrees centigrade C while the current time 2 is shown in the lower part of the display When the temperature is over 100 C the upper part of the display blinks even if a function other than TH2O has been set When the temperature is below 30 C the writing cold appears on the ...

Page 38: ...as follows Press the center key 1 LAP TIME chronometer When the function key is pressed for the fourth time the LAP TIME function 1 is displayed This function makes it possible to measure the time per lap with the vehicle on a racetrack or to store the data in such a way as to be able to consult them successively 1 LAP TIME function instructions for use only in case of competitions in private area...

Page 39: ...s the LAP 2 push button The wording Ld 01 corresponds to the lap No 1 the wording Ld 02 corresponds to lap No 2 etc Deleting stored data To delete stored data press key The wording L 10 or L 09 or L 08 etc will be displayed Now press push button and while keeping it pressed press also the LAP 1 key on the left handlebar The stored data will be immediately deleted 2 2 9 ...

Page 40: ...the partial number of kilometres covered Reset it using the special knob Trip meter resetting knob To reset the partial number of kilometers turn it counter clockwise Total kilometers odometer Indicates the total number of kilometers covered Speedometer km h Indicates the driving speed Coolant temperature C It displays the temperature of the coolant in the engine see 2 3 1 If a temperature of 115 ...

Page 41: ...ol lever Fuel delivery line Plate to front fork fastener Front wheel shaft fork clamps Front wheel Front brake line couplings Front brake disc Front brake caliper Engine Sprocket Rear brake control lever Rear swingarm Rear swingarm levers Rear shock absorber Rear wheel Rear brake disc Rear brake caliper Rear brake line couplings WARNING The fastening elements shall be tightened to the specified to...

Page 42: ...ption Q ty Screw Nut Nm Kgm Notes Flanged screw stand connector 2 Te fi M8x35 22 2 2 Stand connector 2 M8 nut 13 1 3 Side stand spindle 1 M10x1 25 10 1 0 Stand spindle lower nut 1 M10x1 25 25 2 5 Switch fastening screw 1 Te fi M6x16 10 1 0 L243 SWINGARM Description Q ty Screw Nut Nm Kgm Notes Chain slider brake line clamp 5 Tbei M5x12 2 0 2 Lower rear mudguard 2 Te fi M6x16 5 0 5 Swingarm pivot sh...

Page 43: ...12 7 0 7 Expansion tank mounting 1 Te fi M6x16 3 0 3 FRONT WHEEL Description Q ty Screw Nut Nm Kgm Notes Front wheel shaft fixing 1 Shaft screw 80 8 0 Legs to wheel shaft fixing 4 Tcei M6 10 1 0 REAR WHEEL Description Q ty Screw Nut Nm Kgm Notes Rear wheel shaft fixing 1 Shaft nut 100 10 0 FRONT BRAKE Description Q ty Screw Nut Nm Kgm Notes Mount to plate fixing 1 Te fi M6x16 7 0 7 Front brake oil...

Page 44: ...late holder mount fixing 2 Tcb 4 8x13 2 0 2 Tail light on mount fixing 2 Tcb 4 2x25 2 0 2 TANK Description Q ty Screw Nut Nm Kgm Notes Front part tank fixing 1 Tcei M6x50 7 0 7 Rear part fuel tank assembling 1 Tepf M6x70 7 0 7 Rear brake oil tank fixing 1 Te fi M6x16 3 0 3 Tank plug fixing 3 Tcei M5x30 5 0 5 Spacer tank plug fixing 6 Tcei M5x16 3 0 3 Fuel cock to tank fixing 2 Te fi M5x12 3 0 3 SE...

Page 45: ...that get in contact with the fluid with abundant fresh water In the event of contact with your eyes carefully wash them with water for fifteen minutes and then consult immediately an eye specialist Should you accidentally drink some fluid drink abundant water or milk then drink magnesia milk or vegetable oil and consult immediately a doctor Battery releases explosive gases Keep flames sparks cigar...

Page 46: ... conditions and not corroded or covered with deposits covered with neutral grease or vaseline If necessary proceed as follows Disconnect the negative cable first and the the positive one Brush the wire with a wire brush in order to eliminate any trace of corrosion Reconnect the positive terminal first and then the negative one Cover the terminals of the cables and of the battery with neutral greas...

Page 47: ...he two wheels resting on the ground Make sure that the fluid level is included between the MIN and MAX marks etched on the battery side If this is not the case Remove the battery 7 2 1 Remove battery plugs WARNING Top up the electrolyte using distilled water only Do not fill above the MAX mark as the level increases during recharging Top up with distilled water 2 17 ...

Page 48: ...aged Remove the battery see 7 2 1 Remove plugs Check the battery electrolyte level see 2 4 3 Connect the battery with a battery charger Recharge the battery with 1 10 th of its amperage Once finished check the electrolyte level once more and if necessary top up using distilled water Refit battery plugs WARNING Reassemble the battery only 5 to 10 minutes after disconnecting the recharge apparatus s...

Page 49: ...l clock and red line setting To reset these functions see 2 3 1 If the vehicle remains unused for more than fifteen days it is necessary to recharge the battery in order to prevent its sulphation see 2 4 4 Remove the battery see 7 2 1 and put it in a cool and dry place It is important to check the charge periodically about once a month during the winter or when the vehicle remains unused in order ...

Page 50: ...ll lighting devices are working properly Check for headlight correct aiming 8 15 1 Make sure that all connectors are well fitted Make sure that all switches are correctly fitted and operational 8 12 1 8 8 1 Check for speedometer sensors correct fitting and operation 8 7 1 WARNING The sensors sensitive area must be always clean Any mud dirt or other deposit could alter the readings and the followin...

Page 51: ...bon deposits nor corrosion marks on the electrodes and on the insulating material if necessary clean them with the special spark plugs cleaners and or a metal brush If the spark plug has crackings on the insulating material corroded electrodes excessive deposits on the rounded tip of the central electrode 3 it must be changed WARNING When changing the spark plug check the thread pitch and length I...

Page 52: ...se the recommended type of spark plugs only in order not to compromise the life and performance of the engine Position the spark plug 2 cap 1 properly so that it does not come off due to the vibrations of the engine DANGER Make sure that the spark plug 2 cap 1 is correctly positioned on the spark plug itself Refit the fuel tank 2 22 ...

Page 53: ...h serious danger for the persons in the vicinity and for the vehicle CLEANING Remove the air cleaner see 4 2 1 Wash the filtering element with clean not inflammable solvents or with solvents having a high volatility point and let it dry with extreme care Apply filter oil or a thick oil SAE 80W 90 on the whole surface then wring it to remove the oil in excess WARNING When cleaning the filtering ele...

Page 54: ...ge them every four years WARNING In case of wear cracking or other damage change the oil pipes In case of wear cracking or other damage change the lines BRAKES Carefully read 1 3 1 Check the brake lines every 4000 km 2485 mi or 12 months Change them every four years WARNING In case of wear cracking or other damage change the brake lines COOLING SYSTEM Carefully read 1 3 1 Check the cooling system ...

Page 55: ...HTENING TORQUE SETTINGS Tank front screw 1 7 Nm 0 7 kgm Turn the fuel cock to the OFF position Remove the seat see 7 1 1 Unscrew and remove the screw 1 Keep the bushing Take the tank rod from the tool kit Lift the front part of the fuel tank and introduce the rod into the special housings 2 25 ...

Page 56: ...e If not proceed as follows Unscrew and remove the filling cap 2 DANGER The coolant is toxic do not swallow it if the coolant gets in contact with the skin or the eyes it can cause serious irritations Do not use your fingers or any other object to check if there is enough coolant 2 1 WARNING Do not put additives or other substances into the fluid If you use a funnel or other similar items make sur...

Page 57: ... tool 0276040 Slide out the protective guard 2 Loosen the ring nut 3 Turn the adjuster 1 until reaching a free play on the clutch lever end of about 10 to 15 mm 1 3 2 Tighten the ring nut 3 lock the adjuster 1 Check the free play on the clutch lever end Refit the protective guard 2 In case the adjuster 1 is fully tightened fully loose or if the free play cannot be set to a correct value proceed as...

Page 58: ...6 Screw the cap 4 Check the clutch lever end free play 10 to 15 mm Refit the left side fairing Start the engine Pull the clutch lever fully and engage the first gear 6 7 5 8 Make sure that the engine does not stop and that the vehicle does not tend to move or that the clutch does not slip during acceleration or running NOTE Check that the clutch cable is in good conditions the sheaths should be fr...

Page 59: ...t from accidentally getting into the circuit CHECK NOTE Place the vehicle on a firm and flat surface Position the vehicle on the stand and steer the handlebar completely rightwards Make sure that the fluid level exceeds the MIN mark If the fluid does not reach at least the MIN mark proceed as follows WARNING When the disc pads wear out the level of the fluid decreases progressively to compensate f...

Page 60: ...AX marks 2 3 WARNING Do not exceed the MAX level while topping up It is advisable to top up until reaching the MAX level only with new pads When the disc pads wear out the level of the fluid decreases progressively to compensate for their wear Do not reach the MAX level with worn out pads since this will cause a fluid outflow when the pads are changed To refit components follow the disassembly pro...

Page 61: ...Loosen the bleed valve 1 2 of about one turn NOTE While carrying out this operation check that some fluid is always present inside the tank If this is not the case once the operation is over the air must be bled out 2 12 5 Check that the fluid is flowing on the tank and before emptying tighten the bleed valve 1 2 Top up see 2 12 1 and 2 12 4 Loosen again the bleed valve 1 2 by about half of a turn...

Page 62: ... pads proceed as follows Position the vehicle on the stand Carry out a visual check between the caliper and the pads proceeding from below on the front part for the front brake calipers 1 from below on the rear part for the rear brake calipers 2 WARNING The excessive wear of the friction material would cause the contact of the pad metal support with the disc with consequent metallic noise and prod...

Page 63: ... Do not use neither old brake fluid nor fluid taken from containers opened for a long time Prevent water or dust from accidentally getting into the circuit CHECK NOTE Place the vehicle on a firm and flat surface Keep the vehicle in vertical position so that the fluid contained in the tank 1 is parallel to the plug 2 Make sure that the fluid level exceeds the MIN mark If the fluid does not reach at...

Page 64: ...1 8 1 until reaching the correct level between the MIN and MAX reference marks WARNING It is advisable to top up until reaching the MAX level only with new pads When the disc pads wear out the level of the fluid decreases progressively to compensate for their wear Do not reach the MAX level with worn out pads since this will cause a fluid outflow when the pads are changed To refit components follo...

Page 65: ...ehicle paintwork and the plastic rubber and other parts In case maintenance operations are to be performed on the hydraulic circuit it is advisable to use latex gloves When using the brake fluid take care not to spill it on the plastic or painted parts since it can damage them FRONT BRAKE Top up fluid inside brake tank see 2 12 1 Remove the rubber cap 1 from the bleed valve 2 Insert one end of a t...

