APRILIA RS4 50 2011 Workshop Manual Download Page 9

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BEFORE DISASSEMBLING COMPONENTS

•

Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.

Use the special tools designed for this bike, as required.

COMPONENTS REMOVAL

•

Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific

wrench.

•

Mark positions on all connection joints (pipes, cables etc.) before separating them, and

identify them with distinctive symbols.

•

Each component needs to be clearly marked to enable identification during reassembly.

•

Clean and wash the dismantled components carefully using a low-flammability detergent.

•

Keep mated parts together since they have "adjusted" to each other due to normal wear.

•

Some components must be used together or replaced completely.

•

Keep away from heat sources.

REASSEMBLING COMPONENTS

CAUTION

BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.

•

Only use ORIGINAL Aprilia SPARE PARTS.

•

Comply with lubricant and consumables use guidelines.

•

Lubricate parts (whenever possible) 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 assembling the bearings, make sure to lubricate them well.

•

Check that each component is assembled correctly.

•

After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on

private grounds or in an area with low traffic.

•

Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a light layer of

lithium-based grease on the oil guard rims. Reassemble oil seals and bearings with the

brand or batch number facing outward (visible side).

ELECTRICAL CONNECTORS

Electric connectors must be disconnected as described below; failure to comply with this procedure

causes irreparable damage to both the connector and the wiring harness:

Press the relative safety clips, if applicable.

•

Grip the two connectors and disconnect them by pulling them in opposite directions.

RS4 50 MY2011

Characteristics

CHAR - 9

Summary of Contents for RS4 50 2011

Page 1: ...MSS RS4 50 MY2011 B043132 RS4 50 MY2011 ...

Page 2: ...re 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 r...

Page 3: ...and changes in repair procedures are communicated to all aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult aprilia CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates and...

Page 4: ......

Page 5: ...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 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...AUSE 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 eth...

Page 8: ... 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 PLENTY O...

Page 9: ...re 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 assembl...

Page 10: ...LE THESE COMPONENTS FAILURE TO COMPLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR EVEN DETACH CAUSING A WHEEL TO LOCK OR COMPROMISING 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...

Page 11: ...git Y year of manufacture S production plant H Martorelles Spain S Scorzè Italy 4 Zongshen China 5 Ponte dera Italy M Mandello del Lario Italy XXXXXX serial number 6 digits CHASSIS NUMBER The chassis number is stamped on the right hand side of the headstock Engine number The engine number is stamped on the rear side close to the transmission oil filler cap Dimensions and mass SIZES Specification D...

Page 12: ...ch operates the selector with fork and distribution drum GEAR RATIOS Specification Desc Quantity 1st gear ratio 11 34 1 3 091 2nd gear ratio 15 30 1 2 000 3rd gear ratio 18 27 1 1 500 4th gear ratio 20 24 1 1 200 5th gear ratio 22 23 1 1 045 6th gear ratio 23 22 1 0 956 final drive gear ratio 11 53 Capacities CAPACITY Specification Desc Quantity Fuel tank 14 5 1 l 3 07 0 22 UK gal 3 70 0 26 US gal...

Page 13: ...r lighting 12 V LED Rear daylight running light stop light LED License plate lamp where provided 12V 5W Frame and suspensions CHASSIS Specification Desc Quantity Type With die cast beam with aluminium alloy Trail 93 6 mm 3 68 in Size A 535 1 mm 21 067 in measurements refer to the bare chassis Size B 357 5 mm 14 075 in measurements refer to the bare chassis SUSPENSIONS Specification Desc Quantity F...

Page 14: ...70 kPa 24 66 PSI Front inflation pressure rider passenger 1 8 bar 180 kPa 26 11 PSI Rear size 130 70 17 62H or alternatively 150 60 17 66H Rear inflation pressure rider only 1 8 bar 180 kPa 26 11 PSI Rear inflation pressure rider passenger 1 9 bar 190 kPa 27 56 PSI Supply FUEL SYSTEM Specification Desc Quantity Fuel premium unleaded petrol as per DIN 51 607 minimum octane rating of 95 NORM and 85 ...

Page 15: ...s 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 50 MY2011 Characteristics CHAR 15 ...

Page 16: ... yoke fastening to sleeve M8 2 25 Nm 18 43 lbf ft 2 Steering retainer nut M20 1 48 Nm 35 40 lbf ft FRONT SUSPENSION pos Description Type Quantity Torque Notes 1 Screws fastening lower yoke to sleeve M8 2x2 25 Nm 8 43 lbf ft Characteristics RS4 50 MY2011 CHAR 16 ...

Page 17: ...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 FRONT MUDGUARD LUG pos Description Type Quantity Torque Notes 1 Lug fixing screw M5x9 2 3 Nm 2 21 lbf ft RS4 50 MY2011 Characteristics CHAR 17 ...

Page 18: ...iring 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 AIR DEFLECTORS pos Description Type Quantity Torque Notes 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 ...

Page 19: ...5 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 RS4 50 MY2011 Characteristics CHAR 19 ...

Page 20: ... 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 Characteristics RS4 50 MY2011 CHAR 20 ...

Page 21: ...tle 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 RS4 50 MY2011 Characteristics CHAR 21 ...

Page 22: ...tral part CHASSIS pos Description Type Quantity Torque Notes 1 TCEI screw M8x16 2 15 Nm 11 06 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 Characteristics RS4 50 MY2011 CHAR 22 ...

Page 23: ...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 RS4 50 MY2011 Characteristics CHAR 23 ...

Page 24: ...e 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 Characteristics RS4 50 MY2011 CHAR 24 ...

Page 25: ...Notes 1 Mixing tank fixing screw M6x16 2 4 4 Nm 3 24 lbf ft Max 5 N 3 68 lbf ft SIDE FAIRINGS pos Description Type Quantity Torque Notes 1 Side fairing fixing screw M5x9 6 1 7 Nm 1 25 lbf ft Max 2 Nm 1 47 lbf ft RS4 50 MY2011 Characteristics CHAR 25 ...

Page 26: ...0 2 10 Nm 7 37 lbf ft 2 Footrest retainer M8x40 1 25 Nm 18 43 lbf ft 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 Characteristics RS4 50 MY2011 CHAR 26 ...

Page 27: ...support fixing screw M8x25 1 1 25 Nm 18 43 lbf ft Loctite 243 2 Footrest protection fixing screw M5x12 2 2 5 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 RS4 50 MY2011 Characteristics CHAR 27 ...

Page 28: ... 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 CENTRAL BODYWORK pos Description Type Quantity Torque Notes 1 Fairing upper fixing screw M5x9 6 3 Nm 2 21 lbf ft 2 Fairing lower fixing screw M4x14 2 Characteristics RS4 50 MY2011 CHAR 28 ...

Page 29: ...nut M10x1 25 1 10 Nm 7 38 lb 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 LOCKS pos Description Type Quantity Torque Notes 1 Fuel tank cap retainer M5x16 3 3 Nm 2 21 lb ft RS4 50 MY2011 Characteristics CHAR 29 ...

Page 30: ...addle lock retainer M6x30 2 6 Nm 4 42 lb ft 4 Steering lock retainer M8x20 2 6 5 Nm 4 79 lb ft 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 Characteristics RS4 50 MY2011 CHAR 30 ...

Page 31: ...e Notes 1 Swingarm to chassis adjustment nut M25x1 5 1 15 Nm 11 06 lbf ft 2 Swingarm pin nut 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 RS4 50 MY2011 Characteristics CHAR 31 ...

