APRILIA RS4 125 Service Station Manual Download Page 140

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Gearbox

Gearbox shafts

Disassembling the gearbox

•

Open the crankcase halves.

•

Remove the gaskets from the crank-

case.

•

Take out both fork rods and the trans-

mission forks (1) (2).

•

Take out the desmodromic control (3).

•

Take out the secondary axle (4).

•

Take out the primary axle (5).

See also

Crankcase opening

Checking the primary shaft

COUPLING CLASSES

The gears of the primary drive are classified according to the coupling with the gear of the clutch housing

and with the gear of the balancing countershaft and follow the logic shown in the tables listed below:

COUPLING CLASSES CLUTCH HOUSING - FIRST GEAR SHAFT

Coupling classes on Crankcase

Clutch housing gear

Transmission gear

COUPLING CLASSES FIRST GEAR SHAFT - BALANCING COUNTERSHAFT

Coupling classes on Crankcase

Transmission gear

Balancing countershaft gear

NOTE

Engine

RS4 125

ENG - 140

Summary of Contents for RS4 125

Page 1: ...SERVICE STATION MANUAL B043126 RS4 125 ...

Page 2: ...e developed and tested during the actual vehicle design stage All Aprilia Original Spare Parts undergo quality control procedures to guarantee reliability and durability The descriptions and illustrations given in this publication are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged Aprilia reserves the right at any time and without being re...

Page 3: ...to prevent injuries to the repairer Personal safety Failure to completely observe these instructions will result in serious risk of personal injury Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment Vehicle intactness The incomplete or non observance of these regulations leads to the risk of serious damage to th...

Page 4: ...R SPECIAL TOOLS S TOOLS MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS BODYWORK BODYW PRE DELIVERY PRE DE ...

Page 5: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 6: ...Y CAUSE THEM TO IGNITE OR EXPLODE DO NOT DISPERSE FUEL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off When handling these components wear insulating gloves or wait until the engine and the exhaust system have cooled down Coolant The coolant contains ...

Page 7: ...EAN WATER AND SEEK MEDICAL ADVICE KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELECTROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID RINSE WELL WITH PLENT...

Page 8: ...before reassembling them When tightening nuts and screws start either from the components with the largest diameter or from the innermost components proceeding diagonally Tighten nuts and screws in suc cessive steps before applying the tightening torque Always replace self locking nuts washers sealing rings circlips O rings OR cotter pins and screws with new parts if the thread is damaged When ass...

Page 9: ...ISING VEHICLE HANDLING THIS MAY LEAD TO FALLS WITH THE RISK OF SERIOUS INJURY OR DEATH Running in Running the engine in correctly is essential for ensuring engine longevity and functionality Twisty roads and gradients are ideal for running in the engine brakes and suspension effectively Vary your riding speed during the running in period This ensures that components operate in loaded conditions an...

Page 10: ...IONS Specification Desc Quantity Maximum length 1 953 mm 76 89 in Maximum width with mirrors 740 mm 29 13 in Maximum height to the windshield 1 138 mm 44 80 in Saddle height 837 mm 32 95 in Height passenger saddle 978 mm 38 50 in Height handlebar 840 mm 33 07 in Minimum ground clearance 137 mm 5 39 in Wheelbase 1 350 mm 53 15 in Kerb weight 140 kg 308 64 lb Weight without fuel 135 8 kg 299 39 lb E...

Page 11: ... Quantity Fuel tank 14 5 0 5 l 3 19 0 11 UK gal 3 83 0 13 US gal Fuel tank reserve 3 3 l 3 19 0 72 UK gal 0 87 USgal Engine oil 1 200 cm 73 23 cu in Seats 2 Coolant 0 78 l 0 171 UKgal 0 206 US gal Coolant reserve 0 23 l 0 0506 UKgal 0 0607 US gal Vehicle maximum load rider passenger luggage 180 kg 396 83 lb Vehicle load without passenger rider luggage 105 kg 231 48 lb Electrical system IGNITION Sp...

Page 12: ...ock absorber Rear wheel travel 122 mm 4 80 in Brakes BRAKES Specification Desc Quantity Front Ø 300 mm 11 81 in disc brake Rear Ø 218 mm 8 58 in disc brake Wheels and tyres WHEEL RIMS Specification Desc Quantity Type made of light alloy Front 2 75 x 17 Rear 3 50 x 17 TYRES Specification Desc Quantity Front size where applicable for approvals 100 80 17 52H or alternatively 110 70 17 54H Front infla...

Page 13: ...ne rating of 95 NORM and 85 NOMM Tightening Torques Chassis Front side FRONT LIGHTS pos Description Type Quantity Torque Notes 1 Headlamp fixing screw M5x14 4 2 5 Nm 1 84 lbf ft 2 Self tapping screw M5 1 1 5 Nm 1 11 lbf ft 3 Turn indicator fixing screw M5 2 1 5 Nm 1 11 lbf ft RS4 125 Characteristics CHAR 13 ...

Page 14: ...STEERING pos Description Type Quantity Torque Notes 1 Upper yoke fastening to sleeve M8 2 25 Nm 18 43 lbf ft 2 Steering retainer nut M20 1 48 Nm 35 40 lbf ft Characteristics RS4 125 CHAR 14 ...

Page 15: ...tes 1 Screws fastening lower yoke to sleeve M8 2x2 25 Nm 8 43 lbf ft FRONT WHEEL pos Description Type Quantity Torque Notes 1 Front wheel spindle nut M14 1 78 Nm 8 85 lbf ft 2 Front disc fixing screw M6x20 6 12 Nm 8 85 lbf ft RS4 125 Characteristics CHAR 15 ...

Page 16: ...rew M6x25 3 4 4 Nm 3 24 lbf ft 5 Nm 3 68 lbf ft 4 Flanged self locking nut M6 1 6 Nm 4 42 lbf ft 5 Screws fastening lower fairing to cra dle M5x12 4 3 Nm 2 21 lbf ft 6 Front mudguard support fixing screw M6x20 2 5 Nm 3 68 lbf ft Max 6 N 4 42 lbf ft 7 Fairing spacer M6 1 12 Nm 8 85 lbf ft 8 Right Left fairing support fixing screw M5 2 2 5 Nm 3 69 lbf ft Characteristics RS4 125 CHAR 16 ...

Page 17: ... 1 Radiator frame screw M5x16 1 2 Nm 1 47 lbf ft Max 2 5 N 1 84 lbf ft 2 Front fixing screw Self t 3 9 2 1 Nm 0 74 lbf ft 3 TCEI screw M5x20 2 2 Nm 1 47 lbf ft Max 2 5 N 1 84 lbf ft 4 Flanged TBEI screw M5x16 2 3 Nm 2 21 lbf ft RS4 125 Characteristics CHAR 17 ...

Page 18: ...2 25 Nm 18 44 lbf ft Loctite 243 2 Handlebar counterweight retainer M5x50 2 5 Nm 3 69 lbf ft Loctite 243 INSTRUMENT PANEL pos Description Type Quantity Torque Notes 1 Self tapping screw M5x4 3 2 5 Nm 1 84 lbf ft 2 Instrument panel fixing screw M5x20 6 2 Nm 1 47 lbf ft Characteristics RS4 125 CHAR 18 ...

Page 19: ...s 1 Front brake pump fixing screw M5 2 5 Nm 3 68 lbf ft 2 Brake pipe clamp fixing screw M5x16 1 5 Nm 3 68 lbf ft FRONT CALLIPER pos Description Type Quantity Torque Notes 1 Front calliper fixing screw M10x60 2 50 Nm 36 87 lbf ft RS4 125 Characteristics CHAR 19 ...

Page 20: ...rottle cable ring fixing screw M6x16 1 6 Nm 4 42 lbf ft 2 Throttle control fixing screw M6x20 1 10 Nm 7 37 lbf ft WINDSHIELD pos Description Type Quantity Torque Notes 1 Rear view mirror fixing screw Self t 3 9 4 0 4 Nm 0 29 lbf ft Characteristics RS4 125 CHAR 20 ...

Page 21: ... Quantity Torque Notes 1 Support coil fixing screw M8 2 20 Nm 14 75 lbf ft 2 TCEI screw M8 2 25 Nm 18 43 lbf ft 3 TCEI screw M10x45 4 50 Nm 36 88 lbf ft 4 TE screw M8x40 2 25 Nm 18 43 lbf ft 5 TE screw M6x16 2 12 Nm 8 85 lbf ft Loctite 243 6 Right and left engine mount M10x16 2 38 Nm 28 02 lbf ft Loctite 243 RS4 125 Characteristics CHAR 21 ...

Page 22: ...Nm 2 21 lbf ft 3 Side fairing to chassis fixing screw M5x9 2 3 Nm 2 21 lbf ft 4 Side fairing to chassis fixing screw M5x9 2 3 Nm 2 21 lbf ft 5 SWP Screw M5x20 2 2 Nm 1 47 lbf ft 6 Self tapping screw 3 9x10 4 0 4 Nm 0 29 lbf ft 7 Self tapping screw M5x14 2 1 5 Nm 1 11 lbf ft 8 TBEI screw M5x12 1 3 Nm 2 21 lbf ft Characteristics RS4 125 CHAR 22 ...

Page 23: ...rque Notes 1 Rear tank fixing screw M8x40 1 1 25 Nm 18 44 lbf ft 2 Front tank fixing screw M6x35 1 10 Nm 7 37 lbf ft 3 Fastener screw M5x9 4 3 Nm 2 21 lbf ft 4 Tank cover fixing screw M5x9 4 3 Nm 2 21 lbf ft RS4 125 Characteristics CHAR 23 ...

Page 24: ...tes 1 Side fairing fixing screw M5x9 6 1 7 Nm 1 25 lbf ft Max 2 Nm 1 47 lbf ft EXHAUST pos Description Type Quantity Torque Notes 1 Drainage retainer M6x20 2 10 Nm 7 37 lbf ft 2 Footrest retainer M8x40 1 25 Nm 18 43 lbf ft Characteristics RS4 125 CHAR 24 ...

Page 25: ...RADIATOR pos Description Type Quantity Torque Notes 1 Radiator retainer M6x25 2 10 Nm 7 37 lbf ft 2 Expansion tank support fixing screw M6x20 1 3 5 4 Nm 2 58 2 95 lbf ft RS4 125 Characteristics CHAR 25 ...

Page 26: ...Nm 3 69 lbf ft 3 Passenger footrest fixing screw M8x40 4 20 Nm 14 75 lbf ft 4 Rider pedal retainer M8x26 2 25 Nm 18 44 lbf ft REAR BRAKING SYSTEM pos Description Type Quantity Torque Notes 1 Brake lever fixing screw M6x40 1 12 Nm 8 85 lbf ft 2 Rear brake pump fixing screw M6x30 2 10 Nm 7 37 lbf ft 3 Brake pump joint retainer M6 1 10 Nm 7 37 lbf ft Characteristics RS4 125 CHAR 26 ...

Page 27: ...ype Quantity Torque Notes 1 Fairing upper fixing screw M5x9 6 3 Nm 2 21 lbf ft 2 Fairing lower fixing screw M4x14 2 STAND pos Description Type Quantity Torque Notes 1 Thin nut M10x1 25 1 10 Nm 7 38 lb ft RS4 125 Characteristics CHAR 27 ...

Page 28: ...s Flang M5x25 2 3 Nm 2 21 lb ft 5 TE Screws M6x30 2 10 Nm 7 38 lb ft LOCKS pos Description Type Quantity Torque Notes 1 Fuel tank cap retainer M5x16 3 3 Nm 2 21 lb ft 2 Fuel tank cap retainer M5x30 2 3 Nm 2 21 lb ft 3 Saddle lock retainer M6x30 2 6 Nm 4 42 lb ft 4 Steering lock retainer M8x20 2 6 5 Nm 4 79 lb ft Characteristics RS4 125 CHAR 28 ...

Page 29: ...Back side REAR SUSPENSION pos Description Type Quantity Torque Notes 1 Upper retainer M12 1 58 Nm 42 78 lbf ft 2 Lower retainer M12 1 58 Nm 42 78 lbf ft Loctite 243 RS4 125 Characteristics CHAR 29 ...

Page 30: ...fixing screw M 4 8x13 4 1 Nm 0 74 lbf ft 4 Chainguard fixing screw Self tap 2 REAR WHEEL pos Description Type Quantity Torque Notes 1 Rear wheel axle nut M14 2 78 Nm 57 53 lbf ft 2 Rear disc fixing screw M6x20 6 12 Nm 8 85 lbf ft 3 Sprocket fixing screw TEF M8 6 25 Nm 18 44 lbf ft 4 Chain tensor fixing screw M8 2 12 Nm 8 85 lbf ft Loctite 243 Characteristics RS4 125 CHAR 30 ...