Page 66: ...her end in a container for collection Operate the brake lever repeatedly then keep it fully pulled Loosen the bleed valve by of a turn so that the brake fluid can flow inside the container The tension on the brake lever will thus be eliminated and you will be able to take it to the end of stroke Repeat this last procedure until no air bubbles can be seen inside the fluid flowing inside the contain...

Page 67: ...brake adjuster 2 until the brake pedal 5 is in the desired position Lock the brake adjuster 2 with the check nut 1 Unscrew the master cylinder control rod 4 and make it contact the master cylinder piston Screw the rod again so as to obtain a min clearance of 0 5 to 1 mm between the master cylinder rod 4 and piston WARNING To avoid the early wear of braking parts make sure that the brake lever has ...

Page 68: ...d using the transmission rod 1 Proceed as follows Loosen the nuts 2 3 Rotate the transmission rod and adjust the gearbox lever height Tighten the nuts 2 3 The gearbox lever pin is constantly greased thanks to the special slot and the two oil seals NOTE In case of disassembly lubricate and do not damage the oil seals 1 2 3 2 38 ...

Page 69: ...d bent in tight turns or twisted Using the motorcycle in this condition may lead to loss of control while riding Turn the handlebars and ensure that idling speed is unaffected by handlebar movement Open the throttle and ensure that the twistgrip springs back to the closed position smoothly when released If needed Make sure the components listed below are in the proper position and well lubricated ...

Page 70: ...e If not so Place the motorcycle on the stand Slip off the rubber gaiter 1 Loosen the locknut 2 Rotate the adjuster 3 until setting the specified free play After adjusting tighten the locknut 2 and check free play again Refit the rubber gaiter 1 3 1 2 WARNING Turn the handlebars and ensure that idling speed is unaffected by handlebar movement Open the throttle and ensure that the twistgrip springs...

Page 71: ...he gearbox in neutral Look at engine idle speed rpm on the rev counter Engine idling speed should be about 1250 100 rpm If needed Place the motorcycle on the stand Rotate the knob 1 ROTATE CLOCKWISE to increase idling speed ROTATE ANTI CLOCKWISE to decrease idling speed Flip the throttle twistgrip open and closed repeatedly to check for proper operation Idling speed should remain stable 2 41 ...

Page 72: ...he motorcycle on the stand Lift the fuel tank see 2 9 1 Adjust working from the left side of the motorcycle NOTE DO NOT disturb the rubber gaiter of the throttle cable 1 Slip off the rubber gaiter 2 Slacken the nut 3 Work the adjuster 4 located on the carburetor When finished Tighten the nut 3 to lock the adjuster 4 and refit the rubber gaiter 2 3 4 2 1 2 42 ...

Page 73: ...m 8 0 kgm Slacken but do not remove the two bolts 1 securing the top yoke 2 Release and remove the top bush 3 Tap the underside of the top yoke 2 gently to lift out the top yoke together with handlebar and steering lock ignition switch Lean the top yoke 2 forward Place a cloth underneath the top yoke to protect the instrument panel Slacken the adjusting ring 4 fully using a lockring spanner Tighte...

Page 74: ...ueezed in and press down repeatedly on the handlebars to compress the front fork The front fork should compress in a smooth motion Inspect the fork legs for any traces of oil If the front fork has a tendency to bottom out change oil see 7 10 4 Check the front fork for oil leaks and inspect the surface of the fork legs for cracks or scoring Any damaged components should be repaired or where repair ...

Page 75: ...ection procedure Place the motorcycle on the front service stand OPT see 1 7 1 Remove the fuel tank see 4 1 1 Fix the slings to the frame at the engine top mounting point Lift hoist arm until stretching the slings taut Push and pull the rear wheel up and down then rock it from side to side If you feel any play adjust the swinging arm see 2 17 3 If this fails to eliminate play change the bearings s...

Page 76: ...ting may be modified to suit specific needs in accordance with vehicle usage DANGER Allow the engine and silencer to cool down completely before working the adjusters Never tighten the adjuster nut any deeper than 25 mm from the beginning of the thread see figure Exceeding this dimension will result in sudden jerking whenever you come across any small changes in the road surface Work the adjuster ...

Page 77: ...slings to the frame at the engine top mounting point Lift the hoist arm until stretching the slings taut Slacken the spindle 1 working from the left side NOTE Make sure to have the special tool no 8101945 ready at hand socket for swinging arm spindle adjustment Working from the right hand side of the motorcycle slacken the lockring 2 fully using the special socket Tighten the adjusting bush 3 to t...

Page 78: ...motorcycle firmly with your hands Press down and release repeatedly If you feel any hardness or play or hear squeaking noises change the bearings of the rear suspension linkage system see 7 12 3 Press down the vehicle tail If the tail is slow to spring back up when released check rear suspension adjustment see 2 17 2 If the problem persists after the adjustment it means that the shock absorber is ...

Page 79: ...y wobble inspect wheel and affected components see 7 5 4 A spinning wheel that always stops in exactly the same position needs balancing REAR WHEEL Check every 4000 km 2485 mi Place the vehicle on the rear wheel stand see 1 7 2 Rotate the wheel manually in both directions The wheel should be spinning smoothly with no hardness or unusual noise If not so change the bearings see 7 6 3 If you detect a...

Page 80: ... correct wear inspection procedure with your supplier Never use tube tyres on tubeless tyre rims or viceversa Always check that the caps are in place on the valves 1 or the tyres may deflate suddenly Tyre replacement and repair and wheel servicing and balancing are delicate operations They should be carried out using adequate tools and are best left to experienced mechanics The wheel must be balan...

Page 81: ...n the exhaust manifold nuts after the first 1000 km 621 mi and every 4000 km 2485 mi or 12 months afterwards DANGER Allow the engine to cool down to ambient temperature Lift the fuel tank see 2 9 1 Remove the battery mount see 7 2 1 Tighten the two nuts 1 of the exhaust manifold 2 51 ...

Page 82: ...ee 2 21 3 Improper maintenance may lead to early wear of the chain and or sprocket damage Service the final drive more frequently when the motorcycle is used in demanding conditions or on dusty muddy roads DRIVE CHAIN INSPECTION Place the vehicle on the stand Put the gearbox in neutral Rotate the rear wheel manually and slowly Visually inspect chain front and rear sprockets looking for damaged cha...

Page 83: ...el WARNING If slack is greater at particular positions of the chain it means that some links are warped or have seized To prevent seizure lubricate the chain frequently see 2 21 5 Chain slack must be adjusted whenever outside the specified range of 25 35 mm even when it is consistent at all positions of the chain See 2 21 3 WARNING Exceeding slack in the chain may cause the chain to rattle or knoc...

Page 84: ...he vehicle on the rear wheel stand OPT 1 7 2 Completely loosen nut 1 WARNING For and easier wheel centering there are two fixed references 2 3 on the inner face of tensioner seats on swinging arms before wheel spindle Loosen the two locknuts 4 Use adjusters 5 to set chain slack and check on either sides that references 2 3 match Tighten the two locknuts 4 Tighten nut 1 Check chain slack see 2 21 2...

Page 85: ...ngs Exceedingly worn or damaged sprocket teeth WARNING If chain rollers are damaged chain link pins are loose renew the drive chain and the front and rear sprockets as a set The chain should be lubricated frequently especially after finding any dry or rusty components Lubricate and repair any warped or seized chain links Check the chain tensioner roller 1 for wear Lastly check the slider that prot...

Page 86: ... it seems appropriate Lubricate with aerosol lubricant for chains or SAE 80W 90 oil Never wash the drive chain using steam cleaners high pressure water nozzles or highly flammable solvents NOTE Do not ride when you have only just lubricated the chain Centrifugal force would cause the newly applied lubricant to fly all over adjacent vehicle parts TINE MAINTENANCE 2 56 RS 125 ...

Page 87: ...ROUTINE MAINTENANCE RS 125 2 21 6 CHAIN SLIDER INSPECTION Place the vehicle on the stand Check the chain slider 1 for damage or wear Replace as required see 7 1 15 2 57 ...

Page 88: ...ROUTINE MAINTENANCE RS 125 2 58 ...

Page 89: ...LUBRICATION RS 125 LUBRICATION 3 3 1 ...

Page 90: ...LUBRICATION RS 125 SUMMARY 3 1 REMOVING THE ENGINE OIL TANK 3 3 1 1 REMOVING THE ENGINE OIL TANK 3 3 2 ...

Page 91: ...isconnect the two connectors 1 NOTE Place some paper underneath the fitting to collect any oil spillage Release the clip 2 WARNING Change the clip 2 on refitting Disconnect the tank hose and block it off Place the hose 3 in a vertical position to avoid spilling oil Release and remove the screw 4 Release and remove the two screws 5 Push down the tank and remove it from the left side of the vehicle ...

Page 92: ...LUBRICATION RS 125 THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK 3 4 ...

Page 93: ...FUEL SYSTEM RS 125 FUEL SYSTEM 4 4 1 ...

Page 94: ... 1 2 DRAINING THE FUEL TANK 4 4 1 3 COMPLETE REMOVAL OF THE FUEL COCK 5 4 2 AIR CLEANER 6 4 2 1 AIRBOX REMOVAL 6 4 2 2 AIR CLEANER REMOVAL 7 4 3 CARBURETOR 8 4 3 1 CARBURETOR REMOVAL 8 4 3 2 REMOVING THE FUEL FEED FILTER 9 4 3 3 CARBURETOR SPECIFICATIONS 1999 2002 10 4 2 ...

Page 95: ...m 0 7 Kgm NOTE It is not necessary to drain the fuel Lift the fuel tank see 2 9 1 Withdraw the fuel hose 1 from the carburetor Cut the ties and withdraw the fuel tank drain hoses Remove the rod and lower the tank Undo the nut 2 and remove the screw 3 Collect the washer 4 the two grommets 5 and the back spacer 6 Remove the fuel tank 4 3 ...

Page 96: ...oke or use bare flames near fuel vapours Do not release fuel into the environment Remove the fuel tank see 4 1 2 Prepare a fire proof metal jerry can of more than adequate capacity to contain the amount of fuel in the tank and place it on the ground Place the free end of the hose into the canister you will have prepared previously Open the filler cap Wait until all fuel has drained out of the fuel...

Page 97: ...OF THE FUEL COCK TORQUE WRENCH SETTINGS Fuel cock retaining screws 3 Nm 0 3 kgm Read 1 2 1 and 1 3 1 carefully Drain the fuel tank see 4 1 2 Remove the fuel tank see 4 1 1 Release and remove the two screws 1 Remove the complete fuel cock 2 4 5 ...

Page 98: ...l tank see 4 1 1 Release and remove the two screws 1 Release and remove the two screws 2 and collect the nuts from beneath the screws Remove the airbox cover 3 Slacken the clip 4 Remove the airbox complete with air cleaner NOTE Block off the carburetor opening with a clean cloth to prevent the ingress of debris into the intake ducts 4 6 ...