Page 32: ...x20 6 12 Nm 8 85 lbf ft 3 Sprocket fixing screw M6 6 12 Nm 8 85 lbf ft 4 Chain tensor fixing screw M8 2 12 Nm 8 85 lbf ft Loctite 243 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 Characteristics RS4 50 MY2011 CHAR 32 ...

Page 33: ...REAR MUDGUARD pos Description Type Quantity Torque Notes 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 RS4 50 MY2011 Characteristics CHAR 33 ...

Page 34: ...6x110 4 8 10 Nm 5 90 7 38 lbf ft 2 Clamp retainer 1 0 3 0 4 Nm 0 22 0 29 lbf ft OIL PUMP Description Type Quantity Torque Note Oil pump cover retainer M5x80 4 3 5 4 5 Nm 2 58 3 31 lbf ft Oil pump retainer M5x80 2 3 5 4 5 Nm 2 58 3 31 lbf ft Characteristics RS4 50 MY2011 CHAR 34 ...

Page 35: ... MAIN SHAFT pos Description Type Quantity Torque Note 1 Main axle bearing retainer M5x80 2 3 5 4 5 Nm 2 58 3 31 lbf ft 2 Pinion retainer M4x10 2 2 4 Nm 1 47 2 95 lbf ft Loctite 243 RS4 50 MY2011 Characteristics CHAR 35 ...

Page 36: ... 5 Nm 2 58 3 31 lbf ft 2 Water pump cover retainer M6x100 3 8 10 Nm 5 90 7 38 lbf ft CLUTCH pos Description Type Quantity Torque Note 1 Clutch housing retainer M12 1 35 45 Nm 28 81 33 19 lbf ft 2 Clutch spring retainer M5x80 5 3 5 4 5 Nm 2 58 3 31 lbf ft Characteristics RS4 50 MY2011 CHAR 36 ...

Page 37: ...CLUTCH COVER pos Description Type Quantity Torque Note 1 Cover retainer M6x110 7 8 10 Nm 5 90 7 38 lbf ft RS4 50 MY2011 Characteristics CHAR 37 ...

Page 38: ...8 10 Nm 5 90 7 38 lbf ft 3 Head nut retainer M7 4 19 22 Nm 14 01 16 23 lbf ft 4 Thermistor retainer M14 1 32 38 Nm 23 60 28 03 lbf ft DEPRESSION CARBURETTOR pos Description Type Quantity Torque Note 1 Carburettor chamber retainer 1 1 Nm 0 73 lbf ft 2 Starter cover retainer 1 1 1 Nm 0 73 lbf ft Characteristics RS4 50 MY2011 CHAR 38 ...

Page 39: ...TER MOTOR pos Description Type Quantity Torque Note 1 Starter motor retainer M6x100 2 8 10 Nm 5 90 7 38 lbf ft 2 Countershaft retainer M10 1 15 18 Nm 11 06 13 27 lbf ft RS4 50 MY2011 Characteristics CHAR 39 ...

Page 40: ...te 1 Crankcase retainer M26x100 8 8 10 Nm 5 90 7 38 lbf ft LEVERS pos Description Type Quantity Torque Note 1 Gearbox lever fixing screws M6x20 1 10 Nm 7 73 lbf ft 2 Gearbox lever fixing screws M6x16 1 10 Nm 7 73 lbf ft Characteristics RS4 50 MY2011 CHAR 40 ...

Page 41: ...SPEZIAL ENI ANTIFREEZE Coolant Fluid without amines nitrites or phos phates intended to 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 AGIP FI...

Page 42: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 43: ...ores code Description 020376Y Adapter handle 020357Y 32 x 35 mm adaptor 020441Y Oil seal punch 020456Y Ø 24 mm punch 020358Y 37 x 40 mm adaptor 020426Y Piston fitting fork RS4 50 MY2011 Special tools S TOOLS 43 ...

Page 44: ... water pump shaft 020362Y 12mm oil guard guide 020412Y 15 mm Oil seal guide 020439Y 17 mm guide for oil seal 020363Y 20 mm Oil seal guide 0 0H 053 0 004 1 Clutch locking tool 0 0H 056 0 032 1 Primary drive pinion extractor Special tools RS4 50 MY2011 S TOOLS 44 ...

Page 45: ... Flywheel lock calliper spanner AP8106698 Crankcase separator AP8501501 Flywheel extractor AP8140266 Dial gauge mounting 020330Y Stroboscopic light for timing checking 020331Y Digital multimeter RS4 50 MY2011 Special tools S TOOLS 45 ...

Page 46: ...Stores code Description 020333Y Single battery charger 020334Y Multiple battery charger 866714 Swingarm adjustment Special tools RS4 50 MY2011 S TOOLS 46 ...

Page 47: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 48: ...I I Tyres pressure 4 I I I I I I Vehicle and brake system test I I I I I I Radiator External cleaning C C Tightening screws I I I I I I Steering I I I Head Cylinder Piston I I Brake hoses I I Fuel and oil filters pipes 3 I I R I R I I INSPECT AND CLEAN ADJUST LUBRICATE 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 conditio...

Page 49: ...aning Check carefully that the parts are in good conditions The throttle valve should slide freely inside the mix chamber replace valve in case of excessive clearance due to wear If there are wear marks in the mix chamber causing inadequate tightness or valve slide even if it is new replace the carburettor It is advisable to replace the gasket at each refit WARNING PETROL IS HIGHLY EXPLOSIVE ALWAY...

Page 50: ...1 before TDC Spark plug Lift the tank Disconnect the spark plug HV wire cap Unscrew the spark plug using the sock et wrench Examine the condition of the spark plug check that the insulating material is whole and measure the distance be tween the electrodes using a feeler gauge Adjust the distance if necessary by bending the side electrode very care fully In the case of defects replace the spark pl...

Page 51: ...ARK PLUG Specification Desc Quantity Standard NGK BR8ES Alternatively CHAMPION RN3C Electrode gap 0 5 mm 0 020 in Gearbox Oil Inspection NOTE PARK THE MOTORCYCLE ON SAFE AND LEVEL GROUND Carefully unscrew the level inspection screw 1 on the right hand engine cov er Check that the oil level reaches the threaded hole TOP UP If necessary top up Unscrew and remove the filler plug 2 Add a small quantit...

Page 52: ...ATES THE WEAR AND TEAR OF THE MOVING PARTS AND CAN CAUSE IR RETRIEVABLE DAMAGE Recommended products AGIP GEAR 10W 40 Gearbox oil API GL 4 Replacement 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 ...

Page 53: ...REGULARLY THAT THERE ARE NO LEAKS IN THE CRANKCASE COVER GASKET DO NOT RIDE THE MOTORCYCLE WITH INSUFFICIENT LUBRICATION OR WITH CONTAMINATED OR INCOR RECT LUBRICANTS AS THIS ACCELERATES THE WEAR AND TEAR OF THE MOVING PARTS AND CAN CAUSE IR RETRIEVABLE DAMAGE 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...

Page 54: ...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 IT IS NOT TORN IF IT IS REPLACE THE FILTERING ELEMENT AIR FILTER REPLACEMENT Replace the air filte...