Page 31: ...REAR LIGHTS pos Description Type Quantity Torque Notes 1 Turn indicator retainer M5 2 3 Nm 2 21 lbf ft 2 Turn indicator cover retainer 2 2 0 3 Nm 0 22 lbf ft RS4 125 Characteristics CHAR 31 ...

Page 32: ...tes 1 Rear mudguard to swingarm fixing screw Self tap 4 3 Nm 2 21 lbf ft Max 4 5 Nm 3 31 lbf ft Engine CRANKSHAFT pos Description Type Quantity Torque Notes 1 Countershaft gear retainer nut M10 1 35 45 Nm 25 81 33 19 lbf ft Characteristics RS4 125 CHAR 32 ...

Page 33: ...ription Type Quantity Torque Notes 1 Chain tensioner screw M8 1 6 Nm 4 43 lbf ft THROTTLE BODY pos Description Type Quantity Torque Notes 1 Intake manifold fixing screw M6x20 3 10 Nm 7 38 lbf ft RS4 125 Characteristics CHAR 33 ...

Page 34: ...ype Quantity Torque Notes 1 Clutch cover fixing screw M6x35 10 11 13 Nm 8 11 9 58 lbf ft 2 Oil filter cover M56x1 5 1 24 26 Nm 17 70 19 17lbf ft 3 Oil pressure sensor M10 1 12 14 Nm 8 85 10 32 lbf ft Characteristics RS4 125 CHAR 34 ...

Page 35: ...cover fixing screw M6 4 10 12 Nm 7 38 8 85 lbf ft FLYWHEEL COVER pos Description Type Quantity Torque Notes 1 Flywheel cover fastener screw M6 10 11 13 Nm 8 11 9 58 lbf ft 2 Timing control cover M18 2 3 5 4 5 Nm 2 58 3 31 lbf ft 3 Oil dipstick M12x1 5 1 4 6 Nm 2 95 4 42 lbf ft RS4 125 Characteristics CHAR 35 ...

Page 36: ...tion Type Quantity Torque Notes 1 Chain tensioner slider fulcrum fixing screw M6x16 1 10 Nm 7 38 lbf ft Loctite 243 2 Transmission timing gear fixing screw M8x40 1 27 Nm 19 91 lbf ft Loctite 243 Characteristics RS4 125 CHAR 36 ...

Page 37: ...spring screw M5 5 3 5 4 5 Nm 2 58 3 31 lbf ft 2 Clutch housing retainer nut M12 1 35 45 Nm 25 81 33 19 lbf ft STARTER MOTOR pos Description Type Quantity Torque Notes 1 Starter motor fixing screw M6x25 2 11 13 Nm 8 11 9 58 lbf ft RS4 125 Characteristics CHAR 37 ...

Page 38: ... Type Quantity Torque Notes 1 Water pump fixing screw M5 3 5 6 Nm 3 68 4 42 lbf ft OIL PUMP pos Description Type Quantity Torque Notes 1 Oil pump fixing screw M6x25 3 10 Nm 7 38 lbf ft Loctite 243 Characteristics RS4 125 CHAR 38 ...

Page 39: ...GEAR SELECTOR pos Description Type Quantity Torque Notes 1 Selector spider screw M5 1 3 5 4 5 Nm 2 58 3 31 lbf ft 2 Engaging lever screw M6 1 8 10 Nm 5 90 7 38 lbf ft RS4 125 Characteristics CHAR 39 ...

Page 40: ...Type Quantity Torque Notes 1 Head fastener screw chain side M6x130 2 11 Nm 8 11 lbf ft 2 Exhaust side fixing stud bolt M8x40 2 12 Nm 8 85 lbf ft 3 Camshaft support fixing screw M6x40 8 10 Nm 7 38 lbf ft 4 Head fixing screw M8x166 4 25 Nm 90 18 44 lbf ft 90 5 Thermostat cover fixing screw M6x20 2 10 Nm 7 38 lbf ft Characteristics RS4 125 CHAR 40 ...

Page 41: ...e Quantity Torque Notes 1 Flywheel rotor fixing screw M14x1 5 1 83 90 Nm 61 21 66 38 lb ft LEVERS pos Description Type Quantity Torque Note 1 Pinion retainer nut M12x1 25 1 30 Nm 22 12 lb ft Loctite 270 RS4 125 Characteristics CHAR 41 ...

Page 42: ...all end Maximum diameter 15 023 mm 0 591 in Standard diameter 15 010 15 018 mm 0 5910 0 5912 in Crankcase crankshaft connecting rod BUSHING SEAT DIAMETER ON CRANKCASE Specification Desc Quantity Class 1 MIN 36 500 mm 1 4370 in MAX 36 508 mm 1 4373 in Class 2 MIN 36 508 mm 1 4373 in MAX 36 516 mm 1 4376 in CRANKSHAFT DIAMETER Specification Desc Quantity Class 1 MIN 32 480 mm 1 2787 in MAX 32 485 mm...

Page 43: ...be used in mixtures with de ionised water AGIP BRAKE 4 Brake fluid As an alternative to the recommended fluid other fluids that meet or exceed the required specifications may be used SAE J1703 NHTSA 116 DOT 4 ISO 4925 Synthetic fluid AGIP GREASE 30 Grease for steering bearings pin seats and swinging arm NEUTRAL GREASE OR PETROLEUM JELLY BATTERY POLES Neutral grease or petroleum jelly AGIP CHAIN GR...

Page 44: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 45: ...cription AP8140266 Dial gauge mounting 866380 Water pump tool set 865259 Flywheel retainer 864868 Flywheel extractor 020911Y Fitting adaptor engine RS 125 020710Y 864567 Locking pins timing camshafts RS4 125 Special tools S TOOLS 45 ...

Page 46: ... the countershaft 00H05600351 Guide for oil seal 020382Y011 Tool to remove fit valves 020287Y tool for sealing ring fitting 865261 Piston locking pin 00H05300041 Clutch retainer 865260 Camshaft sprocket lock Special tools RS4 125 S TOOLS 46 ...

Page 47: ...apter handle 020359Y 42 x 47 mm adaptor 020358Y 37 x 40 mm adaptor 020357Y 32 x 35 mm adaptor 020439Y Shaft 2 oil seal punch 17 mm 020891Y Adapter 25 mm 0 98 in 020363Y Crankshaft oil seal punch D 20 mm RS4 125 Special tools S TOOLS 47 ...

Page 48: ...Stores code Description 020412Y Clutch oil seal punch D 15 mm 020375Y 28x30 mm punch 020483Y 30 mm guide 020364Y 25 mm Adaptor 866714 Swingarm adjustment Special tools RS4 125 S TOOLS 48 ...

Page 49: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 50: ...RICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE 1 Grease every 500 Km 310 mi and before each use in severe conditions 2 Replace every 2 years or 18000 Km 11185 mi 3 Replace every four years 4 Check every month 5 Check at each starter brakes direction clutch suspension engine lights warning lights 6 Replace when reaching the first of the following two options 36 000 km 22 369 ...

Page 51: ...n of the spark plug check that the insulating material is whole and measure the distance between the electrodes using a feeler gauge Adjust the distance if necessary by bending the side electrode very carefully In the case of defects replace the spark plug with one of the specified type Engage the spark plug with the due inclination and screw it right down by hand then do it up with the wrench at ...

Page 52: ...TILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL PREFERABLY CHECK THE OIL AFTER A JOURNEY OF AFTER TRAVELLING APPROXIMATELY 15 Km 10 miles IN EXTRAURBAN CONDITIONS ENOUGH TO WARM UP THE ENGINE OIL TO OPERATING TEMPERATURE Stop the engine and wait at least five minutes Keep the vehicle upright with both wheels on the ground Working on the left hand side of the engine un...

Page 53: ...in the reservoir until you reach the correct level Replacement Remove the left fairing lug beforehand Start the engine and let it idle for a few minutes in this way it is easier to drain the oil during the subsequent drainage stage CAUTION PARK THE MOTORCYCLE ON SAFE AND LEVEL GROUND Shut off the engine OIL BECOMES VERY HOT WHEN THE ENGINE IS HOT BE CAREFUL NOT TO GET BURNED WHEN CARRYING OUT THE ...

Page 54: ... quirements of CCMC G 4 A P I SG specifications can be used Characteristic Engine oil 1 200 cm 73 23 cu in Screw the filler plug 1 Start the engine and let it at idle speed for about a minute to allow the oil circuit to get filled Check the oil level and refill if necessary TIGHTEN UP THE FILLER CAP AND MAKE SURE THE OIL DOES NOT SEEP CHECK REGULARLY THAT THERE ARE NO LEAKS IN THE CRANKCASE COVER ...

Page 55: ...e the spring and oil filter Gearbox Oil Air filter Remove the passenger saddle and collect the supporting rod of the fuel tank Lift the fuel tank and fasten it with the supporting rod Unscrew and remove the two screws 1 RS4 125 Maintenance MAIN 55 ...

Page 56: ...INLET DUCTS AIR FILTER CLEANING DO NOT USE SCREWDRIVERS OR ANY OTHER ELEMENT ON THE FILTER Clean the air filter 4 with a blast of compressed air direct from the inner to the outer part of the filter Clean the external side of the air filter 4 with a clean cloth Clean the inside of the filter casing 5 and the intake ducts 6 with a clean cloth CAUTION WHEN CLEANING THE FILTERING ELEMENT CHECK THAT I...

Page 57: ...elow zero degrees centigrade check the cooling system fre quently and add more antifreeze solution if needed up to 60 max Use distilled water in the coolant mixture to avoid damaging the engine DO NOT REMOVE THE EXPANSION TANK PLUG WHEN THE ENGINE IS HOT SINCE COOLANT IS UNDER PRESSURE AND VERY HOT CAUTION WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING UP COOLANT LEVEL Level check Mak...

Page 58: ...TED CONTACT WITH YOUR EYES OR SKIN MAY CAUSE IRRITA TION IF THE FLUID GETS IN CONTACT WITH THE EYES OR SKIN RINSE REPEATEDLY WITH PLENTY OF WATER AND SEEK MEDICAL ADVICE IF SWALLOWED INDUCE VOMITING RINSE MOUTH AND THROAT WITH PLENTY OF WATER AND SEEK MEDICAL ADVICE IMMEDIATELY Braking system Level check Periodically check the brake fluid level via the brake fluid reservoir sight glasses 1 2 locat...

Page 59: ...r on its stand For the front brake turn the handlebar fully to the right For the rear brake keep the vehicle upright so that the fluid in the reservoir is at the same level with the plug Check that the fluid level in the reser voir is above the MIN reference mark MIN minimum level MAX maximum level If the fluid does not reach at least the MIN refer ence mark Check the brake pads and disc for wear ...

Page 60: ...D RESERVOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE Lift and remove the cover and seals TO AVOID SPILLING FLUID WHILE TOPPING UP KEEP THE TANK PARALLEL TO THE RESERVOIR EDGE IN HORIZONTAL POSITION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN Top up the tank you are working on un til the ...

Page 61: ...NT IS USED MAKE SURE THAT IT IS PERFECTLY CLEAN Recommended products AGIP BRAKE 4 Brake fluid As an alternative to the recommended fluid other fluids that meet or exceed the required specifica tions may be used SAE J1703 NHTSA 116 DOT 4 ISO 4925 Synthetic fluid FRONT BRAKE FLUID TOP UP Unscrew and remove the cap 1 Remove the gasket 2 CAUTION DO NOT EXCEED THE MAX LEVEL MARK WHEN TOPPING UP TOP UP ...

Page 62: ... vehicle on its stand Remove the protection casing 2 Loosen the lock nut 3 Turn the set screw 1 until the empty travel at the clutch lever end is approx imately 10 15 mm 0 39 0 59 in see figure After adjusting tighten the check nut 3 to lock the adjuster screw 1 Check the empty travel at the clutch lever end Refit he protection casing 2 NOTE CHECK THE CLUTCH WIRE IS IN GOOD CONDITIONS THERE SHOULD...

Page 63: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 64: ...Components arrangement KEY 1 Stop switch 2 Taillight 3 Injector Electrical system RS4 125 ELE SYS 64 ...

Page 65: ...lity The purpose of this document is to define the position of the vehicle cable harness its routing and how it is fixed on the chassis tool kit compartment support and the saddle mounting any potential problems and particular checks to be carried out on the connections and routings in order to reach the objectives of vehicle reliability Materials used and corresponding quantities The electrical s...

Page 66: ...sponge on the license plate bracket light REAR SEC TION TABLE B2 Check the ECU connection cable and insertion of protective rubber CENTRAL SECTION TABLE E4 Check correct securing of metallic bracket screw on the throttle body CENTRAL SECTION TABLE E5 Check injector connection CENTRAL SECTION TABLE E3 Check water temperature sensor connection CENTRAL SECTION TABLE E4 Check injector and water temper...