Page 99: ...eneath the screws Remove the airbox cover 3 Remove the air cleaner 4 together with its meshing NOTE Block off the opening with a clean cloth to prevent the ingress of debris into the intake ducts On refitting be sure to remove the cloth and any other objects you may have placed inside the airbox before positioning the airbox cover 3 Make sure the air cleaner is positioned correctly otherwise it wi...

Page 100: ...d Block off the intake manifold with a cloth to prevent the ingress of debris into the engine Release and remove the two screws 3 Remove the throttle cable complete with needle and slide Release and remove the screw 4 and remove the complete throttle cable Remove the hose 5 of the mixer oil pump NOTE Place some paper underneath the hose 5 to collect any oil spillage 4 8 ...

Page 101: ... FUEL FEED FILTER Read 1 2 1 and 1 3 1 carefully Close the fuel cock Lift the fuel tank see 2 9 1 Release and remove the screw 1 Remove the cap 2 Remove the fuel filter 3 NOTE Place some paper under the cap to collect any fuel spillage 4 9 ...

Page 102: ... D DK E EU F GR I J JJ NL P SF SGP U Throttle valve 40 B D E F I SF 11 kW MP 50 A 11 kW MP 45 11 kW SF 50 AA AUS B D DK E EU GR J JJ NL P SGP UK f p 55 CH EU f p 50 D 80km Idle emulsioner jet 50 CH EU f p 62 f p 62 11 kW SF 65 11 kW MP 65 B D E F I SF 11 kW MP 62 f p 65 A 11 kW MP 65 D 80km 62 11 kW SF Atomizer BN 266 AA AUS B D DK E EU GR J JJ NL P SGP UK f p T 262 CH f p MP BN 264 D 80km BN 264 ...

Page 103: ...COOLING SYSTEM RS 125 COOLING SYSTEM 5 5 1 ...

Page 104: ...DIAGRAM 3 5 1 1 COOLING SYSTEM DIAGRAM 3 5 2 COOLANT 4 5 2 1 COOLANT CHANGE 4 5 3 RADIATOR 5 5 3 1 RADIATOR 5 5 4 THERMISTOR 6 5 4 1 COOLANT THERMISTOR 6 5 5 THERMOSTAT 7 5 5 1 70 THERMOSTAT 7 5 6 EXPANSION RESERVOIR 8 5 6 1 EXPANSION RESERVOIR 8 5 2 ...

Page 105: ...down engine internals When coolant expands from heat the expansion reservoir takes up excess coolant LOW and FULL level marks facilitate coolant level inspection and top up see 2 10 1 See 1 3 1 for more details on coolant 10 11 9 3 8 1 2 4 7 5 6 Key 1 Cylinder thermistor 2 Expansion reservoir connection tubing 3 Plain radiator cap no breather 4 Radiator to thermal expansion valve tube 5 Centrifuga...

Page 106: ...lease and remove the drain plug 1 Remove the cap 2 of the expansion reservoir 3 to facilitate drainage DO NOT RELEASE COOLANT INTO THE ENVIRONMENT Refit the drain plug 1 Fill the expansion reservoir 3 up to maximum level Slacken the screw 4 on the radiator Wait until coolant drains out and then tighten the screw 4 Top up with coolant see 2 10 1 Slacken the screw 5 on the union Wait until coolant d...

Page 107: ...ly forward while lifting until the two bottom mounting bosses are clear of their holes in the radiator bracket Remove the radiator WARNING Block off the openings of the hoses to pre vent the ingress of dirt INSTALLATION WARNING Remove any build up dirt etc caught be tween the radiator fins blowing with com pressed air Straighten any bent fins using a small flat blade screwdriver Renew the hoses if...

Page 108: ...ove the rubber cover 1 Disconnect the electrical connector 2 Unscrew and remove the thermistor 3 INSTALLATION Smear the thread of a new thermistor with LOCTITE 574 Screw the new thermistor 3 finger tight and then tighten If any coolant has been spilled during the removal procedure top up to correct level when finished see 2 10 1 5 6 ...

Page 109: ...d cover 4 Release and remove the two screws 6 Remove the thermostat 7 and collect bridge 10 spring 9 and thermostat mount 8 WARNING Block off the openings to prevent the ingress of dirt INSTALLATION Fit in the order thermostat 7 thermostat mount 8 spring 9 and thermostat bridge 10 into the cylinder head cover 4 Tighten the two screws 6 Refit the cylinder head cover 4 Tighten the four screws 5 NOTE...

Page 110: ... clip 2 Disconnect the tube 3 from the expansion reservoir 4 Remove the expansion reservoir 4 WARNING Store the expansion reservoir 4 in a safe place INSTALLATION Position the expansion reservoir 4 NOTE Be sure to have the special clip tweezers no 0277295 ready at hand and renew all clips using the same type fitted originally Refit the tube 3 to the expansion reservoir 4 Tighten the screw 1 Fill t...

Page 111: ...ENGINE RS 125 ENGINE 6 6 1 ...

Page 112: ...NE COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE INSTALLED IN THE FRAME 5 6 2 3 ENGINE REMOVAL 6 6 2 4 INSTALLING THE ENGINE INTO THE FRAME 11 6 3 RAVE 16 6 3 1 RAVE VALVE SPECIFICATIONS 16 6 3 2 SPECIAL TOOLS 17 6 3 3 RAVE EXHAUST VALVE REMOVAL 18 6 3 4 COMPONENT INSPECTION 20 6 3 5 RAVE EXHAUST VALVE INSTALLATION 21 6 2 ...

Page 113: ...the screw 1 and collect the two washers and the nut Release and remove the screw 2 on the left hand passenger footpeg bracket and collect the washer and the nut Remove the exhaust pipe together with its clamp If needed remove the exhaust flange as follows Release and remove the two screws 3 and collect the lap plate Remove the exhaust flange and collect the seal 4 WARNING On refitting use a new ex...

Page 114: ...l displacement 124 82 cu cm Bore stroke 54 mm 54 5 mm Compression ratio 12 5 0 5 1 Starter electric Engine idling speed rpm 1250 100 rpm Clutch Wet multi plate clutch operated by manual control on left handlebar Cooling liquid cooling Gearbox 6 speed mechanical transmission with control pedal on left side of engine Carburetor DELL ORTO PHBH 28 Ignition CDI Spark advance 12 2 at 2000 rpm 6 4 ...

Page 115: ...LEFT SIDE OF ENGINE Clutch cover Mixing pump Coolant pump Balancing shaft gear Kick starter where fitted Clutch CENTRAL AREA OF ENGINE Carburetor Radiator Exhaust pipe Cylinder head Piston RAVE valve fitted to f p models only Reed valve Starter motor low in the centre RIGHT SIDE OF ENGINE Drive chain and front chain sprocket Ignition flywheel Pick up Starter gear 6 5 ...

Page 116: ...manual Some of the operations described there may not be strictly required for the job at hand Proceed sensibly to avoid redundant work that is always make sure you really need to remove a particular component before proceeding Engine removal procedures are listed in the proper sequence in this section NOTE You will need a hoist and suitable slings to lift the engine Put the motorcycle on front wh...

Page 117: ...bed at paragraph 5 5 1 Disconnect the clutch cable at the engine end only see 7 3 4 Remove the battery and battery box mount together see 7 2 1 Release and remove the two screws 3 and remove the sprocket cover Remove the circlip NOTE Slacken the drive chain to aid removal of the chain sprocket Slide the chain sprocket and the drive chain off the shaft Disconnect the following electrical connectors...

Page 118: ...ENGINE RS 125 Generator 5 Pick up 6 ECU ground 7 Neutral light switch 8 6 8 ...

Page 119: ...1 NOTE You need not remove the swinging arm completely When you are removing the engine of a full power f p vehicle Disconnect the RAVE valve connector Release and remove the two screws 10 NOTE Release all cables and hoses from the ties and clips along their full length Release and remove the rear lower mounting bolt 11 and collect nut and washer 6 9 ...

Page 120: ...he next steps of the procedure Plan work ahead together Undo and remove the nut 13 and collect the washer DANGER The engine is retained to the frame by the upper mounting bolt only Use great care and be careful of your fingers and limbs Choose the location where you will place the engine and clear the floor area from any tools Support the engine and remove the bolt Lower the engine until placing i...

Page 121: ...ver screws 10 5 Nm 0 5 kgm Screw 13 10 Nm 1 0 kgm CAUTION Handle the engine with care and be careful of your finger and limbs Shift the engine in small motions until matching the mounting holes perfectly Insert the top mounting bolt with the washer and tighten the nut 1 Insert the front mounting bolt fit the washer and tighten the nut 2 Insert the rear mounting bolt 3 fit the washer and tighten th...

Page 122: ...wer f p engines Secure the RAVE valve by the two screws 14 Connect the RAVE valve connector Refit the swinging arm spindle see 7 11 5 Connect the following electrical connectors in the order System grounding connectors fix them with the screw 4 Neutral light switch 5 6 12 ...

Page 123: ...ENGINE RS 125 ECU ground 6 Pick up 7 Generator 8 Starter motor 9 6 13 ...

Page 124: ...throttle cable to the mixer oil pump see 7 3 2 Fit the hose 11 to the cylinder head cover and fix it with a new clip Refit the spark plug and connect the cap correctly Connect the electrical connector 12 at the thermistor end Connect the clutch cable at the engine end see 7 3 4 Install the battery and connect it to the system see 7 2 1 Connect the oil tubes using a new clip 6 14 ...

Page 125: ... Top up coolant level see 2 10 1 Check drive chain slack and adjust as required see 2 21 3 NOTE Inspect any components you have disturbed and check that electrical leads are secured correctly with the suitable ties WARNING The leads should not be twisted or trapped under any components electrical connectors are connected to the matching connectors hoses and hose couplings are inserted correctly an...

Page 126: ...ngine rpm NOTE The RAVE exhaust valve has been designed for racing and motorcycles equipped with it are not street legal in some countries RAVE valve operation The RAVE exhaust valve opens between 500 and 2500 rpm to allow for valve stem self cleaning It closes between 2550 rpm and operation point about 8000 rpm depending on engine version Above the operation point the valve stays open RAVE valve ...

Page 127: ...ENGINE RS 125 6 3 2 SPECIAL TOOLS Exhaust valve extractor ROTAX part no 277 445 6 17 ...

Page 128: ...the valve stem housing 3 through 180 and disconnect the Bowden cable 4 If the valve is locked in the open position because of combustion residue Push back the valve stem housing 3 using a screwdriver WARNING Push gently or the sealing surface will damage Rotate the valve stem housing 3 through 180 and disconnect the Bowden cable 4 Remove the valve stem housing 3 and collect spring 6 and seal 5 Rem...