Page 55: ...ove the sight glass with the reservoir completely level Otherwise top up THE SYSTEM MUST ONLY BE TOPPED UP WITH DOT4 TYPE BRAKE FLUID BRAKE FLUID IS HIGHLY CORROSIVE AVOID CONTACT WITH PAINTWORK IN THE EVENT OF SPILLAGE ON PAINTED PARTS RINSE IMMEDIATELY WITH WATER WARNING THE FLUID IN THE BRAKING CIRCUIT IS HYGROSCOPIC THAT IS IT ABSORBS MOISTURE FROM THE SUR ROUNDING AIR IF THE MOISTURE CONTENT ...

Page 56: ...ESERVOIR 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 ins...

Page 57: ...gh the set screw 1 Rest the 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 G...

Page 58: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 59: ...Small parts and mountings N 8 Large black clamps 290x4 5 11 42x0 18 in N 6 Medium black clamps 190x4 5 7 48x0 18 in N 5 Small black clamps 160x4 5 6 30x0 10 in Nº 4 Rubber clamps N 6 Cable guide of various types N 3 Retaining clip Special checks for the correct connection and laying of cables It is extremely important that any security locks for the following connectors are properly connected and ...

Page 60: ...ctors 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 The installation is shown on the three ideal divi sions of the vehicle 1 Front section 2 Central section 3 Rear section Fr...

Page 61: ... 11 Speed sensor the speed sensor must be fitted with two clamps on the clutch odometer and must have a turn as on the engine TABLE C Positioning left and right handlebar cables 12 Rubber clamp RS4 50 MY2011 Electrical system ELE SYS 61 ...

Page 62: ...hand grip Left Switch must be without passing The clamp must take the switch cable The right Switch must be without Engine Kill The clamp must take the switch cable 13 Clamps Electrical system RS4 50 MY2011 ELE SYS 62 ...

Page 63: ...t compartment support especially the main cable harness must be provided with the clamp on the grey sheathing 16 Main cable harness TABLE F Special laying of cables on headlight 2 Cable guide 17 Headlight cable harness 18 Turn indicator cable harness 19 Headlight cable harness 20 Turn indicator cable harness RS4 50 MY2011 Electrical system ELE SYS 63 ...

Page 64: ...TABLE G Instrument panel 21 Mix oil reserve warning light TABLE H Regulator positioning 22 Main cable harness 23 Regulator ground cable 24 Cable guide Electrical system RS4 50 MY2011 ELE SYS 64 ...

Page 65: ...TABLE I Special cable RS4 50 MY2011 Electrical system ELE SYS 65 ...

Page 66: ...Central part TABLE A Pre fitting chassis 1 Cable retaining clip 2 Cable guide 3 Cable guide Electrical system RS4 50 MY2011 ELE SYS 66 ...

Page 67: ...RS4 50 MY2011 Electrical system ELE SYS 67 ...

Page 68: ...nsor 6 ATTENTION check carefully if the connec tion has been carried out and if there are pins slide off Signal with a permanent marker after having made the control IF NOT WELL CON NECTED THE ENGINE COULD SEIZE 7 Low fuel connector Electrical system RS4 50 MY2011 ELE SYS 68 ...

Page 69: ...e White Red cable in the branch of the Main Cable harness 11 ATTENTION Connect the cables from the flywheel to the transducer according to the written colours on the transducer as shown in the picture 12 Flywheel cable TABLE E Installing main cable harness 13 Relay 5 contacts for vehicle shut off 14 Main fuse 15 CAUTION If the cables are not correctly positioned or if wrong relay is used can not b...

Page 70: ...Electrical system RS4 50 MY2011 ELE SYS 70 ...

Page 71: ...ION see CENTRAL SECTION TABLE D 21 Connection 22 CAUTION Check carefully if the connec tion has been carried out and if there are pins slide off Signal with a permanent marker after having made the control CAN CAUSE THE EN GINE SEIZURE 23 Main cable harness 24 If this is the resistance put on the clamp TABLE F Position engine ground 24 Towards chassis ground 25 Towards main cable harness 26 Engine...

Page 72: ...Side stand connection 30 Relay 31 Relay TABLE H 32 The horn cable is put on the 3 indicated clamps 33 Horn cable 34 Neutral cable 35 N 5 Clamp to keep the cables positioned Horn Stand and Neutral Sensor 36 Stand sensor cable Electrical system RS4 50 MY2011 ELE SYS 72 ...

Page 73: ...erve sensor TABLE K Proper battery positioning Place the battery cables as indicated to facilitate the test 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 RS4 50 MY2011 Electrical system ELE SYS 73 ...

Page 74: ...t blue 2b Blue 3 Rear right turn indicator 3a red 3b blue 4 Left rear turn indicator cable harness routing 5 EU License plate frame cable harness 6 CH License plate frame cable harness 7 Right rear turn indicator cable harness routing 8 Rear right turn indicator 9 Only version CH Electrical system RS4 50 MY2011 ELE SYS 74 ...

Page 75: ...ail fairing cable harness fitting 10 Clamps CAUTION this clamp to be put on the joist be low saddle mounting 11 Taillight Cable harness 12 Main cable harness 13 LED Rear light 14 Cable guide RS4 50 MY2011 Electrical system ELE SYS 75 ...

Page 76: ...Electrical system RS4 50 MY2011 ELE SYS 76 ...

Page 77: ...General wiring diagram KEY 1 MULTIPLE CONNECTORS 2 COMPLETE HEADLAMP 3 HIGH BEAM BULB 4 LOW_BEAM BULB RS4 50 MY2011 Electrical system ELE SYS 77 ...

Page 78: ... 19 LICENSE PLATE LIGHT only for Switzerland 20 REAR LEFT TURN INDICATOR 21 START UP RELAY 22 STARTER MOTOR 23 BATTERY 24 FUSE 7 5A 25 Flywheel 26 PICK UP 27 SPARK PLUG 28 ECU CONTROL UNIT with engine revs outlet 29 REGULATOR 30 LOW FUEL 31 Water Temperature Sensor 32 SPEED SENSOR 33 NEUTRAL SENSOR 34 MIXER OIL SENSOR 35 NEUTRAL LOGIC RELAY 36 MAIN RELAY 37 FRONT LEFT TURN INDICATOR 38 RESISTANCE ...

Page 79: ...connection 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 If the failure persists check the alternator and the stator components as follows After a sight control of the electrical connections use a specific tester to measure the stator winding and the pick up If checks on the ...

Page 80: ...screw and remove the four fixing screws and slide off the ground lead Disconnect the flywheel connections Slide off the tube from the spark plug Remove the coil Check the resistance of the secondary winding of the high voltage coil resistance between points A and B WARNING IF THE READINGS OF THE SECONDARY WINDING AND THE MAGNETO FLYWHEEL ARE RIGHT REPLACE THE COIL Electric characteristic Resistanc...

Page 81: ...the right of the battery support re tainer Before replacing a blown fuse find and solve the problem that caused it to blow Do not substitute the fuse with any al ternative form of conductor NOTE THERE IS ONE SPARE FUSE Battery This vehicle 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 tha...

Page 82: ...ING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP OUT OF THE REACH OF CHILDREN Characteristic Battery 12 V 4 Ah MF Battery maintenance If the vehicle is not be used for a certain time 1 month or more the battery needs to be recharged periodically The battery runs down completely in about three months If it is necessary to refit the battery in the vehicle be car...

Page 83: ...NT WATER FOR APPROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK FOLLOWED BY MAGNESIUM MILK BEATEN EGG OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN TH...