Page 67: ... connection of the other connectors is also important and essential for proper vehicle operation It is also important and essential that the instructions regarding the routing and fixing of the cable har ness in the various areas are followed meticulously in order to guarantee functionality and reliability WIRING DIAGRAM Ensure that you have the most up to date electrical circuit diagram downloadi...

Page 68: ...able harness TABLE A3 Headlight cable running right side 1 Daylight running light 5W 2 Cable guide 4 Low beam light 19 Turn indicator cable harness 20 Headlight cable harness TABLE A4 3 Lights relay 6 High beam bulb 7 Clamp 8 Grey sheathing Indicates that the connector must be connected to the central bulb high beam Electrical system RS4 125 ELE SYS 68 ...

Page 69: ...igh beam light 35W TABLE B SPEED SENSOR The speed sensor must be fixed with a clamp 11 on the clutch cable 9 and must be positioned with a wide radius bend in order to avoid damage 9 Clutch cable 10 Speed sensor cable 11 Clamp RS4 125 Electrical system ELE SYS 69 ...

Page 70: ...C TABLES LEFT AND RIGHT POSITIONING OF CABLES TABLE C1 12 Rubber clamp TABLE C2 12 Rubber clamp Electrical system RS4 125 ELE SYS 70 ...

Page 71: ...p must secure all cables inside the instrument holder support the main cable har ness must be secured with the clamp on the grey taping 14 Main cable harness TABLE D2 15 Front headlamp cable harness connector RS4 125 Electrical system ELE SYS 71 ...

Page 72: ...Clamps 17 Left light switch The clamp must secure the light switch cable 18 Right light switch The clamp must secure the light switch cable TABLE F KEY SWITCH 19 Starter cable 20 Key switch Electrical system RS4 125 ELE SYS 72 ...

Page 73: ...NG 22 Main cable harness 23 Regulator CAUTION CHECK THE CORRECT CONNECTION OF THE REGULA TOR IN THE AREA HIGHLIGHTED IN RED REGULATOR CA BLE BEHIND THE RADIATOR THE FLYWHEEL CONNEC TION MUST NOT COME OUT BUT MUST BE HIDDEN INSIDE THE PLASTIC OF THE COVER RS4 125 Electrical system ELE SYS 73 ...

Page 74: ...TABLE I FLYWHEEL POSITIONING CAUTION CHECK THE CORRECT CONNECTION OF THE FLY WHEEL Electrical system RS4 125 ELE SYS 74 ...

Page 75: ...Central part TABLE A PRE FITTING CHASSIS TABLE A1 1 Retaining clip 2 Cable guide 3 Cable guide throttle cable TABLE A2 RS4 125 Electrical system ELE SYS 75 ...

Page 76: ...TABLE A3 TABLE A4 TABLE A5 Free hole for chassis ground TABLE B FUEL RESERVE PROBE PRE FIT TING 4 Fuel pump 5 Fuel reserve sensor Electrical system RS4 125 ELE SYS 76 ...

Page 77: ...ckets 9 H V Cable 10 Elastic clip 11 Coil H V Cable connection CAUTION CHECK THAT THE H V CABLE IS PROPERLY CONNEC TED WITH THE COIL BE CAREFUL NOT TO DAMAGE THE TERMINAL DURING FITTING TABLE D2 10 Elastic clip 23 Coil ground 24 Coil connector CAUTION CONNECT THE COIL CONNECTOR 24 FIT THE BLUE GROUND CABLE 23 ON THE ELASTIC CLIP 10 E TABLES MIU CONTROL UNIT CONNEC TION 3G INJECTOR WATER TEMPERA TU...

Page 78: ...L BRACKET 14 BLOCKING THE ECU AND FIXING WITH SPECIFIC SCREW 13 TABLE E3 16 Connector 17 Injector CAUTION CONNECT THE CONNECTOR 16 TO THE INJECTOR AND ENSURE THAT IT IS CORRECTLY CONNECTED TABLE E4 CAUTION CONNECT THE GREEN WATER TEMPERATURE SENSOR 18 AND ENSURE THAT IT IS CORRECTLY CONNECTED CHECK THE POSITIONING OF THE INSULATING SLEEVE Electrical system RS4 125 ELE SYS 78 ...

Page 79: ...R FAN G TABLES THE MAIN CABLE HARNESS FIT TING TABLE G1 CAUTION POSITION THE GREY REFERENCES IN THE CABLE HAR NESS ON THE RESPECTIVE CLAMPS AND CLOSE THEM POSITIONING THE CABLE HARNESS CORRECTLY AS IL LUSTRATED TABLE G2 CAUTION POSITION THE GREY REFERENCE PRESENT ON THE CA BLE HARNESS ON THE RESPECTIVE CLAMP AND CLOSE IT POSITIONING THE CABLE HARNESS AS SHOWN IN THE PHOTO RS4 125 Electrical system...

Page 80: ...HE METALLIC BRACKET OB SERVING THE POSITION GREEN AND BROWN FUSES RIGHT Main 21 YELLOW AND BLUE FUSES LEFT Auxiliary 22 I TABLES TABLE I1 25 Engine chassis ground lead 26 Screw and spring washer TABLE I2 25 Engine chassis ground lead CAUTION CHECK CORRECT SECURING OF THE ENGINE CHASSIS CABLE Electrical system RS4 125 ELE SYS 80 ...

Page 81: ...ndicators 28 12V 30A Fan relay 29 30A 12V Injection relay TABLE J2 30 Electric fan connector insert the connector in the specific tongue in the battery support after con necting it TABLE J3 31 80A 12V Starter relay RS4 125 Electrical system ELE SYS 81 ...

Page 82: ...TABLE J4 Correct positioning of the battery TABLE J5 RUNNING REAR BRAKE SENSOR Electrical system RS4 125 ELE SYS 82 ...

Page 83: ... Stand sensor cable TABLE K1 Lambda probe and engine oil sen sor cable run 36 Rubber clamp 37 Lambda probe 38 Oil bulb CAUTION CHECK CORRECT INSERTION OF THE HOOD ON THE EN GINE OIL BULB 38 THE LAMBDA PROBE CABLE 37 MUST BE POSITIONED WITH A WIDE RADIUS BEND PAY CLOSE ATTENTION TO THE MOVEMENTS OF THE CABLE IN ORDER TO AVOID DAMAGING IT RS4 125 Electrical system ELE SYS 83 ...

Page 84: ...rter motor ground screw 41 Starter motor positive screw CAUTION CHECK TIGHTNESS OF THE STARTER MOTOR GROUND SCREW 40 AND THE STARTER MOTOR POSITIVE SCREW 41 CHECK CORRECT INSERTION OF THE HOOD TABLE M Neutral cable detail 34 Neutral cable CAUTION CHECK THAT THE NEUTRAL CABLE 34 IS CORRECTLY FIXED WITH THE SCREW Electrical system RS4 125 ELE SYS 84 ...

Page 85: ...BRANCH 37 FUEL RE SERVE SENSOR AND PUMP WITH THE FUEL HOSE 35 USING TWO CLAMPS 38 IN CORRESPONDENCE WITH THE GREY TAPINGS THE THIRD CLAMP 36 MUST SECURE THE CABLE HAR NESS 37 ON THE SADDLE MOUNTING TABLE N2 37 Fuel sensor and pump cable CAUTION CONNECT THE RESERVE FUEL SENSOR TO THE MAIN CABLE HARNESS RS4 125 Electrical system ELE SYS 85 ...

Page 86: ...FT SIDE OF THE TANK INSERTING IT ON THE SPECIFIC CABLE TIES 6 PREVI OUSLY FITTED TABLE N4 39 Fuel pump cable CAUTION CONNECT THE FUEL PUMP AND CHECK THAT THE CON NECTOR IS PROPERLY CONNECTED CHECK THAT THE THREE RED CAPS ARE STILL IN THE SEAT AFTER CON NECTION Electrical system RS4 125 ELE SYS 86 ...

Page 87: ...ot connected and should be left free Back side TABLE A REAR LIGHT PRE FITTING 1 Grey sheathing that indicated the left turn indicator 2 Faston of 2 8 mm 0 11 in cable colour light blue and blue 3 Faston of 2 8 mm 0 11 in cable colour red and blue RS4 125 Electrical system ELE SYS 87 ...

Page 88: ... Rear left turn indicator cable harness run 5 License plate frame cable harness 6 Rear right turn indicator cable harness run 7 Rear right turn indicator 8 License plate light TABLE B2 CAUTION VERIFY THE PRESENCE OF THE VIBRATION ABSORP TION SPONGE BETWEEN THE SUPPORT AND THE LI CENSE PLATE LIGHT Electrical system RS4 125 ELE SYS 88 ...

Page 89: ...C Breather pipe D TABLES DIAGNOSTICS CABLE DETAIL STEPS FOR CORRECT FITTING TABLE D1 Step 1 TABLE D2 Step 2 TABLE D3 9 Insert the diagnostics plug in the specific sup port RS4 125 Electrical system ELE SYS 89 ...

Page 90: ...sitioning of the cable harness TABLE E2 11 Taillight Cable harness 12a Clamps join the taillight cable harness and the diagnostics cable 12b Optional clamp 12c Clamp TABLE E3 10 Connector positioning 11 Taillight cable harness 13 Main cable harness Electrical system RS4 125 ELE SYS 90 ...

Page 91: ...TABLE E4 11 Taillight cable harness 14 LED Rear light 15 Cable guide RS4 125 Electrical system ELE SYS 91 ...

Page 92: ...General wiring diagram Key 1 MULTIPLE CONNECTORS 2 ECU 3 FRONT LEFT TURN INDICATOR 4 TAIL LIGHT BULB Electrical system RS4 125 ELE SYS 92 ...

Page 93: ...AR STOP SWITCH 20 FRONT STOP SWITCH 21 Rear right turn indicator 22 TAILLIGHT LED 23 LICENSE PLATE LIGHT BULB 24 REAR LEFT TURN INDICATOR 25 START UP RELAY 26 STARTER MOTOR 27 Battery 28 FUSES 1 29 FUSES 2 30 Voltage regulator 31 ALTERNATOR 32 PICK UP 33 GEAR IN NEUTRAL SWITCH 34 OIL LEVEL SENSOR 35 INJECTION RELAY 36 LAMBDA PROBE 37 FUEL PUMP 38 LIGHT LOGIC RELAY 39 INJECTOR 40 SPARK PLUG 41 COIL...

Page 94: ...ks and inspections In case the cause of ignition failure or malfunction cannot be easily identified at sight first of all re place the control unit by another one in operating conditions Remember that disconnection due to replacement of the central unit must be done with the engine off If after replacement the vehicle starts properly the control unit is failing and must be replaced Electrical syst...

Page 95: ... 020331Y Digital multimeter Dashboard Diagnosis Oil level If low oil level has been detected check if the general warning light and the icon turn on There are no reference indicators It is necessary to check if there is no engine oil left in the reservoir If a circuit break has been detected the general warning light does not turn on and the icon remains off There are no reference indicators Perio...

Page 96: ...arning light does not turn on Water temperature If coolant temperature is too high T 116 the general warning light turns on The icon will be lit along with all of the temperature indication bars Operation of the instrument panel is controlled by the SET A 2 and SET B 1 buttons Segments turned on in the Key on con figuration Electrical system RS4 125 ELE SYS 96 ...

Page 97: ...the total odome ter and trip counters Within the desired function hold in for 10 sec onds the SET A 2 control button to respectively RESET the TRIP I TRIP II and MAX functions The ODO function total odometer function can be reset only once in the life of the instrument panel and within the first 255km travelled Use the SET B 1 button to display the total odometer ODO and hold in SET B 2 for more t...

Page 98: ... 27 Battery 28 MAIN FUSES 30 Voltage regulator 31 ALTERNATOR RECHARGING SYSTEM Disconnect the six way connector 1 black colour located behind the left side cover NOTE THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER A Electrical system RS4 125 ELE SYS 98 ...

Page 99: ...atively 3 of the 5 connector pins no 2 4 6 stage 1 pin 2 4 stage 2 pin 2 6 stage 3 pin 4 6 Take the measurement The correct value is determined by the value measured for each stage in which from time to time the resistance of the tester wires is subtracted obtained by touching the two lugs Example Resistance of stage 1 read on the display 0 67 Ohm Resistance of the wires read on the display 0 47 O...

Page 100: ...ssis side of the motorcycle The outgoing wires from pins 1 and 5 must maintain the continuity of the positive and negative of the pick up otherwise the engine will not start while the out going cables from pins 2 4 6 alterna tor side must have the ends free in order to perform the appropriate ac tion CAUTION KEEP THE THREE ENDS OF THE FREE CABLES WELL SEPARATED TO AVOID DANGEROUS SHORT CIRCUITS Fo...