Page 129: ...ENGINE RS 125 Disconnect the control unit connector at the wiring harness end Release and remove both screws 8 from the battery bracket Remove the complete RAVE valve 6 19 ...

Page 130: ...ated inside the valve housing for wear or damage EXHAUST VALVE Remove any combustion residue from the exhaust valve 3 and the valve duct in the cylinder Check the valve for wear or damage CYLINDER GASKET Change the cylinder gasket 4 on assembly SOLENOID See 8 11 1 for control unit inspection 6 20 ...

Page 131: ...derated engine first remove the fixed slide This is done by unscrewing the two screws 1 Collect the washers COMPLETE VALVE INSTALLATION Insert the exhaust valve assembly complete with seal 5 into the cylinder NOTE Change the seal 5 on assembly Use the two screws 1 with washers of the fixed slide to secure the exhaust valve assembly Fit the control unit to the battery bracket using the two screws 2...

Page 132: ...the exhaust valve assembly complete with seal 5 into the cylinder NOTE Change the seal 5 on assembly Tighten the two screws 1 with washers of the exhaust valve assembly WARNING Check the exhaust valve assembly as follows after installation With the valve fully open the valve stem must be flush with the exhaust port This inspection must be done with the exhaust flange removed see 6 1 1 Make sure th...

Page 133: ...CHASSIS 7 1 RS 125 CHASSIS 7 ...

Page 134: ...RECTION INDICATORS 34 7 2 10 REMOVING THE REAR DIRECTION INDICATORS 35 7 2 11 WARNING HORN REMOVAL 36 7 2 12 REMOVING THE TAIL LIGHT 37 7 3 CONTROLS 38 7 3 1 REMOVING THE THROTTLE CONTROL 38 7 3 2 REMOVING THE THROTTLE CABLE FROM INTERMEDIATE PULLEY TO OIL PUMP 39 7 3 3 REMOVING THE FRONT BRAKE CONTROL 40 7 3 4 REMOVING THE FRONT BRAKE CONTROL 41 7 3 5 REMOVING THE CLUTCH CABLE 42 7 3 6 COMPLETE R...

Page 135: ...DSTOCK RE ASSEMBLY 88 7 10 FRONT FORK 89 7 10 1 FRONT FORK DIAGRAM 89 7 10 2 REMOVING THE STANCHION TUBES SLIDERS 90 7 10 3 DISASSEMBLING THE STANCHION TUBES SLIDERS 91 7 10 4 CHANGING FRONT FORK OIL 93 7 10 5 COMPONENT INSPECTION 94 7 10 6 STANCHION TUBE SLIDER ASSEMBLY 95 7 10 7 INSTALLING STANCHIONS AND SLIDERS 96 7 11 REAR SWINGING ARM 98 7 11 1 REMOVING THE REAR SWINGING ARM 98 7 11 2 DISMANT...

Page 136: ...hts 5 Fuse carrier 6 Fuel tank 7 Seat lock 8 Left hand seat subframe cover 9 Passenger seat 10 Tail section 11 Tail light 12 Left hand passenger footpeg spring loaded snaps open closed 13 Rear brake disc 14 Rear brake caliper 15 Left hand rider footpeg 16 Left fairing cover 17 Side stand 18 Gear shift lever 19 Gearbox oil sight glass 20 Left body panel 21 Warning horn 22 Front fork 23 Front mudgua...

Page 137: ...er 29 Coolant expansion reservoir 30 Battery 31 Front brake fluid reservoir 32 Right rearview mirror 33 Front fairing 34 Right body panel 35 Front wheel 36 Front brake disc 37 Front brake caliper 38 Rear brake fluid reservoir 39 Rear shock absorber 40 Rear brake lever 41 Right rider footpeg 42 Drive chain 43 Rear swinging arm 44 Rear wheel 45 Right passenger footpeg spring loaded snaps open closed...

Page 138: ...ise Lift and remove the seat Remove the lid 3 INSTALLATION Locate the tabs 4 at the seat rear end into the suitable recesses Locate the anchor point 5 into its seat Lower the seat and press down and the latch will engage NOTE Make sure the seat is positioned correctly and safely engaged before riding ...

Page 139: ...ws 1 3 7 9 3 Nm 0 3 Kgm Screws 12 2 Nm 0 2 Kgm RIGHT HAND SIDE FAIRING Release and remove the six screws 1 Withdraw the pin 2 Release and remove the two screws 3 at the front end Disconnect the two electrical connectors 4 of the direction indicator Remove the right side fairing 5 ...

Page 140: ... and remove the six screws 7 Withdraw the pin 8 Release and remove the two screws 9 at the front end Disconnect the two electrical connectors 10 of the direction indicator Remove the left side fairing 11 sliding it along the side stand The following applies to both side fairings If you need to remove the inner protection 13 release and remove the four screws 12 ...

Page 141: ...5 7 1 4 AIR DAM REMOVAL TORQUE WRENCH SETTINGS Screws 1 2 3 3 Nm 0 3 Kgm Release and remove the two side screws 1 on either side Release and remove the two screws 2 Release and remove the two screws 3 Remove the air dam ...

Page 142: ... Nm 0 3 Kgm Repeat these three steps on either side Release and remove the two screws 1 Remove the rearview mirror 2 Release and remove the three screws on the side fairing 3 Release and remove the screw 4 Disconnect the headlight connector 5 Remove front fairing and headlamp together ...

Page 143: ...1 RS 125 7 1 6 WINDSCREEN REMOVAL Working from inside the front fairing remove the seven washers 1 and collect the seals 2 Remove the seven retaining pins 3 Remove the windscreen NOTE Fit new washers 1 on assembly ...

Page 144: ...e the three screws 1 NOTE The other three screws are there for aesthetic purposes only and can be left in place Open the filler cap 2 WARNING Be careful when removing the screw 3 Take care not to drop it into the fuel tank Release and remove the screw 3 Remove the filler cap 2 together with the flange 4 WARNING Block off the filler opening to prevent the ingress of dirt ...

Page 145: ...gm Remove the fuel tank and place it on a work bench see 4 1 2 Release and remove the two screws 1 Collect the washers and the rubber spacer 2 NOTE Fit the rubber spacer 2 in the correct position on assembly Remove the filler cap see 7 1 6 Remove the tank fairing and collect bush 3 and grommet 4 at the front end ...

Page 146: ...nner screw 3 3 Nm 0 3 Kgm Nut 4 5 Nm 0 5 Kgm Remove the seat see 7 1 1 Release and remove the two front screws 1 Release and remove the two rear screws 2 Release and remove the inner screw 3 and collect the nut Undo and remove the nut 4 Remove the seat subframe cover NOTE If needed repeat the process for the other seat subframe cover ...

Page 147: ...m Screws 3 2 Nm 0 2 Kgm Remove both seat subframe covers see 7 1 8 Undo and remove the two inner nuts 1 and collect the screws Release and remove the two screws 2 on both sides Remove the tail section complete with passenger seat To remove the passenger seat and the strap Release and remove the seven screws 3 ...

Page 148: ...CHASSIS 7 16 RS 125 7 1 11 REMOVING THE FRONT MUDGUARD TORQUE WRENCH SETTINGS Screws 1 2 Nm 0 2 Kgm Release and remove the two screws 1 on both sides Remove the front mudguard ...

Page 149: ...CHASSIS 7 17 RS 125 7 1 12 REMOVING THE REAR MUDGUARD Release and remove the screw 1 on both sides Remove the rear mudguard ...

Page 150: ...UE WRENCH SETTINGS Screws 1 2 Nm 0 2 Kgm Screws 2 3 Nm 0 3 Kgm Screws 4 3 Nm 0 3 Kgm Remove the seat see 7 1 1 Release and remove the two screws 1 on both sides Release and remove the four screws 2 Lower the seat end cover Remove the flasher 3 from its housing ...

Page 151: ...CHASSIS 7 19 RS 125 Remove the number plate bracket see 7 1 13 Unscrew the two screws 4 and collect the nut Remove the ECU Pull the seat end cover in a rearward motion to remove ...

Page 152: ...0 3 kgm Nut 2 3 Nm 0 3 kgm Release and remove the two screws 1 Undo and remove the nut 2 Disconnect the four connectors of the rear direction indicators 3 Disconnect the number plate light connector 4 Disconnect the tail light connector 5 Remove the number plate bracket together with direction indicators and tail light ...

Page 153: ...CHASSIS 7 21 RS 125 7 1 15 CHAIN GUARD REMOVAL TORQUE WRENCH SETTINGS Screws 1 2 Nm 0 2 kgm Release and remove the two screws 1 Remove the chain guard 2 ...

Page 154: ...S Screw 1 2 Nm 0 2 kgm Screw 3 2 Nm 0 2 kgm NOTE The chain slider is best accessed after splitting the drive chain see 7 13 1 Release and remove the screw 1 and collect the nut 2 Release and remove the screw 3 and collect the grommet 4 Remove the upper chain slider 5 4 3 1 5 2 ...

Page 155: ... 17 LOWER CHAIN SLIDER REMOVAL TORQUE WRENCH SETTINGS Screws 1 2 Nm 0 2 kgm NOTE The chain slider is best accessed after splitting the drive chain see 7 13 1 Release and remove the two screws 1 Remove the lower chain slider 2 ...

Page 156: ...CHASSIS 7 24 RS 125 7 1 18 AIR SCOOP REMOVAL Remove the front fairing see 7 1 4 Remove the air scoop 1 ...

Page 157: ... 2 7 1 Disconnect the negative lead and the positive lead in the order Remove the battery breather tube 1 Release and remove the screw 2 Move aside the coolant expansion reservoir 3 Take the battery out its mount Place the battery on a level surface in a cool dry place WARNING On refitting pay particular attention to the breather tube Make sure to connect the positive lead first then the negative ...

Page 158: ...VING THE ENGINE CONTROL UNIT TORQUE WRENCH SETTINGS Screw 2 3 Nm 0 3 kgm Remove the tail section see 7 1 9 Disconnect the connector 1 Release and remove the two screws 2 and collect the nuts underneath Remove the Engine Control Unit ...

Page 159: ... 10 Nm 1 0 Kgm Remove the tail section see 7 1 9 Release the wiring from the clip Release and remove the screw 1 and collect the washer Release and remove the screw 2 NOTE Refit the two grounding wires under the screw 2 on assembly Disconnect the connector Remove the voltage rectifier ...

Page 160: ...onnectors 1 of the right hand light dip switch Release and remove the two screws 2 securing the two shells at the bottom end Separate the two shells WARNING On refitting position the bottom shell first making sure the locating peg becomes fully seated into the handlebar hole Disconnect the throttle cable 3 Release the wiring from the clips and remove the right hand light dip switch ...

Page 161: ...nector 1 of the left hand light dip switch Release and remove the two screws 2 securing the two shells at the bottom end Separate the two shells WARNING On refitting position the bottom shell first making sure the locating peg becomes fully seated into the handlebar hole Disconnect the cold start cable 3 Release the wiring from the clips and remove the left hand light dip switch ...