Page 84: ...tely empty and proceed immediately to the next point 6 Battery closing Insert the airtight cover strips into the filling holes Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery Note To do this do not use sharp objects that could damage the closing strip use gloves to protect your hands and do not bring your face close to the battery The fi...

Page 85: ... yellow timer c connect the clamps of the battery charger to the battery poles black clamp to negative pole and red clamp to positive pole d Press the red button as shown in figure e Press the MF black button to activate the 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 RS4 50 MY2011 Electrical system ELE SYS 85 ...

Page 86: ...w recharge of the battery starting from point c of the recharge pro cedure of the new battery otherwise go to point i i The battery is now completely activated disconnect the battery charger from the fuel supply grid disconnect the clamps from the battery and proceed to fitting the battery on the vehicle Connectors Dashboard Key pin out 1 General ground 2 Key 3 Speed sensor positive 4 Sensor groun...

Page 87: ...dicator warning light 9 10 Neutral warning light neutral 11 Water Temperature Sensor 12 Mixer oil reserve warning light 13 Rpm indicator input 14 Configuration pin 50 125 15 16 17 18 Speed sensor input 19 Low fuel warning light 20 Battery RS4 50 MY2011 Electrical system ELE SYS 87 ...

Page 88: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 89: ...s OPTIONAL front service stand Support the vehicle rear part using belts and hoist Drain off the cooling system Beforehand remove the lug the side fairings the battery the fuel tank the side fairings the drive chain the mixer oil tank the air filter box the carburettor Position an under sump stand that will be supported on the lower side of the engine See also Removing the radiator Lower cowl Side...

Page 90: ...cle preparation Release the clutch cable and release it from the clamps and from the cable grommet Unscrew and remove the battery sup port fixing screw See also Vehicle preparation Slide off the three relays fastened to the battery support Unscrew and remove the screws and collect battery support Engine from vehicle RS4 50 MY2011 ENG VE 90 ...

Page 91: ... coil connector Disconnect the horn connector Disconnect the temperature sensor Disconnect the electrical system con nector engine Disconnect the coil cable connector engine RS4 50 MY2011 Engine from vehicle ENG VE 91 ...

Page 92: ...ew the screw by releasing the neutral sensor Make sure that the vehicle is well fitted on the previously positioned devices for its support and the for the engine Working from both sides of the vehicle Unscrew and remove the screw and collect the nut and the corresponding washers Engine from vehicle RS4 50 MY2011 ENG VE 92 ...

Page 93: ...t side and from the right one 1 working from the left side unscrew and re move the nut and collect the washer 2 Tap slightly with a rubber hammer on the swingarm pin removing it from the right side and collecting the washer Specific tooling 866714 Tools for the swingarm nut adjustment Slide off downwards the engine togeth er with the cradle To release the cradle from the engine operate on three fi...

Page 94: ...Installing the engine to the vehicle When before removed from the cradle fasten the engine to it on the three in dicated points Engine from vehicle RS4 50 MY2011 ENG VE 94 ...

Page 95: ...itable special key tighten the ring and position the nut Specific tooling 866714 Tools for the swingarm nut adjustment Operating from the left side position the nut Operating together on both sides of the vehicle tighten two swingarm pin nuts to the prescribed torque Position and tighten the cradle upper fixing screw of the to the chassis RS4 50 MY2011 Engine from vehicle ENG VE 95 ...

Page 96: ...tighten the screw and the nut Fasten the neutral sensor with the screw Fitting the clutch cover with the three screws Insert the transmission lever in the groove crankshaft at the required incli nation and tighten the screw Engine from vehicle RS4 50 MY2011 ENG VE 96 ...

Page 97: ... the coil cable connector en gine Connect the electrical system connec tor engine Connect the temperature sensor Connect the horn connector Connect the coil connector RS4 50 MY2011 Engine from vehicle ENG VE 97 ...

Page 98: ...ten the battery support screw Position correctly the clutch cable on the leverage and on the cable grom met Proceed with the refit of all previously removed components ensuring to apply all the pre scribed tightening torque Engine from vehicle RS4 50 MY2011 ENG VE 98 ...

Page 99: ...INDEX OF TOPICS ENGINE ENG ...

Page 100: ...axle bearing retainer M5x80 2 3 5 4 5 Nm 2 58 3 31 lbf ft 2 Pinion retainer M4x10 2 2 4 Nm 1 47 2 95 lbf ft Loctite 243 Disassembling the gearbox Open the crankcase halves Take out the selector guiding fork and the selec tor after removing the relative bolts Engine RS4 50 MY2011 ENG 100 ...

Page 101: ...Checking the primary shaft Clean and degrease the gear shaft then check it Carry out a visual inspection of the gears Re place the gears if they show signs of overheating or surface softening or abnormal wear of teeth Replace the whole shaft if it is damaged or ab normally worn RS4 50 MY2011 Engine ENG 101 ...

Page 102: ...have been re moved Check there gear studs and clefts are not roun ded or show signs of abnormal wear Check the secondary shaft rings for wear Replace them if 25 of their surface is worn Make sure that the secondary shaft roller bear ings show no signs of wear Otherwise replace it Engine RS4 50 MY2011 ENG 102 ...

Page 103: ...ndary shaft making sure all components are fitted correctly Refit the gear unit in the crankcase the main and the secondary shafts must be mounted at the same time First check the overall volume of the secondary shaft including shimmings Characteristic Secondary shaft overall height Max 87 7 mm 3 4527 in Min 87 35 mm 3 4390 in Gear selector Removing the gear selector Take out the clutch assembly R...

Page 104: ...pedal Pull and extract the shaft selector unit together with its shimming Undo the screw of the gear selector lever Undo the screw of the drum control head See also Disassembling the clutch Engine RS4 50 MY2011 ENG 104 ...

Page 105: ...te 270 on the thread of the screw of the drum control head Make sure that the selector shaft springs and the gear selector lever spring have been correctly fit ted Starter motor STARTER MOTOR pos Description Type Quantity Torque Note 1 Starter motor retainer M6x100 2 8 10 Nm 5 90 7 38 lbf ft 2 Countershaft retainer M10 1 15 18 Nm 11 06 13 27 lbf ft RS4 50 MY2011 Engine ENG 105 ...

Page 106: ...m washers Remove the electrical connections to the starter motor Unscrew the two screws to remove the starter motor Installing the starter motor Follow the removal procedure but in reverse order being careful to replace and grease the sealing O ring on the starter motor coupling Check that the lower and upper shim washers are fitted Engine RS4 50 MY2011 ENG 106 ...

Page 107: ...th the aid of a spe cific calliper spanner Unscrew the flywheel fixing screw and collect the spacer Specific tooling 020565Y Flywheel lock calliper spanner Remove the flywheel with the specific extractor Specific tooling AP8501501 Flywheel extractor Detach the connector between stator and the clamps fixing the wire to the chassis RS4 50 MY2011 Engine ENG 107 ...

Page 108: ...l cable Installing the flywheel Align the reference point 2 on the engine and fix it with three screws Make the electrical cable go from the seat to the stator plate Make the notch 1 of the stator plate coincide with the reference point on the engine crankcase Fix the plate with the three screws Fit the stator on the stator plate Engine RS4 50 MY2011 ENG 108 ...

Page 109: ...ount the flywheel checking the proper insertion of the key in the slot on the crankshaft Lock the flywheel with the aid of a specific calliper spanner and tighten the flywheel fixing screw Mount the rest of the components following the removal procedure but in reverse order Specific tooling 020565Y Flywheel lock calliper spanner Locking torques N m Flywheel to shaft 40 Nm 29 50 lbf ft Clutch side ...