Page 101: ...1 and 5 must maintain the continuity of the positive and negative of the pick up otherwise the engine will not start while the ends of the outgoing cables from pins 2 4 6 alternator side must be short circuited with each other in order to be able to perform the appropriate action Start the engine and with an ammeter clamp measure each single cable If there is a significant difference be tween the ...

Page 102: ...en measure with a tester the voltage at the battery poles that must always be between 13V and 15V Otherwise if the correct operation of the alternator has already been checked replace the regulator CAUTION PERFORM THE CHECK DESCRIBED ABOVE WITH A BATTERY IN GOOD CONDITION START VOLTAGE ABOUT 13V MAKING SURE THAT THERE ARE NO ELEMENTS IN THE SHORT CIR CUIT Voltage regulator check Output voltage 13 ...

Page 103: ...TION SWITCH 25 START UP RELAY 26 STARTER MOTOR 27 Battery 29 Secondary fuses 33 GEAR IN NEUTRAL SWITCH STARTER MOTOR CHECK To check power the starter with a 12 V 9 AH battery With a DC ammeter clamp measure the current requirement at continuous running after 5 seconds Correct value 50 60 A RS4 125 Electrical system ELE SYS 103 ...

Page 104: ...tion control unit between PIN 5 and 10 are involved ELECTRICAL ERRORS Starter command P0170 shorted to positive Error cause Shorted to positive excessive voltage at PIN 10 of the control unit connector Troubleshooting Shorted to positive This malfunction is detected with a brake activated and the starter button pressed voltage of 12V read at PIN 5 If the battery voltage does not drop thanks to the...

Page 105: ...ank Disconnect the connector With a tester check the values between the male terminals inside the connec tor Correct value Warning light off approximate ly 1 kOhm Warning light on Magnitude range MOhm CAUTION UPON REFITTING MAKE SURE THE ELECTRIC CONNEC TOR IS CORRECTLY COUPLED RS4 125 Electrical system ELE SYS 105 ...

Page 106: ...5 Twin tail light stop light bulb 6 License plate light 7 Rear right turn indicator 8 Rear stop switch 9 Front stop switch 10 Front right turn indicator 11 High beam bulb 12 Tail light bulb 13 Complete headlamp 14 Tail light bulb 15 Low beam bulb 16 Front left turn indicator Electrical system RS4 125 ELE SYS 106 ...

Page 107: ...urrent sink 20 mA Maximum output voltage low level 500 mV Maximum output voltage high level Vdc of the pull up resistance Operating temperature range 20 60 C 4 F 140 F REAR LIGHT Rear tail light license plate light stop light 12 V 5 21 W FRONT HEADLAMP Halogen low beam light 12 V 55 W H 11 Halogen high beam light 12 V 55 W H 11 Tail light 12V 5W RS4 125 Electrical system ELE SYS 107 ...

Page 108: ... is fitted with a battery without maintenance If the battery is exhausted or disconnected and the engine is started with a not conventional method or in case that the battery is disconnected during the running or there is a collapse of an element can be checked the following problems turn indicators the proper flashing function is not ensured according to the Regulations headlamps it is not ensure...

Page 109: ...tery in the vehicle be careful not to reverse the connections remembering that the ground wire black marked must be connected to the negative clamp while the other two red wires marked must be con nected to the clamp marked with the positive sign 1 Recharging the battery First detach the negative terminal before removing the battery from the vehicle Regular bench charging must be carried out with ...

Page 110: ...THE REACH OF CHILDREN 1 Battery preparation Position the battery on a flat surface Remove the adhesive sheet closing cells and proceed as quick ly as possible to run the subsequent activation phases 2 Electrolyte preparation Remove the container of the electrolyte from the pack Remove and preserve cover strips from the container in fact the strip will later be used as a closing cover Note Do not p...

Page 111: ... face close to the battery The filling process is now complete Do not remove the strip of caps under any circumstances do not add water or electrolyte Place the battery down for 1 to 2 hours prior to the charging from the battery 7 Recharging the new battery With the above mentioned procedure the battery will have gained around 70 75 of its total electrical capacity Before installing the battery o...

Page 112: ... bat tery recharge Maintenance Free as shown in fig ure f Check the ignition of the green LED indicated with a red arrow in figure g The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place Electrical system RS4 125 ELE SYS 112 ...

Page 113: ...proceed as follows visually check that there are no signs of sulphation signalled by white colouring of one or more cells the electrolyte level is between the two MIN and MAX reference notches the container outer casing does not leak Charge the battery slowly for at least 10 hours With a densimeter check the electrolyte density at every cell after recharging If the density is below 1 26 at any cel...

Page 114: ...ulty sensor or cabling interference on the signal Troubleshooting Disconnect the sensor connector Verify with the key ON the presence of voltage 5V between PIN A and B of the control unit side connector If no voltage is read verify the continuity of the cabling between the control unit side sensor connector PIN A B and C and the control unit connector itself PIN 21 15 and 28 If the cabling is inta...

Page 115: ...94 F 196 Ohm 8 Ohm Function Serves the purpose of communicating the engine temperature to the control unit in order to optimise performance Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Pin out 1 Control unit ground B2 2 Instrument panel power A2 3 Control unit power B1 4 Instrument panel ground A1 CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTIN...

Page 116: ...nit connector Control unit PIN 13 sensor PIN 3 and control unit PIN 15 sensor PIN 1 If necessary restore the cable harness If the cabling is intact but the sensor resistance value is incorrect this means that the sensor is faulty and must be replaced otherwise proceed with the checks Shorted to positive With the sensor connector and the control unit disconnected verify that the fault is shorted wi...

Page 117: ... the air fuel ratio Lambda probe P0130 short to positive open circuit short to negative or carburetion excessively lean signal not plausible for abnormal title correction or probe signal fault Error cause Shorted to positive excessive voltage at PIN 11 or PIN 12 of the control unit connector Circuit open or shorted to negative interruption of the circuit or null voltage between control unit con ne...

Page 118: ...ctor PIN A The circuit is open interruption of the circuit Troubleshooting Shorted to positive Disconnect the control unit connector and the sensor connector Verify that there is no short to battery positive on sensor connector PIN B corresponding to control unit connector PIN 31 if there is a short restore the cabling The circuit is open Disconnect the control unit connector and the sensor connec...

Page 119: ...component through the diagnostics instrument Verify the absence of voltage at the injector connector PIN 1 if present restore the cable harness otherwise proceed with the following checks Shorted to negative Disconnect the injector connector turn the key to ON and activate the component through the diagnostics instrument Verify the presence of voltage at the ends of the injector connector if there...

Page 120: ... 2 toward the cabling If no voltage is read disconnect the control unit and verify insulation from battery positive of the relay PIN 1 or control unit PIN 22 Restore the cabling if necessary Shorted to negative Disconnect the injection relay No 35 on the electrical circuit diagram and the control unit Verify ground insulation of the relay connector PIN 1 and 2 toward the cabling if there is no ins...

Page 121: ...LECTRICAL SYSTEM CHAPTER ELECTRICAL ERRORS H V Coil P0351 shorted to positive open circuit or shorted to negative Error cause Shorted to positive excessive voltage at PIN 1 of the control unit connector Circuit open or shorted to negative interruption of the circuit or null voltage at PIN 1 of the control unit connector Troubleshooting Shorted to positive Disconnect the coil connector turn the key...

Page 122: ...heck the values with a tester with the gear engaged the tester indi cates a voltage value of 5 Volt between the ground and the sensor the resist ance is infinite In neutral position the tester indicates a voltage value of zero Volts between the ground and the sensor Side stand sensor Switch check With a tester check the values between the two terminals With the stand unfolded the tester indicates ...

Page 123: ...asure the voltage read at the relay connector PIN 1 toward the cabling if the voltage is 12V restore the cabling If the voltage is zero replace the relay Shorted to negative Disconnect the fan control relay No 42 on the electrical circuit diagram and the control unit Verify ground insulation of the cable between the fan control relay PIN 1 and the control unit PIN 24 Restore the cabling if necessa...

Page 124: ...ENSOR or ange 14 ECU CONTROL UNIT black 15 ECU CONTROL UNIT blue green 16 ECU CONTROL UNIT DIAGNOSTICS white blue 17 INSTRUMENT PANEL brown black 18 CLUTCH SWITCH brown white 19 SIDE STAND SWITCH grey yellow 20 FLYWHEEL cable x1 21 SPEED SENSOR orange black 22 INJECTION RELAY red blue 23 ECU CONTROL UNIT blue 24 FAN RELAY blue 25 INSTRUMENT PANEL purple brown 26 27 28 SPEED SENSOR blue orange 29 F...

Page 125: ...AM WARNING LIGHT 8 LEFT TURN INDICATOR WARNING LIGHT 9 IMMOBILIZER ABS WARNING LIGHT not used 10 NEUTRAL WARNING LIGHT 11 WATER TEMPERATURE WARNING LIGHT 12 OIL PRESSURE WARNING LIGHT 13 RPM INPUT 14 CONFIGURATION PIN 15 Not connected 16 Not connected 17 Not connected 18 SPEED SENSOR 19 FUEL RESERVE SENSOR 20 BATTERY RS4 125 Electrical system ELE SYS 125 ...

Page 126: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 127: ...e air filter box the radiator and the expansion tank Position an under sump stand that will be supported on the lower side of the engine See also Air box Side fairings Removing the expansion tank Removing the radiator Coolant replacement Fuel tank Lower cowl Removing the engine from the vehicle Prepare the vehicle as described Disconnect the quick coupler Loosen the clutch adjuster screw See also ...

Page 128: ...ve the screw and dis connect the starter ground cable Remove the rubber plug and loosen the screw Disconnect the starter motor cable Unscrew and remove the two fixing screws Remove the pinion cover Undo and remove the fixing screw Take out the gearbox rod Engine from vehicle RS4 125 ENG VE 128 ...

Page 129: ... Unhook the chain and remove it Water temperature connector Disconnect the neutral sensor connec tor Remove the oil temperature sensor RS4 125 Engine from vehicle ENG VE 129 ...

Page 130: ... Remove the oil temperature sensor Remove the battery compartment Remove the coil Remove the clamp Remove the breather pipe Engine from vehicle RS4 125 ENG VE 130 ...

Page 131: ...he screw Remove the cable guide Disconnect the injector connector Remove the main cable harness cable grommet Working on both sides unscrew and remove the two fixing screws RS4 125 Engine from vehicle ENG VE 131 ...

Page 132: ...e loosen the swingarm pin Operating from both sides remove the pass through screws and collect the retaining nuts Operating from both sides remove the upper fixing screws Working from the right side slide off the pin Engine from vehicle RS4 125 ENG VE 132 ...

Page 133: ...scribed torque Specific tooling 866714 Swingarm adjustment Insert the swingarm pin from the right side and slide it until it reaches the oth er side Working from both sides tighten the upper screw with the relative washer Tighten the screw to the prescribed tor que RS4 125 Engine from vehicle ENG VE 133 ...

Page 134: ...m pin and start the nut Ensure the presence of the washer and the nut on the swingarm pin on the right side Working from both sides tighten the nuts to the prescribed torque Working on both sides start the two plate screws Tighten the screws to the prescribed torque Place the main cable harness in the cable grommet Engine from vehicle RS4 125 ENG VE 134 ...

Page 135: ... cable harness Place the cable guide Tighten the screw to the prescribed tor que Place the breather pipe and secure it with the clamp Connect the ground and fix it with the screw Connect the coil connector RS4 125 Engine from vehicle ENG VE 135 ...

Page 136: ...t and in sert the relays in the appropriate seats Tighten the battery compartment screw to the prescribed torque Connect the horn Connect the oil temperature sensor Connect the neutral sensor Engine from vehicle RS4 125 ENG VE 136 ...

Page 137: ...rature sen sor Place and reconnect the chain Place the gear lever and tighten the screw to the prescribed torque Place the pinion cover and tighten the two screws to the prescribed torque RS4 125 Engine from vehicle ENG VE 137 ...

Page 138: ...tor ground wire and tighten the screw to the prescribed torque Reconnect the clutch cable being careful to insert it in the cable guide Adjust the clutch cable Insert the quick coupling Fit the previously removed units following the reverse order of the vehicle preparation de scription Engine from vehicle RS4 125 ENG VE 138 ...

Page 139: ...INDEX OF TOPICS ENGINE ENG ...

Page 140: ...ING CLASSES The gears of the primary drive are classified according to the coupling with the gear of the clutch housing and with the gear of the balancing countershaft and follow the logic shown in the tables listed below COUPLING CLASSES CLUTCH HOUSING FIRST GEAR SHAFT Coupling classes on Crankcase Clutch housing gear Transmission gear X X X Y Y Y COUPLING CLASSES FIRST GEAR SHAFT BALANCING COUNT...