Page 162: ...see 2 9 1 Disconnect the connector 1 of the ignition switch assembly at the main wiring harness Release and remove the two screws 2 Pull the switch 3 in a downward motion to remove If you need to remove the ignition switch steering lock 4 completely Perform the first five steps Release and remove the two screws 5 6 Pull the ignition switch steering lock 4 in a downward motion to remove ...

Page 163: ...speedometer cable 1 and remove it from the left fairing Undo and remove the three nuts 2 and collect the washers Release the instrument panel wiring from the ties Disconnect the four connectors 3 Remove the instrument panel NOTE Remove the individual components if required MULTI FUNCTION COMPUTER Disconnect the two connectors 4 ...

Page 164: ...the bushes Lift the sponge Release and remove the two screws 6 Remove the multi function computer SPEEDOMETER REV COUNTER Undo and remove the two nuts 7 and collect the washers Separate the speedometer warning light holder 8 from the rev counter multi function computer 9 ...

Page 165: ...IGHT REMOVAL Read 1 2 1 carefully TORQUE WRENCH SETTINGS Screws 1 2 Nm 0 2 kgm Remove the front fairing see 7 1 4 Release and remove the three screws 1 Remove the headlight NOTE See 8 15 1 for instructions on how to replace the bulbs ...

Page 166: ...34 RS 125 7 2 9 REMOVING THE FRONT DIRECTION INDICATORS Read 1 2 1 carefully Disconnect the connector 1 NOTE It is not necessary to remove the fairing Release and remove the screw 2 Remove the direction indicator ...

Page 167: ...plate bracket but leave it attached to the wiring see 7 1 13 Disconnect the pair of connectors 1 of the direction indicator you wish to remove Look at the colour to identify the connectors Right indicator red blue Left indicator light blue blue Release and remove the screw 2 Remove the direction indicator ...

Page 168: ...36 RS 125 7 2 11 WARNING HORN REMOVAL Read 1 2 1 carefully TORQUE WRENCH SETTINGS Screw 2 22 Nm 2 2 kgm Remove the air dam see 7 1 3 Disconnect the two connectors 1 Release and remove the screw 2 Remove the horn ...

Page 169: ...ully Remove the number plate bracket but leave it attached to the wiring see 7 1 13 Disconnect the three tail light connectors 1 WARNING Make sure to refit the connectors 1 to the matching connectors on assembly Release and remove the two screws 2 Remove the tail light ...

Page 170: ...tom Separate the two shells WARNING On refitting position the bottom shell first making sure the locating peg becomes fully seated into the handlebar hole Disconnect the throttle cable 2 Unscrew the screw 3 and remove the counterweight Slide the twistgrip off the handlebar Use an air gun to aid removal Slide the throttle control off the handlebar NOTE Check throttle cable free play on refitting an...

Page 171: ... 9 1 Remove the left fairing see 7 1 2 Loosen and remove the three screws 1 and remove oil pump cover Slide out the throttle cable Loosen and remove screw 2 from frame inner face on vehicle left side Remove throttle cables pulley cover Slide out throttle cable from oil pump WARNING Upon reassembly adjust throttle cable tension by turning nut 3 on the oil pump ...

Page 172: ...id leading to a dangerous condition COMPLETE REMOVAL Drain the front brake circuit see 2 12 2 When all fluid has drained out release and remove the screw 3 and collect the two sealing washers NOTE Renew the two sealing washers on assembly Use washers of the same type fitted originally Slide a plastic bag onto the fitting 4 and seal the bag using adhesive tape Prise the two connectors of the front ...

Page 173: ...id leading to a dangerous condition COMPLETE REMOVAL Drain the front brake circuit see 2 12 2 When all fluid has drained out release and remove the screw 3 and collect the two sealing washers NOTE Renew the two sealing washers on assembly Use washers of the same type fitted originally Slide a plastic bag onto the fitting 4 and seal the bag using adhesive tape Prise the two connectors of the front ...

Page 174: ...lly Detach the clutch cable 3 from the lever Remove the left fairing see 7 1 2 Undo and remove the gearbox oil filler cap 4 With a small flat screwdriver prise off the clutch cable 3 until releasing it from its anchor point Withdraw the clutch cable 3 WARNING Check clutch lever play on refitting see 2 11 1 ...

Page 175: ...ase the nut 1 Slide the actuating rod off the lever Undo and remove the nut 2 Remove the gear shift lever and collect spindle 3 and Belleville washer COMPLETE REMOVAL Remove the left fairing see 7 1 2 Slacken the screw 4 and withdraw the gearbox link rod Undo and remove the nut 2 Remove the complete gear shift lever and collect spindle 3 and Belleville washer ...

Page 176: ... 44 RS 125 7 3 7 REMOVING THE REAR BRAKE LEVER TORQUE WRENCH SETTINGS Lever adjuster screw 10 Nm 1 0 Kgm Unhook the spring 1 Release and remove the pivot bolt 2 and collect the washer Remove the rear brake lever ...

Page 177: ...e the left light dip switch from the handlebar see 7 2 5 NOTE You need not detach the connector from the wiring Release and remove the two screws 4 Remove the clamp and move the clutch control aside The clutch control is retained by the clutch hose Release and remove the screw 5 Remove the left handlebar RIGHT HANDLEBAR Remove the throttle control see 7 3 1 Remove the right light dip switch from t...

Page 178: ...ead 1 2 1 carefully TORQUE WRENCH SETTINGS Nuts 1 10Nm 1 0 kgm Remove the instrument panel see 7 2 7 Release the tie securing the wiring to the instrument panel subframe Release and remove the two nuts 1 and collect the washers Remove the two bolts Remove the subframe ...

Page 179: ...CH TORQUE WRENCH SETTINGS Screws 1 10 Nm 1 0 kgm Remove the seat see 7 1 1 Remove the left cover of the seat subframe see 7 1 8 Release and remove the two bolts 1 and collect the two nuts Release and remove the two screws 2 Remove the complete latch ...

Page 180: ...Nm 2 2 Kgm Screw 5 2 Nm 0 2 Kgm Release and remove the screw 1 Release and remove the two screws 2 and collect nuts bushes washers and guard 4 Release and remove the two screws 3 Remove the rider footpeg bracket together with brake master cylinder actuating rod brake lever and rider footpeg If needed unscrew the screw 5 and remove the chain tensioner ...

Page 181: ... SETTINGS Nut 1 5 Nm 0 5 Kgm Screws 2 22 Nm 2 2 Kgm Screws 3 3 Nm 0 3 Kgm Undo and remove the nut 1 Release and remove the two screws 2 Remove the rider footpeg bracket complete with gear shift lever and footpeg If needed remove the guard 4 and release and remove the two inner screws 3 ...

Page 182: ...0 RS 125 7 4 6 REMOVING THE RIDER FOOTPEG Read 1 2 1 carefully Remove the retaining ring 1 Withdraw the spindle 2 Collect footpeg 3 and spring 4 NOTE Repeat the process to remove the other rider footpeg if needed ...

Page 183: ...OTPEG BRACKETS TORQUE WRENCH SETTINGS Screws 1 13 Nm 1 3 Kgm NOTE The following procedure applies to both footpeg brackets Remove the side body panel see 7 1 8 Release and remove the two screws 1 and collect the nuts Remove the passenger footpeg bracket ...

Page 184: ...he retaining ring 1 Withdraw the spindle 2 WARNING The ball 3 sits on a spring 4 and might be thrown out due to spring action on disassembly Proceed carefully and make sure to collect the ball Remove the footpeg and collect the shim 5 the ball 3 and the spring 4 ...

Page 185: ...bolt 10 Nm 1 0 Kgm Place the motorcycle on the rear wheel stand OPT see 1 7 2 Lower the side stand Release and remove the two screws 1 Release and remove the screw 2 Remove the fairing cover Disconnect the side stand connector on the right side of the motorcycle Release and remove the two bolts 3 and collect the nuts at the opposite end Remove the side stand complete with switch and bracket ...

Page 186: ...ove both passenger footpeg brackets see 7 4 7 Remove the seat latch see 7 4 7 Release and remove the screw 1 and collect the nut Move aside the rear brake fluid reservoir WARNING Keep the rear brake fluid reservoir in a vertical position to avoid spilling brake fluid Any brake fluid spills could lead to a dangerous condition Release the seat subframe from all wiring ties Release and remove the two...

Page 187: ... to remove a particular component before proceeding Remove the engine from the frame see 6 2 3 Remove the instrument panel subframe see 7 4 2 Remove the front end complete with front wheel assembly see 7 9 2 Disconnect the two horn connectors Working from the right hand side undo and remove the top nut 1 Remove the bolt from the opposite end and collect the washer Working from the right hand side ...

Page 188: ...and remove the two screws 3 Remove the left hand rider footpeg bracket Disconnect the connector of the starter relay Disconnect the connector of the left light dip switch Disconnect the two connectors of the right light dip switch ...

Page 189: ...carburetor oil tank and airbox see 7 4 10 Working on both sides of the motorcycle release and remove the two screws 4 at the front end Remove the two radiator brackets mounted to the battery frame Working on both sides of the motorcycle release and remove the two upper screws 5 Remove the frame head plate ...

Page 190: ... sure you really need to remove a particular component before proceeding Position the frame head plate Working on both sides of the motorcycle tighten the two upper screws 1 Locate the two radiator brackets to the battery frame Working on both sides of the motorcycle tighten the two screws 2 at the front end Install the seat subframe see 7 4 10 Install the side stand see 7 4 9 Install the front en...

Page 191: ...ng arm spindle Insert the shock absorber top bolt 4 from the left side and tighten the nut Locate the linkages to the frame Insert the bolt from the left side and tighten the nut 5 Adjust the swinging arm see 2 17 3 Connect the following electrical connectors in the order coil and coil ground horn ...

Page 192: ...talling the frame check the following Ensure that all components are fastened securely Check that wiring and cables are properly routed and fastened Ensure that all electrical connectors are properly fitted to the matching connectors Turn the handlebars and check that cables and tubes do not bind Refit the fairings ...

Page 193: ...RONT WHEEL DIAGRAM 9 8 7 5 6 1 2 3 4 5 Key 1 Wheel spindle 2 Speedometer drive 3 Seal 4 Drive ring 5 Front wheel bearing 6 Bearing spacer 7 Front wheel right hand outer spacer 8 Washer 9 Wheel spindle special bolt NOTE Grease the wheel spindle 1 ...

Page 194: ...is safely supported and stable Have an assistant hold the handlebars steady in position as in forward travel so that the steering cannot move Release and remove the two mounting bolts 1 of the front brake caliper Remove the brake caliper from the brake disc but leave the caliper attached to the brake hose WARNING Do not operate the front brake lever when the calipers are not in place or the piston...