Page 110: ... 1 35 45 Nm 28 81 33 19 lbf ft 2 Clutch spring retainer M5x80 5 3 5 4 5 Nm 2 58 3 31 lbf ft Removing the clutch cover Remove the oil pump Remove the clutch cover undoing the eight screws indicated in the figure Remove the clutch cover bolts NOTE THE START UP PEDAL SHAFT SHOULD REMAIN ON THE ENGINE UNIT WHILE THE CLUTCH COVER IS TAKEN OUT See also Removing Engine RS4 50 MY2011 ENG 110 ...

Page 111: ...er Remove the 4 clutch plates and the three steel discs Straighten the bevelled washer See also Removing the clutch cover Lock the disc thrust plate with the specific tool and unscrew the nut Detach the locking washer and the star washer Slide off the clutch bell as well as the bushing and the shim washer RS4 50 MY2011 Engine ENG 111 ...

Page 112: ... Measure each plate thickness Characteristic Serviceability limit 3 8 mm 0 1496 in Check the steel discs Use thickness gauges to check that the plates are not deformed Characteristic Serviceability limit 0 15 mm 0 0059 in Engine RS4 50 MY2011 ENG 112 ...

Page 113: ...to crown gears Main shaft lever coupling CAUTION REPLACE THE PART IN CASE OF UNDUE DAMAGE Checking the pusher plate Check the disc thrust plate and its axial bearing CAUTION REPLACE THE PART IN CASE OF UNDUE DAMAGE Checking the clutch hub Check that the disc holding plate is in good condi tions Check that the coupling between the surface and the plate is not eroded or grooved Replace the part if a...

Page 114: ...tch spring Measure the length of each spring when exten ded Characteristic Spring serviceability limit 31 mm 1 2205 in Assembling the clutch Fit the shim washer and the clutch bushing Fit the clutch housing Engine RS4 50 MY2011 ENG 114 ...

Page 115: ...cking tool Lubricate the clutch plates with new oil Fit the plates with the visible mark on one of the friction surfaces facing out Be careful with the trim driver discs alignment that must have the lubrication channels facing in the opposite direction to the rotation Fit the clutch springs and their fixing screws Tighten to the specified torque Locking torques N m Clutch spring screws 9 Nm 6 64 l...

Page 116: ...ides with the tappet Turn the water pump rotor so as to engage the driving gear with the pin of the crankshaft Repeat this procedure also with the oil pump transmission gear use a screwdriver to turn the oil pump shaft Push the clutch cover until it stops on the engine crankcase Tighten the screws on the crankcase cover in two or three stages first screw in on screw and then the one that is diamet...

Page 117: ...nd collect the coolant Remove the rubber pipes connecting the head and the radiator Disconnect the electrical connector of the tem perature sensor Remove the spark plug Undo the five fixing screws to remove the head cover Undo the four stud bolt nuts to remove the head and its gasket Remove any carbon deposits present on the head being careful not to scratch the coupling sur faces Use a trued bar ...

Page 118: ...on Remove the cylinder Remove the seeger ring retaining the pin Remove the pin Be careful to support the con necting rod properly to avoid deformations Remove the piston Remove the gasket rings from the piston piston rings Remove the roller cage of the connecting rod small end Check and clean the components Clean the piston crown carefully to remove any carbon deposits Visually check the piston se...

Page 119: ...mm TYPE A Specification Desc Quantity Nominal cylinder diameter A 39 890 mm 1 57047 in Cylinder diameter A 39 8875 39 8925 mm 1 570369 1 570566 in Piston nominal diameter A 39 840 mm 1 568499 in Piston diameter A 39 8375 39 8425 mm 1 568401 1 568598 in TYPE B Specification Desc Quantity Nominal cylinder diameter B 39 895 mm 1 57066 in Cylinder diameter B 39 8925 39 8975 mm 1 570566 1 570763 in Pis...

Page 120: ...ceability limit 0 05 mm 0 0019 in Fitting the piston Refit the piston sealing circlips Fit a new cylinder base gasket Refit the roller cage at the connecting rod small end and make sure to lubricate the components with recommended oil Refit the piston paying attention to the direction of the arrow indicated at the piston crown This ar row should be facing the outlet Fully fit the previously lubric...

Page 121: ... THE CYLINDER WITH RECOMMENDED ENGINE OIL IN CASE THAT HAVE BEEN REPLACED THE PISTON OR THE CYLINDER IT IS NECESSARY TO CALCULATE THE THICKNESS OF THE NEW GASKET TO BE INSTALLED TO ESTABLISH THE REPORT OF APPROPRIATE COMPRESSION MEASURE WITHOUT PLACING GASKETS BETWEEN CYLINDER AND DIAL GAUGE NOTE MAKE SURE THAT THE COMPARATOR DOOR IS PROPERLY FITTED TO THE STUD BOLTS TO AVOID POSSIBLE CLEARANCES T...

Page 122: ...e cylinder and tighten the four stud bolts in two or three stages tightening one stud bolt and afterwards the one that is diametrically opposite Refit the head cap tightening the screws in several stages Refit the spark plug Connect the thermal switch connector and the spark plug pipe Connect the radiator hose to the cylinder head Connect the radiator hose to the hydraulic pump Fill up the cooling...

Page 123: ...R REMOVAL AND GEAR COUNTERSHAFT Remove the crankcase left cover Lock the magneto flywheel with the specific tool If the flywheel has been already removed reposi tion it on the shaft only for this operation Specific tooling 020565Y Flywheel lock calliper spanner Unscrew and remove the fixing nut Unscrew and remove the countershaft gear nut RS4 50 MY2011 Engine ENG 123 ...

Page 124: ...ove the engine from the chassis Remove the thermodynamic unit cylinder head and piston Remove the magneto flywheel Remove the whole clutch the main gear and the gear selector lever Remove the fixing screws of both crankcase halves located at the left of the engine The two screws 1 are shorter See also Removing the cylinder head Magneto flywheel removal Disassembling the clutch Engine RS4 50 MY2011...

Page 125: ...SCREWDRIVER TO SEPA RATE THE CRANKCASE HALVES REPLACE THE CRANK CASE HALVES IF THE COUPLING SURFACES GET DAM AGED Specific tooling AP8106698 Crankcase separator Removing the crankshaft Open the crankcase halves and remove the gear box shafts Warm the crankshaft seat on the clutch side at about 60 C 140 F and take out the crankshaft See also Disassembling the gearbox RS4 50 MY2011 Engine ENG 125 ...

Page 126: ...aracteristic Serviceability limit 0 04 mm 0 0016 in Make sure that both half shafts are not scratched or unduly worn Use two comparators and a support as indicated in the photograph to check the run out for both half shafts Characteristic Serviceability limit 0 01 mm 0 0004 in Refitting the crankcase halves Fit the selector Lubricate the surfaces with spe cific oil Make sure that the gear housing ...

Page 127: ... branded fully synthetic oils that meet or exceed the ISO L EGD or alternatively JASO FC or API TC specifications requirements Locking torques N m Crankcase halves fixing screws 9 Nm 6 64 lbf ft INSTALLING THE MAIN TRANSMISSION GEAR Insert the key into the hole on the crankshaft and then install the primary drive gear Insert the countershaft of the flywheel side and make sure that the mechani cal ...