Page 141: ...f there are signs of corrosion Check the eccentricity of the transmis sion shafts Check the condition of the two springs 5 and 6 of the selector 7 Check the condition of the gears re place them if they are blue if they have cracks or are worn Assembling the gearbox Place the specific tool on the secon dary shaft to avoid damaging the oil seal Heat up the engine crankcase Apply LOCTITE Anti Seize o...

Page 142: ...1 Guide for oil seal Starter motor STARTER MOTOR pos Description Type Quantity Torque Notes 1 Starter motor fixing screw M6x25 2 11 13 Nm 8 11 9 58 lbf ft STARTER MOTOR Make sure that the toothing 1 is not deformed or worn Make sure that the O ring 2 is not damaged or worn The electric starter motor is not fitted for repair If necessary replace the whole motor Engine RS4 125 ENG 142 ...

Page 143: ...E REMOVED IF THE ENGINE IS FITTED TO THE VEHICLE Installing the starter motor Place the electric starter motor Apply LOCTITE 221 Tighten the starter motor fixing screws Generator side FLYWHEEL COVER pos Description Type Quantity Torque Notes 1 Flywheel cover fastener screw M6 10 11 13 Nm 8 11 9 58 lbf ft RS4 125 Engine ENG 143 ...

Page 144: ...escription Type Quantity Torque Notes 1 Flywheel rotor fixing screw M14x1 5 1 83 90 Nm 61 21 66 38 lb ft Removing the flywheel cover Unscrew and remove the two adjust ment plugs 1 Unscrew and remove the engine oil pre filter plug 2 Remove the engine oil pre filter Undo and remove the ten screws fixing the flywheel cover Remove the flywheel cover Engine RS4 125 ENG 144 ...

Page 145: ...ear Position the locking tool Unscrew and remove the hex head screw and retrieve the washer Specific tooling 865259 Flywheel retainer Position the tool Remove the flywheel and its spline Specific tooling 864868 Flywheel extractor RS4 125 Engine ENG 145 ...

Page 146: ... Remove the oil filter Engine RS4 125 ENG 146 ...

Page 147: ...l Undo and remove the screw from the lock Remove the freewheel Installing the flywheel For refitting follow the operations described previously in reverse order See also Magneto flywheel removal RS4 125 Engine ENG 147 ...

Page 148: ...scription Type Quantity Torque Notes 1 Clutch cover fixing screw M6x35 10 11 13 Nm 8 11 9 58 lbf ft 2 Oil filter cover M56x1 5 1 24 26 Nm 17 70 19 17lbf ft 3 Oil pressure sensor M10 1 12 14 Nm 8 85 10 32 lbf ft Engine RS4 125 ENG 148 ...

Page 149: ... 5 4 5 Nm 2 58 3 31 lbf ft 2 Clutch housing retainer nut M12 1 35 45 Nm 25 81 33 19 lbf ft Removing the clutch cover Unscrew and remove the three water pump cover screws Remove the water pump cover Unscrew and remove the rotor fixing screw Remove the rotor RS4 125 Engine ENG 149 ...

Page 150: ... Unscrew and remove the oil filter plug Remove the spring and oil filter Engine RS4 125 ENG 150 ...

Page 151: ...wel pins WARNING REPLACE THE GASKET DURING REFITTING Remove the lubrication circuit by pass spring Disassembling the clutch Unscrew and remove the six screws by loosening them 1 4 of a turn at a time operate in stages and diagonally and retrieve the washers and the clutch springs RS4 125 Engine ENG 151 ...

Page 152: ...screw by lowering the lock tab Block clutch bell rotation using the spe cific tool Unscrew and remove the clutch bell fixing nut Remove the clutch hub Specific tooling 00H05300041 Clutch retainer Remove the shim and the clutch hous ing Engine RS4 125 ENG 152 ...

Page 153: ...plates thickness 1 46 1 53 mm 0 057 0 06 in Number of driven plates 4 Checking the clutch housing COUPLING CLASSES The gears that are coupled to each other clutch housing first gear shaft and balancing countershaft indicate the coupling classes in this regard see section Checking the primary shaft within the topic Gearshift RS4 125 Engine ENG 153 ...

Page 154: ...ogether Check the worn guiding grooves of the clutch bell 1 max insertion depth A 0 5 mm 0 020 in Checking the clutch hub When the clutch hub is worn it can cre ate problems with sliding of the hous ing The hub should be replaced if the surface of the spring has exceeded the wear limits Max wear limit A 0 3 mm 0 012 in Check the clutch hub for damage and wear that may result in clutch irregular op...

Page 155: ...asure the clutch spring length when unloaded if necessary replace the springs all together Characteristic Minimum wear limit in the release position of the individual clutch springs 31 6 mm 1 24 in Assembling the clutch Insert the shim Fit the clutch housing Fit the shim washer RS4 125 Engine ENG 155 ...

Page 156: ...side of the lock tab Insert the disc covered with the friction material into the bell Continue inserting alternating a metal disc with one with friction material fin ishing with a friction material disc with a black tooth Place the thrust plate Fit the clutch springs Fit the screw washers Tighten the six screws operating in stages and diagonally Engine RS4 125 ENG 156 ...

Page 157: ...and in stages Refit the water pump Refit the oil filter Add engine oil up to the correct level WARNING TO FACILITATE INSERTION OF THE COVER ROTATE WA TER PUMP THE ROTOR UNTIL THE GEARS ENGAGE Crankcase ENGINE CRANKCASE pos Description Type Quantity Torque Notes 1 Crankcase halves union M6 12 11 13 Nm 8 11 9 58 lbf ft RS4 125 Engine ENG 157 ...

Page 158: ... lbf ft Balancing countershaft removal Before taking out the balancing coun tershaft the clutch cover and flywheel cover must be removed Lock the countershaft with the specific tool Specific tooling 864486 Blocking the countershaft Unscrew and remove the nut and col lect the washer See also Engine RS4 125 ENG 158 ...

Page 159: ...om the al ternator side Balancing countershaft fitting Insert the countershaft from the alter nator side Insert the gear aligning its reference to the primary gear Using the specific tool tighten the nut remember first to place the washer Specific tooling 864486 Blocking the countershaft RS4 125 Engine ENG 159 ...

Page 160: ...tall the countershaft blocking tool Specific tooling 864486 Blocking the countershaft Remove the primary gear unscrewing and removing the nut Collect the washer Remove the countershaft gear Remove the primary remaining gears Remove the head and cylinder See also Removing the Engine RS4 125 ENG 160 ...

Page 161: ... slider un screwing and removing the fixing screw Remove the timing chain gear Remove the pump drive gear remov ing the seeger and recovering the washer Remove the base gear of the main shaft Remove the cotter RS4 125 Engine ENG 161 ...

Page 162: ... un screwing and removing the fixing screw Moving from the left side of the engine remove the flywheel and all of its com ponents beforehand Unscrew and remove the six screws on the outside of the crankcase 1 See also Magneto flywheel removal Unscrew and remove the longest screw 2 Engine RS4 125 ENG 162 ...

Page 163: ...n shaft bearing 020358Y Insertion of desmo bearing 020439Y 020357Y Removal of desmo bearing 020891Y Insertion of secondary shaft roller bearing cage 020891Y Removal of the secondary shaft roller bearing cage 020363Y Insertion of countershaft bearing 020412Y 020358Y Removal of countershaft bearing 020375Y LEFT CRANKCASE Insertion of main shaft bearing 020439Y 020359Y Removal of the main shaft beari...

Page 164: ... two ele ments COUPLING CLASS INTERVALS CRANKSHAFT FIRST GEAR SHAFT Specification Desc Quantity X 86 00 86 04 mm 3 386 3 388 in Y 85 96 86 00 mm 3 384 3 386 in Therefore the couplings will be COUPLING CLASSES CLUTCH HOUSING FIRST GEAR SHAFT Coupling classes on Crankcase Clutch housing gear Transmission gear X X X Y Y Y The coupling between the gears of the first gear shaft and gear of the balancin...

Page 165: ...are when handling the housing and hoses for the oil pump the duct with the by pass valve and the main bushings As already described in the lubrication chapter it is especially important that the by pass valve housing shows no wear that may impair the proper sealing of the lubrication pressure adjustment ball Check that the surfaces are free from dents or deformations with special attention to both...

Page 166: ...ANKSHAFT DIAMETER Specification Desc Quantity Class 1 MIN 32 480 mm 1 2787 in MAX 32 485 mm 1 2789 in Class 2 MIN 32 485 mm 1 2789 in MAX 32 490 mm 1 2791 in BUSHING THICKNESS Specification Desc Quantity Red MIN 2 005 mm 0 0789 in MAX 2 010 mm 0 0791 in Blue MIN 2 010 mm 0 0791 in MAX 2 015 mm 0 0793 in CRANKSHAFT COUPLING BUSHING SEAT DIAMETER Specification Desc Quantity Crankshaft type 2 Type 1 ...

Page 167: ... desmo roller bearing cage use universal extractor Insertion of secondary shaft roller bearing cage 020363Y Removal of the secondary shaft roller bearing cage use universal extractor Insertion of countershaft roller bearing cage 020483Y Removal of countershaft roller bear ing cage 020364Y NOTE insertion of the roller bearing cages in line with the crankcase is recommended from the inside to the ou...

Page 168: ...the crank case position and screw the six screws 1 Fit the countershaft Position the selection spider screw Position and screw the screw See also Balancing countershaft fitting Fit a new oil pump gasket Fit the oil pump screwing the three screws Engine RS4 125 ENG 168 ...

Page 169: ...he washer Use the specific tool to tighten the nut Apply the cotter to the main shaft Position the base gear of the primary aligning the two references Insert the pump drive gear Insert the washer and apply the fixing seeger RS4 125 Engine ENG 169 ...

Page 170: ...ion The engraving must face upward Fit the timing chain Position the chain guide slider Position and screw the fixing screw Fit the rest of the primary gears Tighten the fixing nut Remove the countershaft locking tool Fit the gear selector Engine RS4 125 ENG 170 ...

Page 171: ...Head and timing HEAD COVER pos Description Type Quantity Torque Notes 1 Spark plug M10 1 12 14 Nm 8 85 10 32 lbf ft 2 Head cover fixing screw M6 4 10 12 Nm 7 38 8 85 lbf ft RS4 125 Engine ENG 171 ...

Page 172: ...38 lbf ft 4 Head fixing screw M8x166 4 25 Nm 90 18 44 lbf ft 90 5 Thermostat cover fixing screw M6x20 2 10 Nm 7 38 lbf ft TIMING SYSTEM pos Description Type Quantity Torque Notes 1 Chain tensioner slider fulcrum fixing screw M6x16 1 10 Nm 7 38 lbf ft Loctite 243 2 Transmission timing gear fixing screw M8x40 1 27 Nm 19 91 lbf ft Loctite 243 Removing the head cover Remove the adjuster screw covers 1...

Page 173: ... Unscrew and remove the four cylinder head screws 2 Remove the cylinder head 3 Remove the gasket 4 Remove the spark plug RS4 125 Engine ENG 173 ...

Page 174: ...ign 3 Insert the specific pins 4 on the valves cam tower Specific tooling 864567 Locking pins timing camshafts Remove the starter motor beforehand Loosen and remove the tensioner screw 5 Remove the spring Unscrew and remove the two screws 6 and remove the entire tensioner control See also Removing the starter motor Engine RS4 125 ENG 174 ...

Page 175: ...ecific tooling 865260 Camshaft sprocket lock Unscrew and remove the gear Repeat the operation with the other gear Cylinder head Removing the overhead camshaft Unscrew and remove the six screws 1 and 2 Remove the cylinder head 3 RS4 125 Engine ENG 175 ...

Page 176: ... Remove the cylinder head 3 Remove the two pins from the valves cam tower Remove the eight screws 1 Remove the valve cam tower 2 Remove the two camshafts intake and exhaust side Engine RS4 125 ENG 176 ...

Page 177: ...umber the valves and their bucket tappets in order to position them cor rectly upon refitting Remove the valve bucket tappets Compress the valve spring using the specific tool Specific tooling 020382Y011 Tool to remove fit valves Remove both cotter pins RS4 125 Engine ENG 177 ...

Page 178: ...not worn If values measured are not within the specified limits or there are signs of wear replace the defective components with new ones Characteristic Maximum axial clearance allowed 0 4 mm 0 0157 in Valve check Measure the width of the sealing surface on the valve seats and on the valves themselves If the sealing surface on the valve is wider than the specified limit damaged in one or more poin...

Page 179: ...00098 0 00204 in Maximum clearance admitted Intake 0 060 mm 0 0023 in Maximum clearance admitted Exhaust 0 070 mm 0 0027 in Remove the head cover Bring the engine to reach the top dead centre and lock it at that position using the specific tool 4 Specific tooling 864567 Locking pins timing camshafts RS4 125 Engine ENG 179 ...

