APRILIA RX 125 Service Station Manual Download Page 111

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•

Place the cylinder.

ONLY ASSEMBLE TOGETHER PISTONS AND CYLINDERS
BELONGING TO THE SAME TOLERANCE RANGES.

•

Take out the wrench for piston rings.

•

Working from both sides, fasten the

cylinder crosswise with the four M8

nuts and relevant washers.

TIGHTEN THE FIXING NUTS AGAIN, WHEN THE ENGINE
IS COLD, AFTER THE FIRST 500 KM (310 MI).

Selecting the cylinder

•

The cylinder size code is stamped on

the surface of the cylinder base.

•

Read the cylinder diameter at TDC.

•

The bottom section of the cylinder sur-

face undergoes only slight wear. If the

cylinder TDC area is very worn (it is no

longer bright, rough and sharp), it can

be inferred that the engine has been

working fed on a fuel with too much

sulphur.

Cylinder "A" Diam. 54.000 - 54.010 mm (2.12597

- 2.12637 in) Diam. 54.060 mm (2.12834 in)

Cylinder "AB" Diam. 54.010 - 54.015 mm (2.12637

- 2.12657 in) Diam. 54.065 mm (2.12853 in)

Cylinder "B" Diam. 54.015 - 54.025 mm (2.12657

- 2.12696 in) Diam. 54.075 mm (2.12893 in)

Selecting the piston

Measure the piston diameter with a micrometer, 11.5 mm from the piston bottom edge.

RX SX 125

Engine

ENG - 111

Summary of Contents for RX 125

Page 1: ...SERVICE STATION MANUAL 854196 RX SX 125 ...

Page 2: ...y changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions shown in this publication are available in all countries The availability of individual models should be confirmed with the official aprilia sales network Copyright 2008 aprilia All rights reserved Reproduction of this pub...

Page 3: ...d 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 t...

Page 4: ......

Page 5: ...R SPECIAL TOOLS S TOOLS MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS COOLING SYSTEM COOL SYS BODYWORK BODYW PRE DELIVERY PRE DE ...

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

Page 7: ...AY CAUSE IGNITION OR EXPLOSION DO NOT ALLOW FUEL TO DISPERSE INTO 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 c...

Page 8: ...P OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID MAY CAUSE BURNING IF IT COMES INTO 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 OF CLEAN WATER IT IS PARTIC...

Page 9: ...a 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 seal...

Page 10: ...VEN 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 Engine run in is essential to ensure engine long life and correct operation Twisty roads and gradients are ideal to run in engine brakes and suspensions effectively Vary your riding speed during the run in This ensures that components operate under both loa...

Page 11: ...m 10 24 in 300 mm 11 81 in Engine ENGINE Specification Desc Quantity Type single cylinder 2 stroke with reed intake Separate lubrication with automatic mixer with variable value 1 0 3 0 Cylinder quantity 1 Overall engine capacity 124 82 cm 7 616 cu in Bore stroke 54 54 5 mm 2 12 2 14 in Compression ratio 12 5 0 5 1 Squish 1 5 mm 0 06 in Engine revs at idle speed 1250 100 rpm Engine revs at maximum...

Page 12: ...il 600 cm 36 61 cu in 600 cm 36 61 cu in Mixer oil reserve included 1 l 0 22 UKgal 1 l 0 22 UKgal Mixer oil reserve 0 25 l 0 055 UKgal 0 25 l 0 055 UKgal Fork oil 400 cm 24 41 cu in 400 cm 24 41 cu in Fork oil level depth from the rim spring not inclu ded the whole fork comprised 150 mm 5 90 in 150 mm 5 90 in Coolant 50 H2O 50 ethylene glycol anti freeze fluid 0 8 l 0 17 UKgal 0 8 l 0 17 UKgal Sea...