Page 128: ...gear to the specified torque Specific tooling 020565Y Flywheel lock calliper spanner Lubrication Oil pump OIL PUMP Description Type Quantity Torque Note Oil pump cover retainer M5x80 4 3 5 4 5 Nm 2 58 3 31 lbf ft Oil pump retainer M5x80 2 3 5 4 5 Nm 2 58 3 31 lbf ft Engine RS4 50 MY2011 ENG 128 ...

Page 129: ...mp and flow out the coolant of the cooling system Disconnect the clutch lever wire and remove the clutch wire clamp Drain the oil out of the gearbox Remove the oil pump cover Undo the two fixing screws of the oil pump Move the whole oil pump assembly and its cho ses upwards but do not detach them RS4 50 MY2011 Engine ENG 129 ...

Page 130: ... purged from the pump Loosen the oil pump bleed screw 1 located at the front of the pump between the inlet and the delivery pipes to facilitate drainage until the oil flow is constant and no air bubbles are formed Tighten the bleed screw 1 Pipe purging Fill up the fuel tank with a mixture of oil and petrol at 2 5 use the recommended oil specific for this type of engine Start the engine and let it ...

Page 131: ...g gear Fit a new oil seal in the clutch lever seat on the cover Fit the clutch lever Install the clutch cover Mount the oil pump and the pipe support Mount the oil pump wire Operate the nut to align the symbols stamped cage on the oil pump with the throttle control in neutral Mount the oil pump cover Specific tooling 020441Y Oil seal punch See also Installing the clutch cover RS4 50 MY2011 Engine ...

Page 132: ...ews Adjust the clutch lever clearance to a value be tween 2 mm 0 08 in and 4 mm 0 16 in handle bar left side Mount the sleeve connecting the hydraulic pump to the radiator and that connecting the hydraulic pump to the cylinder Fit the start up pedal Fit the rear brake pedal Pour recommended oil in the crankcase Engine RS4 50 MY2011 ENG 132 ...

Page 133: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 134: ...REED VALVE pos Description Type Quantity Torque Note 1 Reed valve retainer M6x110 4 8 10 Nm 5 90 7 38 lbf ft 2 Clamp retainer 1 0 3 0 4 Nm 0 22 0 29 lbf ft Power supply RS4 50 MY2011 P SUPP 134 ...

Page 135: ... OTHERWISE THE NOZZLES CAN GET PARTIALLY OR FULLY CLOG GED WARNING THE CARBURETTOR CAN BE REMOVED OR REPLACED WITH THE ENGINE FITTED ON THE MOTORCYCLE Carburettor Removing Remove the carburettor by releasing the clamps on the inlet manifold and the bellows connected to the air cleaner housing Remove the fuel pipe of the carburettor the mixer oil intake pipe and the fuel cock vacuum pipe and the tw...

Page 136: ...eed valve and its gaskets from the crankcase Check that the valve petals are not damaged or deformed Otherwise replace it Remove the plate limiting the reed valve opening by undoing the three screws fixing the reeds Power supply RS4 50 MY2011 P SUPP 136 ...

Page 137: ...en correctly posi tioned Absence of the plate limiting the reed valve open ing compromises the engine performance and re liability Check the O ring of the reed support Replace it if damaged or deformed Disassembling Undo the two screws to remove the throttle valve and the tapered pin as well RS4 50 MY2011 Power supply P SUPP 137 ...

Page 138: ...er control by undoing the screws indicated in the photograph Remove the starter control Remove the air flow set screw as indicated in the photograph Remove the carburettor float chamber Remove the float by operating the stem that fixes it to the carburettor with a very thin pin Remove the maximum nozzle the idle nozzle and the starter nozzle Power supply RS4 50 MY2011 P SUPP 138 ...

Page 139: ...omponents with solvent Be careful not to damage the carburettor gaskets and the starter control O ring Blow short blasts of compressed air through all the nozzles of the carburettor including the oil and petrol intake ones RS4 50 MY2011 Power supply P SUPP 139 ...

Page 140: ...ood conditions Replace it if worn or deformed Check the starter control pistons are in good con ditions Replace them if they show signs of abnormal wear Check that the calibration of the nozzles is ade quate see the carburettor calibration table Failure to respect these values compromises en gine performance Power supply RS4 50 MY2011 P SUPP 140 ...

Page 141: ...re Thus carburetion can adapt to different climatic condi tions Replace the tapered pin if it shows signs on early wear as shown in the photograph Check that idle set screw shows no signs of ab normal wear This is detrimental to a correct idle speed adjustment Check that the throttle valve shows scratches comprising 25 of its overall surface Otherwise replace it RS4 50 MY2011 Power supply P SUPP 1...

Page 142: ...pipe for the fuel cock control Adjusting the idle speed Tighten the flow set screw slowly until it stops and then unscrew it as many turns as specified for this type of engine 1 1 4 Remember this is the first adjustment Warm the engine up to the regular operating temperature Adjust the idle speed at 1600 200 rpm by operating the idle speed set screw Turn the flow set screw 1 to both sides until th...

Page 143: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 144: ...ainer M12 1 58 Nm 42 78 lbf ft 2 Lower retainer M12 1 58 Nm 42 78 lbf ft Loctite 243 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 Suspensions RS4 50 MY2011 SUSP 144 ...

Page 145: ...12 Nm 8 85 lbf ft 4 Chain tensor fixing screw M8 2 12 Nm 8 85 lbf ft Loctite 243 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 RS4 50 MY2011 Suspensions SUSP 145 ...

Page 146: ...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 Front Removing the front wheel Support the vehicle at the front by fas tening a suitable belt to the handlebar and a crane Slide off the nut cover Suspensions RS4 50 MY2011 SUSP 146 ...

Page 147: ...cle 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 Check the wheel axle by turning the wheel rim on a flat surface If there are bends replace it WARNING NEVER TRY TO STRAIGHTEN THE BEND AXLE RS4 50 MY2011 Suspensions SUSP 147 ...

Page 148: ... 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 Check wheel bearings NOTE BEARINGS MUST ROTATE FREELY WITHOUT JAMMING AND OR NOISE OTHERWISE THEY NEED TO BE RE PLACED Suspensions RS4 50 MY2011 SUSP 148 ...

Page 149: ...l when po sitioning the components and the corresponding tightening torque Front fork CAUTION THE MOTORCYCLE MAY BE FITTED WITH TWO DIFFERENT TYPES OF FORKS PAIOLI E MIN GXING key A Paioli Forks B Mingxing Forks Removing the fork legs The following operations are described for the Mingxing fork but are identical for the operation with the fork model Paioli except where specified RS4 50 MY2011 Susp...

Page 150: ...fixing screw at the upper steering plate See also Rear mudguard Removing the front wheel For the operation with Mingxing fork loosen the two fixing screw at the 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 STAN...

Page 151: ...rips Undo the cap and partially pull out the piston Using a wrench to prevent the internal piston from rotating Remove the cap CAUTION BEFORE PROCEEDING WITH THE FOLLOWING OPERATIONS GET A SUITABLE COLLECTION CONTAINER RS4 50 MY2011 Suspensions SUSP 151 ...

Page 152: ...urface of the stem and the integrity of the dust gaiter Remove the retainer ring 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 Suspensions RS4 50 MY2011 SUSP ...

Page 153: ...ove the complete piston MINGXING 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 RS4 50 MY2011 Suspensions SUSP 153 ...