Page 180: ...rom the values specified record the difference between MAXIMUM ALLOWED CLEARANCE e CLEARANCE MEAS URED Remove the chain tensioner Undo and remove the eight screws and remove the cam tower Remove the timing chain and the gears of the camshaft of the valves in ques tion Engine RS4 125 ENG 180 ...

Page 181: ...the gears and the chain in their correct positions using the references located on the flywheel side of the crankcase Fit the cam tower and tighten the eight screws to the prescribed torque Fit the chain tensioner Check for correct valve clearance Fit the head cover Inspecting the valve sealings Fit the valves into the cylinder head Alternatively test the intake and exhaust valves This test should...

Page 182: ... according to the thrust direction at three different heights Characteristic Intake guide standard diameter 4 012 mm 0 1579 in Intake guide Wear limit 4 020 mm 0 1582 in Discharge guide standard diameter 4 012 mm 0 1579 in Discharge guide Wear limit 4 020 mm 0 1582 in Replace the head if the values corre sponding to the width of the mark on the valve seat or the valve guide diam eter exceed the sp...

Page 183: ...e head surface is not worn or distorted Check that the camshaft bushings are not worn Check that the head cover surface the intake manifold and the exhaust manifold are not worn Installing the valves Lubricate the valve guides with engine oil Position the two oil seals on the cylinder head Fit the valves the springs and the caps Using the specific tool compress the springs and fit the cotters in t...

Page 184: ...ondition of the tensioner spring If signs of wear are found replace the whole assembly Checking the chain Check that the guide slider and the ten sioner pad are not excessively worn Check that the chain assembly the camshaft driving pulleys and the sprocket wheel are not worn Replace the parts if signs of wear are found Cylinder piston assembly Engine RS4 125 ENG 184 ...

Page 185: ...ion Type Quantity Torque Notes 1 Chain tensioner screw M8 1 6 Nm 4 43 lbf ft Removing the cylinder CYLINDER REMOVAL Remove the cylinder head gasket 1 Remove the guide slider 2 Remove the water sleeve clamp 3 RS4 125 Engine ENG 185 ...

Page 186: ...ssembling the piston Apply the tool under the piston 1 Cover the base of the cylinder with a cloth Specific tooling 865261 Piston locking pin Remove the retainer ring which locks the pin 2 Remove the pin 3 Remove the piston 4 Engine RS4 125 ENG 186 ...

Page 187: ...ance using suitable sen sors as shown in the diagram If clearances measured exceed the limits specified in the table the piston should be replaced by a new one NOTE MEASURE CLEARANCE BY INSERTING THE BLADE OF THE FEELER GAUGE FROM THE 2nd SEALING RING SIDE Characteristic Piston cylinder Piston pin hole standard 15 003 15 008 mm 0 5907 0 5908 in Maximum piston cylinder coupling clearance after use ...

Page 188: ...tegories with cast iron cylinder NAME ABBREVIA TION CYLINDER PISTON FITTING CLEARANCE min max min max min max Cylinder Piston M 58 010 58 017 57 963 57 970 0 040 0 054 Cylinder Piston N 58 017 58 024 57 970 57 977 0 040 0 054 Cylinder Piston O 58 024 58 031 57 977 57 984 0 040 0 054 Cylinder Piston P 58 031 58 038 57 984 57 991 0 040 0 054 Inspecting the wrist pin Check the pin outside diameter Ch...

Page 189: ...TE IF THE CONNECTING ROD SMALL END DIAMETER EX CEEDS THE MAXIMUM DIAMETER ALLOWED SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER Characteristic Rod small end Maximum diameter 15 023 mm 0 591 in Standard diameter 15 010 15 018 mm 0 5910 0 5912 in Fitting the piston Install piston and pin onto the connect ing rod aligning the piston arr...

Page 190: ...onally and measure the piston protrusion in rela tion to the reference surface Calculate the necessary thickness of the gasket selecting it based on the values shown in the table below Installing the cylinder Fit a new cylinder base gasket of the chosen thickness Refit the cylinder as indicated in the figure using the specific clamp tighten er tool NOTE BEFORE FITTING THE CYLINDER CAREFULLY BLOW A...

Page 191: ...01 in Installing the cylinder head Fit the chain guide slider onto the cyl inder Fit the head gasket and the alignment dowels Fit the head Screw but do not tighten both central long screws 3 and position the wash ers Screw but do not tighten both central long screws 2 and position the wash ers Screw but do not tighten the two side short screws 1 NOTE BEFORE INSTALLING THE HEAD MAKE SURE THAT THE L...

Page 192: ...ition the camshaft marked with the letter A on the intake side and the camshaft marked with the letter S on the ex haust side WARNING POSITION THE CAMS OF BOTH SHAFTS FACING OUT WARDS Position the cam tower cap Screw but do not and tighten the eight screws Place the pins in their positions on the overhead camshafts Specific tooling 864567 Locking pins timing camshafts Engine RS4 125 ENG 192 ...

Page 193: ...er using a new gasket and tighten the two screws 1 to the prescribed torque Insert the spring with the central screw 2 and o ring and tighten the cap to the prescribed torque Tighten the screws fixing the camshaft gears to the prescribed torque Remove the pins on the camshafts Remove the specific crankshaft locking tool Tighten the screw on the crankcase Check the valve clearance and adjust it if ...

Page 194: ...Lubrication OIL PUMP pos Description Type Quantity Torque Notes 1 Oil pump fixing screw M6x25 3 10 Nm 7 38 lbf ft Loctite 243 Engine RS4 125 ENG 194 ...

Page 195: ...Conceptual diagrams Removing Remove the Seeger ring Remove the pump gear RS4 125 Engine ENG 195 ...

Page 196: ...ake rotor Thickness 13 5 mm 0 53 in Oil supply rotor Thickness 8 5 mm 0 33 in Standard values Radial clearance 1 between points of the rotor 0 04 mm 0 0015 in Radial clearance 2 between points of the rotor 0 08 mm 0 003 in Radial clearance 3 between rotor 1 and the pump body 0 04 mm 0 0015 in Radial clearance 3 between rotor 2 and the pump body 0 05 mm 0 0019 in Engine RS4 125 ENG 196 ...

Page 197: ...Installing Refit the oil pump proceeding in re verse order of disassembly Pay atten tion to the direction of the rotor the dot should stay on the opposite part of the resting face RS4 125 Engine ENG 197 ...

Page 198: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 199: ...Circuit diagram key 1 Fuel tank 2 Fuel pump 3 Fuel pump ring nut 4 Fuel pump gasket 5 Fuel pipe 6 Fuel level sensor 7 Tank opening rod 8 Fuel breather pipe Fuel pump RS4 125 Power supply P SUPP 199 ...

Page 200: ...Removing Remove and empty the fuel tank Remove the fuel hose 4 Loosen the ring nut 3 and slide off the gasket 2 Remove the pump 1 See also Fuel tank Injection Power supply RS4 125 P SUPP 200 ...

Page 201: ...Diagram Key 1 ECU control unit position 2 Ignition switch 3 Fuel pump 4 Instrument panel RS4 125 Power supply P SUPP 201 ...

Page 202: ... sensor 9 Lambda probe position 10 Engine revolution sensor 11 Electric fan Removing the throttle body Remove the filter box Loosen and remove the nut and un hook the throttle cable Disconnect the connector Undo and remove the screw and re move the cable guide Power supply RS4 125 P SUPP 202 ...

Page 203: ... Loosen the clamp and remove the throttle body RS4 125 Power supply P SUPP 203 ...

Page 204: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 205: ...Front FRONT SUSPENSION pos Description Type Quantity Torque Notes 1 Screws fastening lower yoke to sleeve M8 2x2 25 Nm 8 43 lbf ft Key RS4 125 Suspensions SUSP 205 ...

Page 206: ...ternal spacer 7 Sealing ring 8 Circlip 9 Bearing 10 Internal spacer 11 Bare front wheel 12 Front wheel pin 13 Tubeless valve FRONT WHEEL pos Description Type Quantity Torque Notes 1 Front wheel spindle nut M14 1 78 Nm 8 85 lbf ft 2 Front disc fixing screw M6x20 6 12 Nm 8 85 lbf ft Suspensions RS4 125 SUSP 206 ...

Page 207: ...ollect the washer Loosen the lock screw of the calliper mounting bracket Extracting the wheel slide off the pin from the right side of the vehicle pay ing attention to the speed sensor collar Remove the front wheel Checking the front wheel WHEEL INSPECTION NOTE BALANCE THE WHEEL IF A TYRE OR A WHEEL WAS REPLACED WARNING WHEEL RIM REPAIRS MUST NOT BE CARRIED OUT RS4 125 Suspensions SUSP 207 ...

Page 208: ...el axle bending limit 1 0 2 mm TYRES Check the tyres for wear If they are damaged replace them WHEEL RIMS Check the wheel deformation If there are bends or damages replace it Check the wheel deformation limits Radial limit a 0 6 mm Lateral limit b 0 5 mm If the measured values exceed the lim it replace the wheel rim Suspensions RS4 125 SUSP 208 ...

Page 209: ...ED Check the spacer Replace together with the retaining ring if there are scorings or signs of de terioration Installing the front wheel Follow the steps described in the front wheel removal in reverse be very careful when po sitioning the components and the corresponding tightening torque RS4 125 Suspensions SUSP 209 ...

Page 210: ... The following operations are described for the Mingxing fork but are identical for the operation with the fork model Paioli except where specified The following operations only refer to one fork but they apply to both Support the vehicle at the front by fas tening a suitable belt to the handlebar and a crane Position a support under sump stand and the rear stand Remove the front wheel and the fro...

Page 211: ... lower plate For the operation with fork Paioli loos en the fixing screw at the lower plate Slide the stanchion downwards to re move it Disassembling the fork PAIOLI FORKS CAUTION THE FOLLOWING PROCEDURES ARE FOR A SINGLE WHEEL CARRIER STANCHION SLEEVE ASSEMBLY BUT ARE APPLICABLE TO BOTH Fit the fork in the vice using the special Teflon grips RS4 125 Suspensions SUSP 211 ...

Page 212: ...revent the internal piston from rotating Remove the cap CAUTION BEFORE PROCEEDING WITH THE FOLLOWING OPERATIONS GET A SUITABLE COLLECTION CONTAINER Remove the stem from the vice and drain off the oil inside it into the collec tion container Suspensions RS4 125 SUSP 212 ...

Page 213: ...ing Remove the stem from the sleeve CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE INTERIOR WHEN REMOVING THE DIFFERENT COMPONENTS Remove the oil seal from the sleeve taking care not to damage it CAUTION ONLY FOR THE RIGHT STEM IT IS POSSIBLE TO REMOVE THE COMPLETE PISTON OPERAT ING AS FOLLOWS Undo and remove the piston retaining screw on the foot of the fork RS4 125 Suspensions SUSP 213 ...

Page 214: ...NG FORK CAUTION THE FOLLOWING PROCEDURES ARE FOR A SINGLE WHEEL CARRIER STANCHION SLEEVE ASSEMBLY BUT ARE APPLICABLE TO BOTH Fit the fork in the vice using the special Teflon grips Unscrew and remove the cap Suspensions RS4 125 SUSP 214 ...

Page 215: ...OPERATIONS GET A SUITABLE COLLECTION CONTAINER Remove the stem from the vice and drain off the oil inside it into the collec tion container Reposition the stem in the vice using the specific Teflon shoes Remove the dust gaiter taking care for the surface of the stem and the integrity of the dust gaiter Remove the retainer ring RS4 125 Suspensions SUSP 215 ...

Page 216: ...r scratches These scorings can be eliminated by rubbing them with wet sandpaper grain 1 If the scorings are deep replace the stem Use a dial gauge to check that the stem bending is below the limit value If over the value replace the stem Bending limit 0 2 mm CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BE CAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Replace ...

Page 217: ... deep replace the stem Use a dial gauge to check that the stem bending is below the limit value If over the value replace the stem Bending limit 0 2 mm CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Check that there are no damages and or cracks otherwise replace it Check that the sliding bushings 1 for good condit...

Page 218: ... PISTON OPERATING AS FOLLOWS Tighten the piston retaining screw on the foot of the fork and tighten it to the prescribed torque CAUTION THE FOLLOWING PROCEDURES ARE FOR A SINGLE WHEEL CARRIER STANCHION SLEEVE ASSEMBLY BUT ARE APPLICABLE TO BOTH Insert the oil seal in the sleeve Suspensions RS4 125 SUSP 218 ...

Page 219: ... the sleeve Position the retainer and push the dust gaiter into its seat Position the fork vertically in a vice Fill the fork with oil Characteristic Fork Paioli oil 390 5 ml 0 086 0 0010 UK gal 0 103 0 0013 US gal for each stem Screw the cap on the piston and tighten it RS4 125 Suspensions SUSP 219 ...