Page 195: ...CHASSIS 7 63 RS 125 Remove the wheel pulling from the front and collect the spacer 4 4 Disengage the speedometer drive 5 5 ...

Page 196: ... extractor 4 1 2 3 5 WARNING Inspect the bearings after each removal see 7 5 4 Replace as required Collect the inner spacer 5 Clean the wheel hub bore thoroughly Wash all components using clean detergent WARNING Refit the bearings using a drift with the same diameter as the bearing outer ring Do not tap the balls or the inner ring Make sure to push the following components into firm contact with t...

Page 197: ... using a dial gauge Replace the spindle 2 when run out exceeds the maximum limit allowed Wheel spindle run out limit 0 25 mm 0 120 10 30 40 50 60 70 80 90 100 110 20 2 WHEEL RIM Use a dial gauge to ensure that wheel rim 3 radial A and axial B run out does not exceed the maximum limit allowed Exceeding run out is normally due to worn or damaged bearings Replace the bearings first then check run out...

Page 198: ...arger diameter face pointing to the right fork leg Position the spacer 5 to the wheel Place the wheel between the fork legs above the support DANGER Do not attempt to align the holes by putting your fingers into the holes This could result in severe personal injury Move the wheel until the centre hole aligns with the holes in the forks Slide the wheel spindle 1 fully home 5 6 7 Fit the washer and ...

Page 199: ...rk up and down This will allow the fork legs to seat themselves properly Tighten the two wheel spindle clamp bolts 8 working on both sides Remove the front wheel stand OPT see 1 7 1 Remove the rear wheel stand OPT see 1 7 2 WARNING After refitting the wheel work the front brake lever repeatedly and check for proper operation of the brake Ensure that the wheel is properly centred ...

Page 200: ... 7 4 6 1 2 3 4 5 Key 10 Rear wheel spindle 11 Left chain slider 12 Left outer spacer 13 Rear wheel oil seal 14 Rear wheel bearing 15 Rear wheel inner spacer 16 Wheel right outer spacer 17 Right chain slider 18 Rear wheel spindle nut NOTE Grease the wheel spindle 1 ...

Page 201: ... tyre to hold the wheel in position once released 4 2 Undo and remove the nut 1 and collect the washer Withdraw the wheel spindle 2 from the left hand side NOTE Mark the positions of the right 3 and left 4 chain tensioners to refit them in the original position Collect the right 3 and left 4 chain tensioners NOTE Take the chain off the rear sprocket routing it outboard of the sprocket Push the whe...

Page 202: ...CHASSIS 7 70 RS 125 NOTE Note the positions of the spacers 5 and 6 so as to refit them in the original position on assembly Collect the left hand spacer 5 Collect the right hand spacer 6 5 6 ...

Page 203: ... then the left hand bearing 4 using a bearing extractor WARNING Inspect the bearings after each removal and replace as required Collect the inner spacer 5 Clean the hub bore thoroughly 5 4 2 3 1 NOTE Wash all components with clean detergent WARNING Refit the bearings using a drift with the same diameter as the bearing outer ring Do not tap the balls or the inner ring Push the left hand bearing 4 f...

Page 204: ...move the rear sprocket 4 Clean the hub bore thoroughly NOTE Wash all components with clean detergent If needed Remove the sprocket carrier 5 and collect the five nuts 6 Remove the cush drive rubber 7 REASSEMBLY With the sprocket carrier 5 removed fit the rear sprocket 4 to the carrier and tighten the five nuts 6 WARNING Tighten the nuts in a cross pattern Refit the cush drive rubber 7 into the whe...

Page 205: ...ive assembly to the wheel Rotate the rear chain sprocket manually in both directions and check cush drive play in the hub If you feel too much play change the cush drive REAR CHAIN SPROCKET Check the toothing of the front and rear chain sprockets for wear In the event excess wear is found replace front and rear chain sprockets and drive chain as a set see 7 6 4 and 7 13 1 WARNING Drive chain and f...

Page 206: ...ed up Refit each spacer in its original position Fit the left hand 1 and right hand 2 spacers each in its location on the wheel hub 1 2 WARNING Before proceeding to reassemble check that the caliper carrier 3 is positioned correctly The carrier slot must be sitting on the locating peg found on the inboard face of the left swinging arm Be careful when locating the brake disc to the caliper 3 Place ...

Page 207: ... a light coat of grease evenly on the wheel spindle 6 Push the wheel spindle 6 fully home from the left side NOTE Make sure the wheel spindle 6 is fully in with the head fully seated into the left hand chain tensioner 5 5 6 Fit the washer and screw the nut 7 hand tight Check chain slack see 2 21 1 Tighten the nut 7 WARNING After reassembling operate the rear brake lever repeatedly and check for pr...

Page 208: ...iper mounting bolt 21 Brake caliper 22 Bleed nipple 23 Brake fluid hose 24 Brake pad retainer 25 Brake pads 26 Brake pad cover For detailed information see 1 3 1 see 2 12 1 see 2 12 5 see 2 12 3 WARNING After each removal change the brake caliper mounting bolts Use two bolts of the same type fitted originally ...

Page 209: ...WARNING Do not operate the brake lever with the brake pads removed or the brake caliper pistons might fall out leading to loss of brake fluid Fit two new brake pads taking care to align the holes with the caliper holes WARNING The brake pads must always be replaced in pairs Ensure they become properly seated in the brake caliper Position the clip and insert the pin 3 Fit the retaining ring 2 Refit...

Page 210: ... measuring disc thickness with a mi crometer gauge at different positions along the disc When a disc is worn beyond the service limit even at just one position the disc must be replaced Disc thickness limit 4 5 mm Check for disc run out using a dial gauge Replace disc when the maximum run out measured exceeds the disc run out limit see 7 7 4 Disc run out limit 0 3 mm ...

Page 211: ... 2 NOTE The screws 1 are retained with LOCTITE 243 Use of an air gun is recommended to release the screws Release and remove the six brake disc screws 1 WARNING Apply LOCTITE 243 to the threads of the brake disc screws 1 on assembly 2 1 NOTE To refit start all screws 1 manually in their holes and tighten in a cross pattern Remove the brake disc 2 ...

Page 212: ... carrier 31 Brake caliper 32 Caliper pin and clip 33 Brake caliper cover 34 Pair of brake pads 35 Bleed nipple 36 Clips 37 Rear brake hose 38 Rear brake master cylinder 39 Rear brake lever For detailed information see 1 3 1 see 2 12 4 see 2 12 5 see 2 13 1 see 2 12 3 WARNING After each removal change the brake caliper mounting bolts Use two bolts of the same type fitted originally ...

Page 213: ...NING Do not operate the brake lever with the brake pads removed or the brake caliper pistons might fall out leading to loss of brake fluid Fit two new brake pads taking care to align the holes with the caliper holes WARNING The brake pads must always be replaced in pairs Ensure they become properly seated in the brake caliper Position the clip 4 and insert the pin 3 Fit the retaining ring 2 Refit ...

Page 214: ...ferent positions along the disc When a disc is worn beyond the service limit even at just one position the disc must be replaced NOTE When a disc is worn beyond the service limit even at just one position the disc must be replaced see 7 8 4 Disc thickness limit 4 5 mm Check for disc run out using a dial gauge Replace disc when the maximum run out measured exceeds the disc run out limit see 7 8 4 D...

Page 215: ...6 2 NOTE The screws 1 are retained with LOCTITE 243 Use of an air gun is recommended to release the screws Release and remove the five brake disc screws 1 WARNING Apply LOCTITE 243 to the threads of the brake disc screws 1 on assembly NOTE To refit start all screws 1 manually in their holes and tighten in a cross pattern Remove the brake disc 2 ...

Page 216: ...ar brake master cylinder and collect the two sealing washers Slacken the hose clip 3 and slide it aside Detach the hose 4 from the master cylinder fitting Release and remove the two screws 5 Remove the cylinder 6 sliding it forward WARNING Avoid disturbing the pedal joint unless strictly necessary When the joint has been removed apply LOCTITE 270 to the thread before refit ting and tighten firmly ...

Page 217: ... 1 3 5 7 4 6 8 9 Key 40 Top yoke 41 Steering tube cap 42 Bottom lockring 43 Seal 44 Headstock washer 45 Ball bearing 46 Roller bearing 47 Bottom dust seal 48 Bottom yoke and steering stem Always grease the bottom yoke and steering stem on refitting see 1 8 1 ...

Page 218: ... not operate the front brake lever with the brake caliper removed or the brake caliper pis tons might fall out leading to loss of brake fluid The front end is heavy An assistant will be re quired to support it When working with an as sistant plan the whole procedure carefully to gether While the assistant holds the front end steady unscrew and remove the adjusting ring nut and perform the first fi...

Page 219: ...ion Pay special attention to the components listed below BEARINGS Rotate the inner ring manually The ring should turn smoothly with no hardness or noise There should be no end float Replace any bearings that do not meet the above requirements SEALS Inspect the seals and replace if damaged or badly worn ...

Page 220: ... stem and install the bottom yoke and steering stem 6 see 1 8 1 Before finally tightening the adjusting ring turn the steering in both directions repeatedly This will allow the bearings to seat themselves properly Adjust play in the bearings see 2 16 1 Turn the handlebars to ensure that cables and hoses do not bind Ensure that cables and hoses are not twisted or twisted around one another Lower th...

Page 221: ...ORK 7 10 1 FRONT FORK DIAGRAM 1 2 10 9 8 7 6 5 6 3 4 12 11 Key 49 Top cap 50 O ring 51 Half ring 52 Spring cup 53 Spacer 54 Slide bush 55 Guide bush cup 56 Oil seal 57 Retaining ring 58 Dust seal with clip 59 Slider 60 Stanchion tube ...

Page 222: ...he fork legs one at a time Always refit a fork leg in the correct position before removing the other Perform the first seven steps of the procedure described at paragraph 7 9 2 Remove the front wheel see 7 5 2 Place the slider in a vice with soft jaws WARNING The stanchion and slider assembly contains oil Do not turn it over or tilt it during removal Slacken the bolt 1 Slacken the two bolts 2 Slid...

Page 223: ...container having a capacity greater than 430 cu cm ready at hand before proceeding Place the slider in a vice with soft jaws WARNING The stanchion and slider assembly contains oil Do not turn it over or tilt it during removal Undo the top cap 1 carefully Be sure not to damage the O ring when removing the cap Push the stanchion into the slider to give access to the two half rings 2 Extract the half...

Page 224: ...river to remove the retaining ring 5 from inside the slider Extract the oil seal 6 with the aid of a large screwdriver Slide out the guide bush cap 7 from inside the slider Tap the end of the slider firmly on a wooden bench to knock out the slide bushes 8 and the spacer 9 WARNING Keep the slider at right angles to the bench while tapping If the bushes are a tight fit in the slider use a bush extra...