Page 13: ...ith double cradle and high resistant steel tubes Steering inclination angle 28 28 Trail 102 mm 4 02 in suspensions fully extended 113 mm 4 45 in suspensions fully extended Size A 555 mm 21 85 in 555 mm 21 85 in Size B 459 mm 18 07 in 459 mm 18 07 in SUSPENSIONS SUSPENSIONS SX 125 RX 125 Front Upside down with Ø 40 mm 1 57 in stems Upside down with Ø 40 mm 1 57 in stems Front suspension travel 260 ...

Page 14: ...saddle pillar retainer M8x30 2 25 Nm 18 44 lbf ft Lower saddle pillar retainer M8x25 2 25 Nm 18 44 lbf ft Engine upper plate to chassis retainer M8x20 2 25 Nm 18 44 lbf ft Chain tightener roller retainer M8x60 1 25 Nm 18 44 lbf ft FOOTRESTS Name Torque in Nm Passenger footrest support to saddle pillar retainer M8x20 4 25 Nm 18 44 lbf ft Rider footrest support to chassis retainer M8x45 2 25 Nm 18 4...

Page 15: ... lbf ft Filter cover retainer 4 3 Nm 2 2 lbf ft Filter housing to saddle pillar upper retainer 1 6 Nm 4 42 lbf ft Filter casing mudflap to saddle pillar lower retainer 2 6 Nm 4 42 lbf ft SAS valve to chassis horn retainer TE M6x12 screw 2 10 Nm 7 37 lbf ft EXHAUST SYSTEM Name Torque in Nm Muffler retainer TE M6x16 screw 1 10 Nm 7 37 lbf ft Intermediate pipe retainer TE M6x12 screw 1 10 Nm 7 37 lbf...

Page 16: ...etainer TBEI M6x20 screw 2 10 Nm 7 37 lbf ft Rear light retainer screw 2 3 Nm 2 21 lbf ft Front turn indicators retainer TBEI M6x20 screw 2 10 Nm 7 37 lbf ft Rear turn indicators retainer TBEI M6x20 screw 2 10 Nm 7 37 lbf ft License plate retainer screw 1 3 Nm 2 21 lbf ft TANK Name Torque in Nm Fuel cock to tank retainer TE M6x12 screw 2 7 Nm 5 16 lbf ft Tank retainer TE M6x30 screw 2 10 Nm 7 37 l...

Page 17: ... screw retainer 1 Manual Recommended products chart LUBRICANTS CHART Product Description Specifications Agip GEAR SYNTH SAE 75W 90 Gearbox oil As an alternative for recommended oils use top branded oils that meet or exceed the API GL 4 requirements AGIP FORK 7 5W Recommended FORK OIL If you intend to have an intermediate per formance as an alternative to the recom mended AGIP FORK 5W or AGIP FORK ...

Page 18: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 19: ...ng oil seal 250455 AP0277875 Buffer for fitting oil seal 230425 AP0276502 Buffer for fitting oil seal 930675 AP0276770 Buffer for fitting oil seal 230195 AP0277970 Guide bushing for oil seal 930675 AP0876973 Piston ring clamp 54 mm RX SX 125 Special tools S TOOLS 19 ...

Page 20: ...040 Clutch wrench 11 mm AP0277180 Bearing tie rod kit AP0277455 Extractor plate to separate the crankcase halves AP0276380 bolt M10 AP0276370 Split bushing AP0242091 Hexagon nut M10 AP0276382 Bolt Special tools RX SX 125 S TOOLS 20 ...

Page 21: ...P0276372 Split bushing AP0242700 Flanged nut M8 AP0277445 Guillotine extractor AP0277917 Brackets AP0276025 Half ring AP0977490 Ring for half rings AP0876298 Extractor for crankshaft bearings RX SX 125 Special tools S TOOLS 21 ...

Page 22: ...crew for extractor M8x40 AP8146486 Front service stand AP8140192 Chain fitting kit AP8140180 Extractor for bushings AP8705021 Rear service stand AP8140204 Supports for rear service stand AP8140199 Tool panel Special tools RX SX 125 S TOOLS 22 ...

Page 23: ...Stores code Description AP8101945 Fork pin ring nut RX SX 125 Special tools S TOOLS 23 ...