Page 220: ...EL CARRIER STANCHION SLEEVE ASSEMBLY BUT ARE APPLICABLE TO BOTH Insert the oil seal in the sleeve After inserting the dust gaiter in the stem as well as the retainer ring insert the stem itself in the sleeve Position the retainer and push the dust gaiter into its seat Suspensions RS4 125 SUSP 220 ...

Page 221: ...ork MingXing oil quantity Right stem 355 5 ml 0 0781 0 0011 UK gal 0 0938 0 0013 US gal Left stem 360 5 ml 0 0792 0 0792 0 0011 UK gal 0 0951 0 0013 US gal Screw the cap on the sleeve Installing the fork legs The following operations are described for the Paioli fork but are identical for the operation with the fork model Mingxing except where specified RS4 125 Suspensions SUSP 221 ...

Page 222: ...the top of the holding pipes except the plug Provisionally tighten the screw that locks the upper plate on the holding pipes Tighten the screws that lock the lower plate to the holding pipes to the pre scribed torque Tighten completely the screws that lock the upper plate to the holding pipes to the prescribed torque For the operation with Paioli fork tight en the sleeve fixing screw to the lower ...

Page 223: ...ten the two screws on the front headlamp clamp Fasten the brake piping to the left sheath Slide off the wheel axle Mount the front wheel Fit the front brake calliper and tighten the two fixing screws See also Removing the front wheel Removal RS4 125 Suspensions SUSP 223 ...

Page 224: ...he proper fork operation by operating on the front brake and pushing repeatedly on the fork The brake should operate progressively and there should be no oil marks on the stems CAUTION BEFORE RIDING CHECK THAT THE VEHICLE IS CORRECTLY SET Rear key 1 Right ext wheel spacer 2 Left ext wheel spacer 3 Chain with master link 4 Tubeless valve 5 Rear tyre 150 60 6 Rear wheel int spacer 7 Bearing 20x47x14...

Page 225: ... pos Description Type Quantity Torque Notes 1 Rear wheel axle nut M14 2 78 Nm 57 53 lbf ft 2 Rear disc fixing screw M6x20 6 12 Nm 8 85 lbf ft 3 Sprocket fixing screw TEF M8 6 25 Nm 18 44 lbf ft 4 Chain tensor fixing screw M8 2 12 Nm 8 85 lbf ft Loctite 243 Removing the rear wheel BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS ALLOW THE ENGINE AND SILENCER TO COOL OFF TO A...

Page 226: ... on its optional rear stand Remove the drive chain Operating from both sides remove the two adjuster screws Working from the right side of the ve hicle unscrew and remove the fixing nut and retrieve the washer See also Drive chain Move the wheel a few millimetres and extract it slide the pin off the left side Collect the washer and the spacer Suspensions RS4 125 SUSP 226 ...

Page 227: ... nec essary Insert the anti vibration buffer in the wheel hub Fit the entire final transmission unit on the wheel manually rotate the crown gear to right and left and check the clearance between the anti vibration buffer and the hub Replace the anti vibration buffer if excessive clearance is found SPROCKET Check the toothing of the crown and the pinion If excessive wear is found replace the crown ...

Page 228: ...tion the spacers on the left side as indicated in the figure Tighten the nuts to the prescribed tor que Shock absorbers REAR SUSPENSION pos Description Type Quantity Torque Notes 1 Upper retainer M12 1 58 Nm 42 78 lbf ft 2 Lower retainer M12 1 58 Nm 42 78 lbf ft Loctite 243 Suspensions RS4 125 SUSP 228 ...

Page 229: ... a support under the swingarm so that it stays in neutral position Unscrew and remove the front screw and collect the washer At the same time collect the nut and washer from the right side Unscrew and remove the lower screw on the left side and collect the washer At the same time collect the nut and washer from the right side RS4 125 Suspensions SUSP 229 ...

Page 230: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 231: ...8 2 20 Nm 14 75 lbf ft 2 TCEI screw M8 2 25 Nm 18 43 lbf ft 3 TCEI screw M10x45 4 50 Nm 36 88 lbf ft 4 TE screw M8x40 2 25 Nm 18 43 lbf ft 5 TE screw M6x16 2 12 Nm 8 85 lbf ft Loctite 243 6 Right and left engine mount M10x16 2 38 Nm 28 02 lbf ft Loctite 243 RS4 125 Chassis CHAS 231 ...

Page 232: ... M14 1 78 Nm 57 52 lbf ft 3 Chainguard fixing screw M 4 8x13 4 1 Nm 0 74 lbf ft 4 Chainguard fixing screw Self tap 2 Removing Place the vehicle on its OPTIONAL front service stand Support the vehicle rear part using belts and hoist Remove the rear brake calliper and take off the pipe Remove the wheel and rear shock ab sorber Chassis RS4 125 CHAS 232 ...

Page 233: ...with a rubber hammer slide the swingarm pin off the left side of the vehicle If necessary remove the rear mudguard and the chainguard Checking CAUTION CHECK THAT NO COMPONENT IS NOTICEABLY DISTORTED DAMAGED CRACKED AND OR DENTED REPLACE ALL DAMAGED COMPONENTS ROLLER CASINGS Turn the roller casings manually they must rotate continuously and silently There must be no axial clearance Replace the roll...

Page 234: ...val in reverse order being careful to tighten the ring nuts nuts and screws to the prescribed torque Pinion LEVERS pos Description Type Quantity Torque Note 1 Pinion retainer nut M12x1 25 1 30 Nm 22 12 lb ft Loctite 270 2 Pinion cover fixing screw TEF M5x16 2 4 Nm 2 95 lb ft Maximum torque 5 0 Nm 3 68 lb ft 3 TCEI Screws pinion retainer M5x10 2 4 Nm 2 95 lb ft Maximum torque 5 0 Nm 3 68 lb ft Loct...

Page 235: ...ankcase Increase the chain clearance to allow removal of the pinion OPTION 01 Remove fixing screws of the pinion lock plate Rotate the pinion lock plate to remove it the from the shaft Remove the pinion OPTION 02 RS4 125 Chassis CHAS 235 ...

Page 236: ... Unscrew and remove the pinion lock nut Remove the Belleville spring Remove the pinion Installing OPTION 01 Insert the pinion on the shaft Chassis RS4 125 CHAS 236 ...

Page 237: ...ainer plate and rotate it to match the holes Insert the fixing screws of the pinion and tighten them to the prescribed tor que OPTION 02 Insert the pinion on the shaft Insert the Belleville spring RS4 125 Chassis CHAS 237 ...

Page 238: ... the rear adjuster screws Identify the master link slide off the clip Remove the plate underneath Collect the chain CAUTION REPLACE THE ENTIRE UNIT IF THE CHAIN IS PARTICU LARLY WORN See also Adjusting inspection Also check the following parts and make sure that the chain pinion and crown do not present Damaged rollers Loose pins Dry rusty flattened or jammed chain links Excessive wear Excessively...

Page 239: ...chain and fit the master link pins from the inside to the outside Insert the plate on the pins Fit the clip on the pins CAUTION THE MASTER LINK CLIP MUST BE FITTED WITH ITS OPEN SIDE FACING DIRECTION OPPOSITE THE CHAIN FOR WARD MOVEMENT Adjusting To check clearance Shut off the engine Rest the vehicle on its stand Engage neutral gear Check the vertical oscillation at a point between the pinion and...

Page 240: ...le on its optional rear service stand Working from both sides loosen the nut 1 completely Actuate on the adjuster screws 2 and adjust the chain clearance according to the references 3 Check that the references 3 are aligned on both sides Then tighten the nuts 1 CAUTION IF CLEARANCE IS GREATER AT SOME POSITIONS THIS MEANS THAT SOME CHAIN LINKS ARE FLATTENED OR JAMMED TO AVOID RISK OF SEIZURE LUBRIC...

Page 241: ... ft 2 TCEI screw M8x30 2 25 Nm 18 43 lb ft Loctite 243 3 TCEI screw M8x45 1 25 Nm 18 43 lb ft 4 TE Screws Flang M5x25 2 3 Nm 2 21 lb ft 5 TE Screws M6x30 2 10 Nm 7 38 lb ft Removing Remove the screw with the relative re tainer nut being careful to recover the shimming washers RS4 125 Chassis CHAS 241 ...

Page 242: ...e the screw and the relative re tainer nut of the chain tensioner plate If necessary replace the spring Installing Insert the spring 1 on the chain ten sioner plate 2 paying attention to cor rect the positioning Place the bushing 3 with milling ad dress as shown in the figure Chassis RS4 125 CHAS 242 ...

Page 243: ...s and spacer Stand Side stand Rest the vehicle on the optional rear stand Stand rod removal With closed stand release the spring 1 Unscrew and remove the nut 2 Remove stand together with the plate Unscrew and remove the two stand switch fixing nuts 3 Unscrew and remove the internal nut and the pin 4 by collecting the wash er Slide off the nut and remove the cable grommet Slide off the stand togeth...

Page 244: ...tity Torque Notes 1 Drainage retainer M6x20 2 10 Nm 7 37 lbf ft 2 Footrest retainer M8x40 1 25 Nm 18 43 lbf ft Removing the tail pipe Undo and remove the two upper stay screws and collect the relative nuts and washers Chassis RS4 125 CHAS 244 ...

Page 245: ... Beforehand remove the side fairings and the fairing lug Loosen the clamp See also Side fairings Remove the exhaust end RS4 125 Chassis CHAS 245 ...

Page 246: ... the exhaust manifold Unscrew and remove the two screws Remove the manifold Remove the muffler Lift the saddle and disconnect the lambda probe connector See also Removing the tail pipe Chassis RS4 125 CHAS 246 ...

Page 247: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 248: ...1 Front brake pump fixing screw M5 2 5 Nm 3 68 lbf ft 2 Brake pipe clamp fixing screw M5x16 1 5 Nm 3 68 lbf ft FRONT CALLIPER pos Description Type Quantity Torque Notes 1 Front calliper fixing screw M10x60 2 50 Nm 36 87 lbf ft Braking system RS4 125 BRAK SYS 248 ...

Page 249: ... screw M6x30 2 10 Nm 7 37 lbf ft 3 Brake pump joint retainer M6 1 10 Nm 7 37 lbf ft Rear brake calliper CAUTION THE MOTORCYCLE MAY BE FITTED WITH AN A J P OR J JUAN BRAKING SYSTEM THE PROCEDURES FOR REMOVING AND INSTALLING THE BRAKE CALLIPER ARE IDENTICAL key A A J P Brake calliper B J JUAN Brake calliper RS4 125 Braking system BRAK SYS 249 ...

Page 250: ...m the left side Move the rear wheel Move the rear brake calliper plate until the end and slide it one off Undo the joint from the rear calliper after placing an appropriate container to collect the brake fluid Remove the speed sensor It is now possible to remove the complete calliper Braking system RS4 125 BRAK SYS 250 ...

Page 251: ... the braking system line to the calliper and proceed with bleeding Front brake calliper CAUTION THE MOTORCYCLE MAY BE FITTED WITH AN A J P OR J JUAN BRAKING SYSTEM THE PROCEDURES FOR REMOVING AND INSTALLING THE BRAKE CALLIPER ARE IDENTICAL key A A J P Brake calliper B J JUAN Brake calliper Removal Carry out the drainage of the front braking system Unscrew the screw 1 and slide off the brake oil pi...

Page 252: ... disc adequately so that the inscriptions are on the external side Tighten to the specified torque Disc Inspection Check the disc thickness 1 at the most worn points If the disc thickness is less than the minimum limit replace it The meas urement area is approximately at the point 2 In case of cracks or slots replace it Standard thickness of the disc 3 5 mm 0 13 in Serviceability limit 3 mm 0 11 i...

Page 253: ...osition the disc adequately so that the inscriptions are on the external side Tighten to the specified torque Locking torques N m Front brake disc 10 12 Disc Inspection Check the disc thickness A at the most worn points If the disc is worn more than the specific limit replace it Measurement area 2 Check that there are no cracks and slots if it does not comply with the specifications replace it Sta...

Page 254: ...rake calliper on the left hand side of the vehicle Undo and remove the two screws 2 fastening the brake calliper Remove the brake calliper Remove the screw 1 and retrieve the two pads from below Check the pads Measure the thickness of the brake pads If one of the two falls under the serviceability limit replace them Serviceability limit 1 5 mm 0 05 in WARNING IF THE BRAKE LEVER STARTS WITHOUT THE ...

Page 255: ...ake calliper on the left hand side of the vehicle undo and remove the two brake calliper fastener screws Remove the circlip Remove the pad fastener pin Remove the pads Check the pads RS4 125 Braking system BRAK SYS 255 ...