Page 225: ...he operations described below apply to both fork legs DRAINING OIL Perform the first six steps of the procedure described at paragraph 7 10 3 FILLING Place the slider upright in a vice with soft jaws Fill fork fluid into the slider Position the spring cup 1 Insert the two half rings 2 Check the O ring is in place and tighten the top cap 3 3 1 2 ...

Page 226: ...t Service limit 0 2 mm 1 0 120 10 30 40 50 60 70 80 90 100 110 20 DANGER Never attempt to straighten a buckled stanchion as this would weaken the overall structure leading to a dangerous riding condition SLIDER Inspect for damage and or cracking Replace if damaged Check the condition of the slide bushes 2 Change any component which is badly worn or damaged WARNING Clean off any debris collected by...

Page 227: ... bush 3 Lubricate the oil seal 5 Push the oil seal 5 into contact with the guide bush cap 4 The concave side of the seal must be facing into the slider 2 4 3 1 5 Fit the following components to the stanchion in the order dust seal 6 retaining ring 7 Place the stanchion in a vice with soft aluminium jaws Fit the slider to the stanchion Install the retaining ring 7 and dust seal 6 so that they becom...

Page 228: ...5 kgm Bottom yoke bolts 4 25 Nm 2 5 kgm Slide the slider and stanchion assembly through the bottom 1 and top yokes 2 Insert the wheel spindle 3 into both fork legs to keep the holes aligned 3 Check that the slider is correctly seated in the bottom 1 and top yokes 2 Tighten the two bolts 4 securing the bottom yoke 1 to the slider ...

Page 229: ...ned correctly before detaching the slings Detach the slings from the frame When finished operate the front brake and press down on the fork repeatedly Fork operation should be smooth and progressive There must be no traces of oil on the fork legs 3 NOTE Check front suspension setting before riding the motorcycle Install the mudguard see 7 1 10 Install the air scoop see 7 1 17 Install the front fai...

Page 230: ...see 2 9 1 Fix the slings to the frame at the engine top mounting point Raise the hoist arm until stretching the slings taut Remove the drive chain see 7 13 1 Remove the rear wheel see 7 6 2 Working from the left hand side undo and remove the nut 1 and collect the washer Withdraw the screw from the opposite end Remove the linkages from the swinging arm Release and remove the inner screw 2 Slip the ...

Page 231: ... tool no 8101945 socket for swinging arm spindle adjustment ready at hand Working from the right hand side slacken the lockring 5 fully using the special socket Slacken the adjusting bush 6 Working from the left hand side release and remove the swinging arm spindle 7 and collect the two washers Remove the swinging arm from the frame ...

Page 232: ... Place the swinging arm on a work bench Clean both sides of the bearing housings with a cloth Remove the outer plastic washers 1 Slide both bushes of the needle roller bearings 2 off the swinging arm Extract the four O rings 3 Extract the needle roller bearings 4 using a drift with adequate diameter 1 4 4 3 2 3 1 ...

Page 233: ...smoothly with no hardness or noise There should be no end float Replace any needle roller bearings that do not meet these requirements Grease the rollers see 1 8 1 SEALS Check the condition of the seals Replace any damaged or worn seals SWINGING ARM SPINDLE Check spindle run out using a dial gauge Replace spindle when run out exceeds the allowed limit Spindle run out limit 0 3 mm 0 120 10 30 40 50...

Page 234: ...inging arm articulated connection and apply lithium grease Install two new needle roller bearings 1 using a drift with adequate diameter The bearings must be centred axially in the bearing housing Position the four O rings 2 Slide the two bushes of the needle roller bearings 3 into the swinging arm Position the outer plastic washers 4 4 1 1 2 3 2 4 ...

Page 235: ...e following operations When working with an assistant plan the whole procedure carefully together Locate the swinging arm to the frame Position the swinging arm so as to match the holes At the same time push the spindle 1 fully home from the left hand side Correct adjustment of swinging arm spindle play is obtained by screwing the adjusting bush 2 all the way in and tightening an additional 1 4 tu...

Page 236: ...r and tighten the nut 5 Route the brake hose along the swinging arm Secure the brake hose inner clip with the screw 6 Secure the brake hose outer clip with the screw 7 Install the rear wheel see 7 6 6 Install the drive chain see 7 13 2 Lower the hoist arm Disconnect the slings from the frame Install the fuel tank see 4 1 1 ...

Page 237: ...ce the motorcycle on the rear wheel stand OPT see 1 7 2 Place a support between swinging arm and seat subframe to keep the shock absorber uncompressed Working the from the right hand side undo and remove the top nut 1 Withdraw the bolt from the opposite side and collect the washer Working from the right hand side undo and remove the nut 2 Withdraw the bolt from the opposite side and collect the wa...

Page 238: ...CHASSIS 7 106 RS 125 Pull the shock absorber in a downward motion to remove ...

Page 239: ...bolt of the shock absorber complete with washer from the left hand side Tighten the nut 1 on the opposite side Position the linkage to the shock absorber Insert the shock absorber bottom bolt from the right hand side Tighten the nut 2 on the opposite side Locate the double connecting link to its seat in the frame Insert the link to frame mounting bolt complete with washer from the left hand side T...

Page 240: ...winging arm 3 80 Nm 8 0 kgm Working from the right hand side undo and remove the nut 1 Withdraw the bolt on the opposite side and collect the washer Working from the left hand side undo and remove the nut 2 Withdraw the bolt on the opposite side Working from the left hand side undo and remove the nut 3 Withdraw the bolt on the opposite side and collect the washer Remove the complete linkage assemb...

Page 241: ...t hand 2 and left hand bushes 3 from the single connecting link 1 3 2 Remove the oil seals 4 from the double connecting link Withdraw the pin 5 Remove the roller bearing 6 using a suitable extractor Remove the Belleville washer 7 Remove the seal 8 Remove both oil seals 9 Withdraw the pin 10 Remove the roller bearing 11 using a suitable extractor 9 11 10 4 5 6 4 9 8 7 Remove both seals 12 Remove bo...

Page 242: ...ce any damaged components ROLLER BEARINGS Rotate the roller cages manually They must rotate smoothly with no hardness or noise There should be no end float Replace any roller cages that do not meet these requirements Apply grease to the bearing rollers see 1 8 1 SEALS Check the condition of the seals Replace any damaged or worn seals ...

Page 243: ... Slacken the chain see 2 21 3 Rotate the rear wheel until locating the master link Slip off the clip 1 Remove the link plate underneath Remove the master link from the opposite end Remove the chain WARNING When the chain is worn replace chain and front and rear sprockets as a set See 2 21 4 ...

Page 244: ...in open ends should be in the lowermost portion of the chain midway between the sprockets Overlap the two ends and slide the master link pins in place from the inboard side outwards Locate the link plate to the pins Fit the clip 1 to the pins WARNING The master link clip 1 must be installed with the open end pointing away from the direction of chain movement ...

Page 245: ...ELECTRICAL SYSTEM 8 1 RS 125 ELECTRICAL SYSTEM 8 ...

Page 246: ... REV COUNTER 13 8 7 1 SENSORS AND REV COUNTER CIRCUIT 13 8 8 VISUAL AND ACOUSTIC SIGNALS 15 8 8 1 VISUAL AND ACOUSTIC SIGNALLING SYSTEM 15 8 9 BRAKE LIGHTS CIRCUIT 17 8 9 1 BRAKE LIGHTS CIRCUIT 17 8 10 LIGHT CIRCUIT 19 8 10 1 LIGHT CIRCUIT 19 8 11 RAVE VALVE 21 8 11 1 RAVE VALVE CIRCUIT 21 8 12 STAND 23 8 12 1 STAND LOGIC CIRCUIT 23 8 13 BULB REPLACEMENT 26 8 13 1 BULB REPLACEMENT 26 8 14 REPLACIN...

Page 247: ... Fuses 5 Coil 6 Flasher 7 Voltage regulator 8 Tail light 9 Rear left indicator 10 Side stand switch 11 Starter motor 12 Warning horn 13 Starter relay 14 Front left indicator 15 CDI unit 16 Coolant thermistor 17 Diode 18 RAVE control unit fp 19 Front brake light switch 20 Instrument panel 21 Front right indicator 22 Neutral light switch 23 Rear brake light switch 24 Rear right indicator 25 Solenoid...

Page 248: ...ws Press down on the locking tab where fitted WARNING Never separate two connectors by pulling on the wiring Grasp both connectors and pull them in opposite directions until they become separated Remove any dirt rust moisture etc from inside the connector blowing with compressed air Ensure that the wires are securely crimped to the terminals inside each connector NOTE A connector will only locate ...

Page 249: ...ith distilled water only INSPECTION In the event of abnormal operation check the charge system first see 8 5 1 To check the battery Remove the battery from the vehicle see 7 2 1 and proceed as follows Visually check for extensive sulphation typically evident due to one or more parts that become white electrolyte level between MIN and MAX marks leaks from outer casing housing Slow charge the batter...

Page 250: ...Y RULES WARNING Battery electrolyte fluid contains sulphuric acid Keep away from the skin and clothes Keep the battery well away from any sources of ignition such as flames sparks or any heat sources because hydrogen output might ignite ...

Page 251: ...L SWITCH G N G B G Bi TROUBLESHOOTING Check that the 7 5A and 20A fuses are in good condition Check the spark plug and replace as required Check the high tension cable and the spark plug cover Check the coil Check the pick up Connect the green brown wire to ground If the ignition works check the stand logic circuit see 8 12 1 Fit a substitute CDI unit known to be operating properly ...

Page 252: ...rking order resistance readings should approximate the standard values Coil winding resistance Primary 0 11 0 21 ohm Secondary 4 3 8 1 kOhm Pick up test Disconnect the connector of the pick up terminals Measure resistance across the terminals of the yellow blue and yellow green wires using a multimeter set to the 1000 ohm range Correct reading is in the 190 300 ohm range Infinite resistance or a r...

Page 253: ...SYSTEM TEST Start the engine and rev it up to 6000 rpm Measure DC voltage across battery terminals using a multimeter set to the DC voltage scale Switch on the low beam lights Correct voltage reading is 13 5 to 15 Volts V TROUBLESHOOTING Check the condition of the 20A fuse Check the connections of flywheel regulator and fuse leads Check the flywheel Check the battery see 8 3 1 Replace the regulato...

Page 254: ...connect the alternator wiring connector Start the engine and rev it up to 5 000 rpm Measure AC voltage across the three yellow wires using a hand held multimeter A reading below 53 V indicates a faulty alternator Standard loadless voltage over 53 VAC at 6000 rpm ...

Page 255: ...ect the green brown wire to ground If the starter is still working check the stand starter logic circuit see 8 12 1 TEST READINGS Starter relay test To test relay operation Feed 12 Volts to the two male terminals 85 86 Check for continuity between the other two terminals 87 30 using a multimeter set to the ohm range Correct reading when relay is fed 0 Ω Correct reading when relay is not fed Ω Repl...