Page 154: ... the two half cylinders Remove the lock washer 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 50 MY2011 SUSP 154 ...

Page 155: ...E SLEEVE INTERIOR WHEN REMOVING THE DIFFERENT COMPONENTS Remove the oil seal from the sleeve taking care not to damage it Checking the components MINGXING FORK WHEEL HOLDER STEM Check the sliding surface for scorings and or 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 ...

Page 156: ...ive wear or damage replace the affected compo nent CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS TAKING CARE NOT TO SCRATCH THEIR SURFACE PAIOLI FORKS WHEEL HOLDER STEM Check the sliding surface for scorings and or 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 th...

Page 157: ...CE Replace the following components with new ones sealing ring 2 dust scraper 3 O rings on the cap 4 Reassembling the fork PAIOLI FORKS CAUTION ONLY FOR THE RIGHT STEM IT IS POSSIBLE TO INSTALL THE COMPLETE 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 ST...

Page 158: ...ainer ring insert the stem itself in 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 Suspensions RS4 50 MY2011 SUSP 158 ...

Page 159: ...ION THE FOLLOWING PROCEDURES ARE FOR A SINGLE WHEEL 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 RS4 50 MY2011 Suspensions SUSP 159 ...

Page 160: ...rs and lock them in place with the retainer ring Position the fork vertically in a vice Fill the fork with oil Characteristic Fork 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 Suspensions RS4 50 MY2011 SUSP 160 ...

Page 161: ...m on the lower and upper plates Insert the wheel pin through both stems to align the holes Insert the stems holding pipe on the lower plate in the clamps of the front headlamp and on the upper plate Insert the wheel pin through both sheaths to align the holes Align the end of the upper plate to the top of the holding pipes except the plug Provisionally tighten the screw that locks the upper plate ...

Page 162: ...e to the holding pipes to the prescribed torque For the operation with Paioli fork tight en the sleeve fixing screw to the lower plate For the operation with the Mingxing fork operate in the same way on the two sleeve fixing screws at the lower plate Tighten the screw that tightens the up per plate to the sleeve Suspensions RS4 50 MY2011 SUSP 162 ...

Page 163: ...LTS MAKE SURE THAT THE OPTIONAL REAR SERVICE STAND IS ADEQUATELY POSITIONED Correctly fit the lower shield the mudguard the front wheel the brake callipers Release the belts from the chassis Check the 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 CHE...

Page 164: ...HEEL GET THE APPROPRIATE REAR SERVICE STAND OPTIONAL Place the vehicle 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 ...

Page 165: ...c 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 the...

Page 166: ...e the vehicle on its optional front service stand Support the vehicle rear part using belts and hoist Place 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 ...

Page 167: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 168: ...rque Notes 1 Swingarm to chassis adjustment nut M25x1 5 1 15 Nm 11 06 lbf ft 2 Swingarm pin nut 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 Chassis RS4 50 MY2011 CHAS 168 ...

Page 169: ...Notes 1 Thin nut M10x1 25 1 10 Nm 7 38 lb 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 Swinging arm 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 RS4 50 MY2011 Chassis CHAS 169 ...

Page 170: ...g ring with the suitable special key Specific tooling 866714 Tools for the swingarm nut adjustment Lightly tap with a rubber hammer slide the swingarm pin off the left side of the vehicle If necessary remove the rear mudguard and the chainguard Installing Drive chain Removing Support the vehicle with the optional rear stand Loosen the chain tension by unscrew ing the rear adjuster screws Identify ...

Page 171: ... THE CHAIN ON A REGULAR BASIS PARTICULARLY IF YOU DETECT DRY OR RUSTY PARTS FLATTENED OR JAMMED CHAIN LINKS SHOULD BE LUBRICATED AND GOOD OPERATING CONDITIONS RESTORED Installing Check the correct positioning of the chain on the pinion and the sprocket Fit the chain with the two ends joined at a point between the pinion and the sprocket on the lower branch of the chain Join the two ends of the cha...

Page 172: ...LINKS ARE FLATTENED OR JAMMED TO AVOID RISK OF SEIZURE LUBRICATE THE CHAIN ON A REGULAR BASIS CAUTION GET A SPECIFIC REAR SERVICE STAND OPT TO AD JUST THE CHAIN If you need to adjust the chain tension after the check perform the following Place the vehicle 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 cl...

Page 173: ...crew 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 stand together with the plate Exhaust Removing the tail pipe The muffler can also be removed with the fitted exhaust Unscrew and remove the three screws RS4 50 MY2011 Chassis CHAS 173 ...

Page 174: ...r cov er Removing the manifold tail pipe Remove the fairing and the lug Unscrew and remove the stay bolts and collect the nut Unscrew and remove the screw and collect the two washers See also Side fairings Lower cowl Removing the tail pipe Chassis RS4 50 MY2011 CHAS 174 ...

Page 175: ...ry remove the muffler and the cover If necessary unscrew and remove the three screws and remove the central exhaust cover Removing the exhaust manifold Remove the exhaust end Unscrew and remove the two screws from cylinder Locking torques N m Silencer to cylinder 9 Nm 6 64 lbf ft RS4 50 MY2011 Chassis CHAS 175 ...

Page 176: ... Unscrew and remove the front nut re trieve the screw Remove the exhaust manifold See also Removing the tail pipe Chassis RS4 50 MY2011 CHAS 176 ...

Page 177: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 178: ...ront 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 50 MY2011 BRAK SYS 178 ...

Page 179: ...rew 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 50 MY2011 Braking system BRAK SYS 179 ...

Page 180: ...he 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 50 MY2011 BRAK SYS 180 ...

Page 181: ... 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 A 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 pipe...

Page 182: ...sc 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 in B...

Page 183: ...tion 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 Standa...

Page 184: ...e 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 CAL...

Page 185: ... 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 50 MY2011 Braking system BRAK SYS 185 ...

Page 186: ...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 5 m...

Page 187: ... 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 Brake ...

Page 188: ... 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 minim...

Page 189: ...ee 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 flu...

Page 190: ... 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 50 MY2011 BRAK SYS 190 ...

Page 191: ...uid 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 50 MY2011 Braking system BRAK SYS 191 ...

Page 192: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 193: ...MP pos Description Type Quantity Torque Note 1 Water pump shaft retainer M5 1 3 5 4 5 Nm 2 58 3 31 lbf ft 2 Water pump cover retainer M6x100 3 8 10 Nm 5 90 7 38 lbf ft RS4 50 MY2011 Cooling system COOL SYS 193 ...

Page 194: ... 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 Side fairings Release the clamp Slide the pipe off and 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 ENVIRONMENT Water pump Coo...

Page 195: ...he crankcase or the cover See also Removing the clutch cover Slide off and remove the clutch lever from the clutch cover Undo the two fixing screws of the hydraulic pump and remove the pump Detach the gasket and clean off any rests of old gaskets that may be left on the coupling surfaces of the hydraulic pump Lock the driving gear RS4 50 MY2011 Cooling system COOL SYS 195 ...

Page 196: ...ic pump shaft and its oil seals Remove the transmission gear Remove the driving gear and the oil pump shaft Installing On the cover install the hydraulic pump shaft together with the outer seeger ring fitting it from the rotor side Mount the driving gear Cooling system RS4 50 MY2011 COOL SYS 196 ...