Page 256: ...RE THE SAME FOR BOTH THE A J P AND THE J JUAN SYSTEM WARNING IF THE BRAKE LEVER STARTS WITHOUT THE CALLIPER IT MAY BE NECESSARY TO CARRY OUT BLEEDING Remove the rear brake calliper Press on the external pad in the direc tion of the arrow Remove the pads Check the pads Measure the thickness of the brake pads If one of the two falls under the serviceability limit replace them Serviceability limit 1 ...

Page 257: ...LLY DRY THE CALLIPER AND DE GREASE THE DISC SHOULD THERE BE OIL ON IT WHEN THE OPERATION IS OVER TIGHTEN THE OIL BLEED SCREW TO THE PRESCRIBED TORQUE CAUTION MAKE SURE THE BRAKE FLUID DOES NOT GET INTO YOUR EYES OR ON YOUR SKIN OR CLOTHES IF THIS HAPPENS ACCIDENTALLY WASH WITH WATER WARNING BRAKE CIRCUIT FLUID IS VERY CORROSIVE DO NOT LET IT COME INTO CONTACT WITH THE PAINTED PARTS key A A J P Bra...

Page 258: ...ECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Screw the bleeding valve and remove the pipe Top up the reservoir until the correct brake fluid level is obtained Refit and block the front brake oil reservoir cap Refit the rubber protection cover Rear Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by the brake pump and mi...

Page 259: ... free NOTE WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Screw the bleeding valve and remove the pipe Top up the reservoir until the correct brake fluid level is obtained Refit and lock the rear brake oil reservoir cap Refit the rubber protection cover Changing the brake ...

Page 260: ... by disconnecting the hoses collect the brake oil in the tank in an adequate container Unscrew and remove the two U bolt fixing screw at the handlebar and slide off the front brake pump tank During the refit carry out the described operations in reverse order tightening the screws to the prescribed torque Rear brake pump Braking system RS4 125 BRAK SYS 260 ...

Page 261: ... fluid in an ade quate container Unscrew and remove the two screws and collect the corresponding nuts Unscrew and remove the nut retriev ing the nut Slide off the rear brake pump During the refit work in reverse order as described RS4 125 Braking system BRAK SYS 261 ...

Page 262: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 263: ...DIATOR pos Description Type Quantity Torque Notes 1 Radiator retainer M6x25 2 10 Nm 7 37 lbf ft 2 Expansion tank support fixing screw M6x20 1 3 5 4 Nm 2 58 2 95 lbf ft RS4 125 Cooling system COOL SYS 263 ...

Page 264: ... diagram key 1 Breather pipe 2 Radiator expansion tank pipe 3 Cooling liquid reservoir 4 Cap 5 Clamp 6 Clamp D16 24x8 7 D10 1 clamp 8 Water radiator 9 Cap 10 TCEI screw M6x20 11 6 6x18x1 6 washer 12 Elastic plate M6 13 T shaped bushing 14 TE flanged screw M6x25 15 Elastic plate M6 Cooling system RS4 125 COOL SYS 264 ...

Page 265: ...the three screws and collect the washers remove the electric fan See also Removing the radiator Coolant replacement CAUTION DO NOT USE YOUR VEHICLE IF THE COOLANT IS BELOW THE MINIMUM LEVEL CHECK THE COOLANT LEVEL PERIODICALLY OR AFTER LONG TRIPS Remove the right fairing Working on the left side of the vehicle open the expansion tank cap See also RS4 125 Cooling system COOL SYS 265 ...

Page 266: ... let the cooling liquid spill out by pouring it into a container of a suitable capacity CAUTION DO NOT DISPOSE OF THE FLUID INTO THE ENVIRON MENT Water pump Removal Remove the water pump and rotor cov er Remove the rotor Cooling system RS4 125 COOL SYS 266 ...

Page 267: ...external part to the internal one Specific tooling 866380 tool description Turn the clutch cover and acting from the internal part to the external one with the specific tool C take out the seal ring Specific tooling 866380 tool description Support the group of the water pump shaft on a vice and after it is sufficiently heated up separate it with a punch from the gear Installing CAUTION RS4 125 Coo...

Page 268: ...il it stops Specific tooling 866380 tool description Warm up the clutch cover to facilitate the insertion of the shaft with the bear ings Place the specific tools B and A as in the figure in order to push with the press the shaft and the bearings until it stops Specific tooling 866380 tool description Place the oil seal as in figure and push it until it stops Cooling system RS4 125 COOL SYS 268 ...

Page 269: ...oling 866380 tool description Place the sealing ring and push it until it stops with the specific tool C by us ing the press Specific tooling 866380 tool description Install the clutch cover Install the rotor and the water pump cover Removing the radiator Remove the expansion tank and the radiator cowl Unscrew the screw and loosen the ra diator hose fastening clamp RS4 125 Cooling system COOL SYS ...

Page 270: ... with a screwdriver Slide off the radiator head pipe WARNING CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS COLD SCALDING FLUID OR ITS VAPOURS CAN CAUSE SERIOUS BURNS COLLECT THE FLUID IN A SUITABLE CONTAINER THE COOLANT IS HARMFUL AVOID CON TACT WITH THE SKIN AND EYES Unscrew and remove both screws fix ing from the radiator to the chassis Cooling system RS4 125 COOL SYS 270 ...

Page 271: ...s but in reverse order Fill the coolant tank with the recommended product Check that the system does not show leaks Removing the expansion tank Remove the left side fairing and drain off the coolant Lift the tank and fasten it in position with the supplied supporting stem Unscrew and remove the two screws and slide the piping out RS4 125 Cooling system COOL SYS 271 ...

Page 272: ...gs Coolant replacement Unscrew and remove the tank fixing screw Slide off the coolant tank INSTALLATION For the installation proceed in reverse order as described and fill the system after having replaced the recommen ded clamps Cooling system RS4 125 COOL SYS 272 ...

Page 273: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 274: ...Torque Notes 1 Rear tank fixing screw M8x40 1 1 25 Nm 18 44 lbf ft 2 Front tank fixing screw M6x35 1 10 Nm 7 37 lbf ft 3 Fastener screw M5x9 4 3 Nm 2 21 lbf ft 4 Tank cover fixing screw M5x9 4 3 Nm 2 21 lbf ft Bodywork RS4 125 BODYW 274 ...

Page 275: ...irror Remove the rear view mirrors Instrument panel Remove the windshield Lift the instrument panel and discon nect the connector Disconnect the two connectors from the turn indicator and remove the in strument panel from the support See also Headlight fairing RS4 125 Bodywork BODYW 275 ...

Page 276: ...left side and the nut from the right side Unscrew and remove the six perimeter screws and remove the two shells Headlight assy FRONT LIGHTS pos Description Type Quantity Torque Notes 1 Headlamp fixing screw M5x14 4 2 5 Nm 1 84 lbf ft 2 Self tapping screw M5 1 1 5 Nm 1 11 lbf ft Bodywork RS4 125 BODYW 276 ...

Page 277: ...indicators Unscrew and remove the four fixing screws at the top fairing Remove the headlight assembly See also Headlight fairing Headlight fairing Remove the fairing and the rear view mirrors Unscrew and remove the screw of the direction arrow Remove the glass and disconnect the two wires from the bulb Remove the two screws placed in the inside the top fairing from both sides of the motorcycle RS4...

Page 278: ... screws fixing the top fairing to the chassis Unscrew and remove the two top fair ing side screws Unscrew and remove the two screws on the front fairing Disconnect the instrument panel con nector Bodywork RS4 125 BODYW 278 ...

Page 279: ...eel housing that you want to re move Operating from the left shield unscrew and remove the regulator fixing screw collecting the nut and the washer Operating from both sides Unscrew and remove the lower screw Remove the wheel housing See also Side fairings RS4 125 Bodywork BODYW 279 ...

Page 280: ...tail fairing and the pas senger saddle Remove the two side screws 1 Remove the two upper screws 2 Disconnect the connector See also Tail guard Take off the rear light unit by removing it from the hooks Bodywork RS4 125 BODYW 280 ...

Page 281: ...r to one fairing but they apply to both Rest the vehicle on its stand Remove the side fairing Unscrew and remove the two screws 1 and collect the corresponding washers Unscrew and remove the screw 2 and collect the washer Remove the rivet 3 Working on the front side of the vehicle remove the three rivets 4 Loosen and remove the screw 5 Sliding it off the fixing tongues 6 and paying attention to th...

Page 282: ... holder Remove the passenger saddle Remove the lower licence plate sup port cover Unscrew and remove the central lower screw Unscrew and remove the two lower screws Remove the three clamps Bodywork RS4 125 BODYW 282 ...

Page 283: ... support Air box Remove the passenger footrest the saddle the tank the fairing and the splash guard Unscrew and remove the four screws 1 Loosen the clamp and remove the in take tube See also Footrest Fuel tank Rear wheelhouse RS4 125 Bodywork BODYW 283 ...

Page 284: ...uard Unscrew and remove the screw Slide off the pipe grommet Operating from the right side unscrew and remove the central screw Working on the left side unscrew and remove the two screws Remove the rear mudguard Bodywork RS4 125 BODYW 284 ...

Page 285: ...e open side stand Remove the side rivet Carry out the following operations on one side of the vehicle and then on the other Unscrew and remove the rear screw See also Side fairings Unscrew and remove the central screw Unscrew and remove the front screw following the lug downwards RS4 125 Bodywork BODYW 285 ...

Page 286: ...remove the side screw After having removed the passenger saddle collect the supporting rod of the fuel tank Lift the tank and support it appropriate ly Remove the clamps as indicated in the electrical system fitting Disconnect the quick release and the fuel reserve connector CAUTION FIRE HAZARD FUEL OR ANY OTHER FLAMMABLE SUB STANCES MUST NOT BE CLOSE TO ELECTRICAL COM PONENTS See also Bodywork RS...

Page 287: ...ollect the nut on the internal side Keeping the tank in position lower it by removing the supporting rod Remove the tank Rear wheelhouse Beforehand remove the tail fairing the taillight the saddle and the passenger saddle Unscrew and remove the two fixing screws Remove the mudflap RS4 125 Bodywork BODYW 287 ...

Page 288: ...crew and remove the two upper screws Retrieve the corresponding washers Unscrew and remove the two lower screws Slide off the radiator cover Working from both sides of the vehicle release the two rivets and slide off the front lug Bodywork RS4 125 BODYW 288 ...

Page 289: ...de of the vehicle but apply to both Remove the central side fairing and the passenger saddle Unscrew and remove the two front screws and the rear screw Slide off the fairing CAUTION DURING THE REMOVAL PAY ATTENTION TO THE FIT TINGS RS4 125 Bodywork BODYW 289 ...

Page 290: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 291: ...r brake calliper retainer unit front and rear wheel unit engine chassis retainers steering assembly Plastic parts fixing screws Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights ...

Page 292: ... SERIOUS BURNS IT CON TAINS SULPHURIC ACID AVOID CONTACT WITH YOUR EYES SKIN AND CLOTHING IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUN DANT WATER FOR APPROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF ...

Page 293: ...ning of the steering Possible leaks Radiator electric fan operation if present Functional inspection Hydraulic braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre...

Page 294: ...ensor WARNING BEFORE POSITIONING AND TIGHTENING THE QUICK SHIFT SENSOR APPLY LOCTITE 243 ON THE FIXING SCREW OF THE BALL JOINT Install the gear tie rod with integrated Quick Shift sensor by tightening the two screws to the specified torque QUICK SHIFT TIE ROD pos Description Type Quantity Torque Note 1 Nut fixing tie rod to gear lever M6 1 10 Nm 7 lb ft 2 Screw fixing tie rod to selector shaft M6 ...

Page 295: ... Access the Quick Shift connector by lifting the tank the connector is placed as shown in the figure internally on the left side of the chassis Connect the two cables RS4 125 Pre delivery PRE DE 295 ...

Page 296: ... 272 Coolant 127 265 272 Countershaft 158 159 166 168 Crankcase 42 140 157 160 164 167 Crankshaft 42 165 Cylinder 42 161 175 183 185 190 191 D Desmodromic drum 141 Drive chain 238 E ECU 124 Electric fan 122 265 Electrical system 11 64 65 291 Engine oil 52 Engine temperature sensor 115 Exhaust 244 246 Exhaust manifold 246 F Fairings 127 245 266 272 279 281 285 Fork 210 211 218 221 Front wheel 207 2...

Page 297: ...54 P Primary shaft 140 R Radiator 127 265 269 288 Rear wheel 225 227 228 233 Recommended products 43 S Scheduled maintenance Shock absorbers 228 Side fairings 281 Side stand 122 243 Side stand sensor 122 Spark plug 51 Speed sensor 113 Stand 122 243 Start up 103 Starter motor 142 143 174 T Tank 127 200 270 271 283 286 Throttle body 202 Transmission 11 Tyres 12 V Voltage regulator 102 W Warning ligh...

Page 298: ...Windshield Wiring diagram 92 ...

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APRILIA RS4 125, Service Station Manual

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