Page 256: ...CTRICAL SYSTEM 8 12 RS 125 Starter motor test Connect a 12 V 9 AH battery to the starter motor Measure current draw during regular operation after 5 seconds using a DC ampere meter Correct reading 50 60 A ...

Page 257: ...EV COUNTER CIRCUIT 15 A V Bi Vi CDI V B V Vi Bi N COIL THERMISTOR OIL LEVEL SENSOR OIL WARNING LIGHT LED WATER T DISPLAY REV COUNTER KEY TROUBLESHOOTING Check the condition of the 15A fuse Check wiring connection Rev counter Fit a substitute rev counter known to operate properly ...

Page 258: ... the display Resistor rating Display indication 1 000 Ω COLD 50 Ω 90 95 C 15 Ω 120 130 C If display indications are correct change the thermistor Otherwise change the display Key 1 Resistor 2 Thermistor 1 2 V Gr Oil level sensor test Disconnect all leads at the wiring harness end and remove the sensor from the frame Attach a multimeter set to the ohm range to the sensor Hold sensor vertically Corr...

Page 259: ... Bi V R Gr B V Gr Az B N R Gr B Az B N G N PASSING L B 3 5 2 1 4 6 8 11 12 10 9 7 Key 1 Left hand light dip switch 2 Warning horn 3 Fuse 15A 4 Fuse 20A 5 Key 6 Battery 7 Flasher 8 Rear right indicator bulb 9 Rear left indicator bulb 10 Front right indicator bulb 11 Front left indicator bulb 12 Indicator light ...

Page 260: ...er To test flasher operation Disconnect the connector 1 of the flasher 2 Fit a jumper across connector 1 Operate the direction indicator control 3 If the indicator lights come on but do not flash replace the flasher 2 It may also be necessary to check the 20 A main fuses and the electrical system When the bulb of a direction indicator burns out each time the control 3 is operated the other indicat...

Page 261: ...TEM 8 17 RS 125 8 9 BRAKE LIGHTS CIRCUIT 8 9 1 BRAKE LIGHTS CIRCUIT V G V C 6 4 7 8 3 1 2 5 Key 1 Front brake light switch 2 Rear brake light switch 3 Fuse 15 A 4 Fuse 20 A 5 Key 6 Battery 7 Tail light 8 Brake lights ...

Page 262: ... of the brake light bulb Switches Check switches for continuity using a multimeter Please refer to the relevant diagram Replace any switch assembly found to deviate from the specified mode of operation Front brake light switch Wires Position V V G Activated Rear brake light switch Wires Position V V G Activated ...

Page 263: ...G N RH LIGHT SWITCH LH LIGHT SWITCH PASSING BUTTON HIGH BEAM W LIGHT LOW BEAM N Bi V FRONT PARKING LIGHT REAR PARKING LIGHT INSTRUMENT PANEL LIGHTS TROUBLESHOOTING Check the condition of the 15A and 20A fuses Check the right and left light dip switches for proper operation Check bulb operation ...

Page 264: ... for continuity across the contacts using a multimeter set to the ohm range Please refer to the relevant diagram V N G N V G R G R R N START OFF RH DIP SWITCH LH DIP SWITCH Az R V N Bi Gr B N G N B N PASSING V N V R G R R N START OFF RH DIP SWITCH ADS VERSION ...

Page 265: ...st end at 8100 rpm TROUBLESHOOTING Check the condition of the 15 A fuse Attach a 12V battery direct to the solenoid to check for proper operation Check the flywheel see 8 6 1 Fit a substitute regulator known to operate correctly Fit a substitute RAVE control unit known to operate correctly WARNING Cut the jumper across the grey and red wires of the RAVE control unit and the solenoid will operate t...

Page 266: ...ltage across the yellow G and blue B wires using a multimeter Correct reading 8 5 1 VAC NOTE Any readings other than the specified values indicate a fault in the system not in the control unit SOLENOID Check that the piston moves freely Start the engine and let it idle Measure resistance across the wires using a multimeter Correct reading 2 2 Ohms 10 Measure voltage across the solenoid wires using...

Page 267: ...ER RELAY STAND W LIGHT DIODE M N M B 15 Engine starting and ignition are inhibited when the stand is down and or a gear is engaged TROUBLESHOOTING Check the condition of the 15 A fuses Check the neutral light switch Check the stand switch Check the diode Check the starter relay see 8 6 1 Fit a substitute CDI unit known to be operating correctly ...

Page 268: ...t Wires Pos SCREW V G Neutral Stand test Wires Stand position M V N Down Up DIODE TEST To test diode operation Disconnect the two way connector 1 coloured white WARNING Make sure to refit the connector 1 to the matching connector on assembly Place a multimeter in the diode test mode and measure across the two male terminals accommodated inside the diode as shown in the diagram ...

Page 269: ...ltimeter does not include a diode test feature feed 12 Volts to the diode fit a 12 V 2 W bulb to the positive lead and connect the leads to the diode as shown in the diagram WARNING Do not use a bulb rated higher than 2 W or the diode will damage Test C the bulb stays off Test D the bulb comes on ...

Page 270: ...end of the front fairing grasp the bulb holder 1 and pull until clear of its seat Withdraw the parking light bulb 2 and fit a new bulb of equal rating HIGH BEAM BULB Working from the rear right end of the front fairing slip off the dust cover 3 with your fingers Withdraw the electrical connector 4 Release the retainer 5 at the rear of the bulb holder 6 Extract the bulb NOTE Make sure the locating ...

Page 271: ... 12 carefully and do not overtighten to avoid damage to the guard FRONT AND REAR INDICATOR BULBS Place the motorcycle on the stand Release and remove the screw 14 NOTE Be careful when removing the guard or the locating tab might break off Remove the guard 15 NOTE On refitting make sure the guard locates correctly into its seat Tighten the screw 14 carefully and do not overtighten to avoid damage t...

Page 272: ...rcuits Lift the fuel tank see 2 9 1 NOTE When the 20A fuse is removed the digital clock will be reset to zero Please read 2 3 1 for instructions on how to set the clock again Extract all fuses one by one and check for blown fuses When you find a blown fuse determine and rectify the cause if possible before fitting a new fuse Replace any failed fuses with a fuse of equal current rating NOTE When yo...

Page 273: ...le be on level ground Switch on the low beam and sit astride the motorcycle The light spot on the wall should be just below the horizontal line of the headlight about nine tenths of overall height 9 10 H 10 m H To set beam height Working from the rear left end of the front fairing turn the adjuster screw using a short Phillips screwdriver TURN IN clockwise to raise the beam TURN OUT anti clockwise...

Page 274: ...ELECTRICAL SYSTEM 8 30 RS 125 8 16 WIRING DIAGRAM 8 16 1 WIRING DIAGRAM ...

Page 275: ...Complete instrument panel 22 Multi function display 23 Instrument panel lights 24 Side stand down light 25 Solenoid 26 Neutral light 27 Mixer oil low light LED 28 High beam pilot light 29 Indicator repeater light 30 Warning horn 31 Front right direction indicator 32 Low beam lamp 33 Front parking light 34 Front left direction indicator 35 RAVE control unit 36 Multiple connectors 37 Spark plug 38 H...

Page 276: ...ELECTRICAL SYSTEM 8 32 RS 125 THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK ...

Page 277: ...TROUBLESHOOTING INFORMATION RS 125 TROUBLESHOOTING INFORMATION 9 9 1 ...

Page 278: ...RY 9 1 TROUBLESHOOTING INFORMATION 3 9 1 1 ENGINE 3 9 1 2 CARBURETOR 5 9 1 3 RADIATOR 5 9 1 4 ELECTRICAL SYSTEM 6 9 1 5 BATTERY 6 9 1 6 BRAKES 7 9 1 7 CHASSIS 7 9 2 HOSE ROUTING 8 9 2 1 ROUTING AND CONNECTIONS OF WIRING CABLES AND HOSES 8 9 2 ...

Page 279: ... Replace Crankshaft seal worn Replace No spark Foul spark plug Replace Wet spark plug Clean and dry Defective coil Replace High tension cable interrupted or shorted Replace Ignition system fault Repair or replace Carburetor is receiving no fuel Breather hole in filler cap clogged Clean Fuel cock clogged or defective Clean or replace Carburetor needle valve defective Replace Engine does not start o...

Page 280: ...djust Air cleaner clogged Clean Air leaking past the intake duct Tighten or replace Loss of engine power Engine is receiving too much oil Adjust the oil pump Too much carbon build up on piston crown Clean Engine is receiving insufficient oil Adjust the oil pump Oil pump faulty or oilways obstructed Replace or clean Fuel level in carburetor float chamber too low Adjust Air leaking into intake duct ...

Page 281: ...rottle valve op eration Erratic operation in the mid to high speed range Filter obstructed Inspect and clean Needle valve worn or damaged Replace Float is malfunctioning Check and adjust Debris build up on needle valve Clean Fuel level too high or too low Adjust float height Carburetor breather hose obstructed Clean Erratic overflow and fuel level Needle valve spring broken Replace 9 1 3 RADIATOR ...

Page 282: ... to earth or interrupted Replace Regulator rectifier faulty Replace Generator is undercharging the battery Faulty battery Replace Short circuit inside battery Replace the battery Regulator rectifier damaged or faulty Replace Generator is overcharging the battery Erratic regulator rectifier ground Clean and tighten the ground terminals Terminal insulator worn due to vibration is causing transient s...

Page 283: ...ce Steering stem distorted Replace Hard steering Tyre underinflated Adjust Uneven front fork settings Adjust Front fork buckled Replace Handlebars shake Front wheel rim and or tyre warped Replace Wheel rim warped Replace Front wheel hub bearings worn Sostituire Tyre defective or does not meet specification Replace Wheel spindle nut loose Tighten Front wheel wobbles Front fork oil does not meet spe...

Page 284: ...TROUBLESHOOTING INFORMATION RS 125 9 2 HOSE ROUTING 9 2 1 ROUTING AND CONNECTIONS OF WIRING CABLES AND HOSES FRONT BRAKE HOSES B A REAR BRAKE HOSES C D 9 8 ...

Page 285: ...TROUBLESHOOTING INFORMATION RS 125 FUEL SYSTEM HOSES OIL TUBES B F E G H I 9 9 ...

Page 286: ...TROUBLESHOOTING INFORMATION RS 125 CLUTCH CABLE M L COLD START CABLE N I 9 10 ...

Page 287: ...TROUBLESHOOTING INFORMATION RS 125 THROTTLE CABLE A O H I 9 11 ...

Page 288: ...TROUBLESHOOTING INFORMATION RS 125 COOLING SYSTEM P Q 9 12 ...

Page 289: ...TROUBLESHOOTING INFORMATION RS 125 R T S 9 13 ...

Page 290: ...TROUBLESHOOTING INFORMATION RS 125 THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK 9 14 ...

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