Page 197: ...g outside Specific tooling 020441Y Oil seal punch Mount the pump rotor and fixed it by tightening its nut manually Fit the pump cover with a new gasket and then mount the pump cover Fit the oil pump Fit the clutch cover Fill up the cooling system with the recommended coolant See also Installing Installing the clutch cover RS4 50 MY2011 Cooling system COOL SYS 197 ...

Page 198: ... See also Removing the expansion tank Unscrew the radiator cover and let it connect to the hoses Loosen the clamp 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 Cooling system RS4...

Page 199: ... 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 Release and remove the clamp and slide off the hoses During the refit fit a new clamp of the same type RS4 50 MY2011 Cooling system COO...

Page 200: ...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 50 MY2011 COOL SYS 200 ...

Page 201: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 202: ...swingarm fixing screw Self tap 4 3 Nm 2 21 lbf ft Max 4 5 Nm 3 31 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 2 Top fairing glass fixing screw M4 4 1 Nm 0 73 lbf ft Bodywork RS4 50 MY2011 BODYW 202 ...

Page 203: ... 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 INSTRUMENT PANEL pos Description Type Quantity Torque Notes 1 Self tapping screw M5x4 3 2 5 Nm 1 84 lbf ft RS4 50 MY2011 Bodywork BODYW 203 ...

Page 204: ...orque Notes 2 Instrument panel fixing screw M5x20 6 2 Nm 1 47 lbf ft SIDE FAIRINGS pos Description Type Quantity Torque Notes 1 Side fairing fixing screw M5x9 6 1 7 Nm 1 25 lbf ft Max 2 Nm 1 47 lbf ft Bodywork RS4 50 MY2011 BODYW 204 ...

Page 205: ... 6 3 Nm 2 21 lbf ft 2 Fairing lower fixing screw M4x14 2 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 50 MY2011 Bodywork BODYW 205 ...

Page 206: ...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 Driving mirrors Unscrew and remove the two nuts in side the top fairing two for each mirror Remove the rear view mirrors Bodywork RS4 50 MY2011 BODYW 206 ...

Page 207: ...rn indicator and remove the in strument panel from the support See also Headlight fairing INSTRUMENT PANEL SUPPORT REMOVAL Unscrew and remove the two stay bolts and retrieve the washer from the left side and the nut from the right side Unscrew and remove the six perimeter screws and remove the two shells RS4 50 MY2011 Bodywork BODYW 207 ...

Page 208: ...eadlight 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 Remove the two side screws fixing the top fairing to the chassis Bodywork RS4 50 MY2011 BODYW 208 ...

Page 209: ...nscrew 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 Remove the windshield RS4 50 MY2011 Bodywork BODYW 209 ...

Page 210: ...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 Taillight assy Remove the tail fairing and the pas senger saddle Remove the two side screws 1 Remove the two upper screws 2 Bodywork RS4 50 MY2011 BODYW 210 ...

Page 211: ...ving it from the hooks Footrest PASSENGER FOOTREST The following procedures only refer to one foot rest but they are applicable to both Remove the tail fairing Unscrew and remove the two fixing screws Remove the passenger footrest See also Tail guard RS4 50 MY2011 Bodywork BODYW 211 ...

Page 212: ... 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 the integrity of the plastic parts remove the fairing License plate holder Remove the passenger saddle Remove the lower licence plate sup port cover Unscrew and remove the central lower sc...

Page 213: ...Remove the three clamps Disconnect the connector Remove the license plate support Air box Remove the passenger footrest the saddle the tank the fairing and the splash guard Unscrew and remove the four screws 1 RS4 50 MY2011 Bodywork BODYW 213 ...

Page 214: ... of the intake pipe Slide off the intake pipe See also Footrest Fuel tank Rear wheelhouse Remove the air filter box Rear mudguard Unscrew and remove the screw Slide off the pipe grommet Bodywork RS4 50 MY2011 BODYW 214 ...

Page 215: ...emove the rear mudguard Lower cowl Remove the side fairings Position the vehicle on the optional rear stand with the vehicle on the 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 RS4 50 MY2011 Bodywork BODYW 215 ...

Page 216: ...owing the lug downwards Remove the lower rivet Slide the right semi lug off from the right side Slide off the left semi lug from the left side along the stand profile Fuel tank Remove the rider saddle Working from both sides unscrew and remove the side screw Bodywork RS4 50 MY2011 BODYW 216 ...

Page 217: ...ROLYTIC FLUID GETS INTO CON TACT WITH THE SKIN WASH WITH ABUNDANT COOL WATER IF THE FLUID GETS INTO CONTACT WITH THE EYES WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY IF IT IS ACCIDENTALLY INGESTED DRINK A LOT OF WA TER OR MILK THEN MILK OF MAGNESIA OR VEGETAL OIL AND SEEK MEDICAL ADVICE IMMEDIATELY THE BATTERY RELEASES EXPLOSIVE GASES KEEP IT AWAY OF FLAM...

Page 218: ...e 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 Bodywork RS4 50 MY2011 BODYW 218 ...

Page 219: ...e grommet cable Unscrew and remove the four mud guard fixing screws 1 two for each side Remove the mudguard Mixture oil tank Lift the tank Disconnect the oil reserve sensor con nector Release the clamp RS4 50 MY2011 Bodywork BODYW 219 ...

Page 220: ...SE THE PIPE WITH A COVER OR A CLAMP TO AVOID THAT OIL COMES OUT Unscrew and remove the two screws with the corresponding washers CAUTION CLOSE THE PIPE WITH A COVER OR A CLAMP TO AVOID THAT OIL COMES OUT Slide off the mixer oil tank CAUTION CLOSE THE PIPE WITH A COVER OR A CLAMP TO AVOID THAT OIL COMES OUT Bodywork RS4 50 MY2011 BODYW 220 ...

Page 221: ...w 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 RS4 50 MY2011 Bodywork BODYW 221 ...

Page 222: ...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 Bodywork RS4 50 MY2011 BODYW 222 ...

Page 223: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 224: ...nt and rear wheel unit engine chassis retainers steering assembly Plastic parts fixing screws Levels check Hydraulic braking system fluid level Clutch system fluid level if present Gearbox oil level if present Transmission oil level if present Engine coolant level if present Engine oil level Mixer oil level if present Road test Test ride Cold start Response to throttle control Stability when accel...

Page 225: ...ent 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 Tyre pressure check NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST CAUTION CHECK AND ADJUST TYR...

Page 226: ...4 109 114 116 124 131 195 197 Connectors 86 coolant 194 200 Coolant 194 200 Crankcase 101 122 123 126 Crankshaft 122 125 126 Cylinder 117 119 121 122 124 D Drive chain 170 E Electrical system 13 59 Exhaust 173 175 Exhaust manifold 175 F Fairings 89 174 194 200 210 212 216 Filter box Fork 149 150 157 161 Front wheel 146 147 149 150 163 Fuel 89 214 216 Fuses 81 G Gearbox oil 51 H Handlebar Headlight...

Page 227: ...206 Mudguard 150 214 219 P Primary shaft 101 R Radiator 89 198 221 Rear wheel 163 165 166 170 Recommended products 41 S Secondary shaft 102 Shock absorbers 166 Side fairings 212 Side stand 173 Spark plug 50 Stand 173 Starter motor 105 106 T Tank 89 198 199 214 216 219 Transmission 12 Tyres 14 W Water pump 194 Windshield Wiring diagram 77 ...

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APRILIA RS4 50 2011, Workshop Manual

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