Page 24: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 25: ...I I I I I I I I I I Braking systems I I I I I I I I I I I Brake fluid I I I I I I I I I I I Mixer oil level I I I I I I I I I I I Coolant I I I I I I I I I I I Muffler exhaust silencer I I I I I I I I I I Fork oil and oil seal Gearbox oil R I I R I I R I I R I Front headlight aiming A A A A A A A A A A A Start up lever bolt I I I I I I I I I I I Piston and compression rings I R I R I Mixer pump an...

Page 26: ... AN INCORRECT READING OF THE ENGINE OIL LEVEL Make sure the oil level covers the checking sight glass 1 completely TOPPING UP If necessary top up Unscrew and remove the filler plug 2 Pour a small amount of oil and wait about a minute until the oil flows evenly into the crank case Make sure the oil level covers the sight glass 1 completely If that does not occur top up again with small quantities o...

Page 27: ...D Stop the engine OIL BECOMES VERY HOT WHEN THE ENGINE IS HOT BE CAREFUL NOT TO GET BURNED WHEN CARRYING OUT THE OPERATIONS DESCRIBED BELOW Keep the vehicle upright with both wheels on the ground Place a container with suitable capaci ty under the drainage plug 2 Unscrew and remove the drainage plug 2 Unscrew and remove the filler plug 1 Drain the oil into the container allow several minutes for o...

Page 28: ...e right side central fairing Undo and remove the 4 screws and re move the filter casing side cover Remove the filtering element together with the mesh Wash the filtering element with clean non flammable or high volatility sol vents and let it dry properly Apply filter oil or heavy oil SAE 80W 90 all over the whole surface and then wring the filtering element to eliminate excess oil THE FILTERING E...

Page 29: ...ait a few seconds so that possible pressure in the circuit may be purged Turn the radiator cap 1 anticlockwise again and remove it Make sure the fluid covers the radiator plates completely CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN CAUTION COOLANT IS TOXIC IF INGESTED CONTACT WITH EYES OR SKIN MAY CAUSE IRR...

Page 30: ...OLONGED AIR EXPOSURE OF THE BRAKE FLUID BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR LEAVE THE BRAKE FLUID RESER VOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE Depending on whether you are work ing on the front 1 or the rear 2 brake reservoir lift and remove the relevant cover 3 or 5 and gasket 4 or 6 TO AVOID SPILLING FLUID WHILE TOPPING UP KEE...

Page 31: ...vel of the brake lever or poor performance of the braking system purge the air in the system Clutch system Adjusting the lever Adjustment clutch when the engine stops or the vehicle tends to move forward even when clutch lever is operated and the gear engaged or if the clutch slides resulting in acceleration delay con sidering the engine revs Minor adjustments can be carried out through the set sc...

Page 32: ...al nut 6 Introduce a plain slot screwdriver into the special spanner 5 and tighten the set screw 7 completely Loosen the set screw 7 half a turn about 3 4 mm 0 12 0 16 in of the lever travel 8 Tighten the set screw 7 with the screwdriver operate the special span ner 5 and tighten the internal nut 6 Screw the cap 4 again Check the empty travel at the end of the clutch control lever 10 15 mm 0 39 0 ...

Page 33: ...eck of the correct adjustment of the front light beam Place the vehicle 10 m 32 81 ft away from a vertical wall and make sure the ground is level Turn on the low beam light sit on the vehicle and check that the light beam projected to the wall is a little below the headlight horizontal straight line about 9 10 of the total height To adjust the light beam Operating on both sides undo the screw Adju...

Page 34: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 35: ...N THE EFI WARNING LIGHT THE EFI WARNING LIGHT IS INACTIVE IN THIS VEHICLE THE OPERATOR WHO ENCOUNTERS A FAILURE IN THE ENGINE MUST CARRY OUT ALL THE PRESCRIBED AX ONE CHECKS WITH THE AIM OF ENSURING THE ENGINE HAS BEEN THOROUGHLY CHECKED RX SX 125 Troubleshooting TROUBL 35 ...

Page 36: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 37: ...Components arrangement RX SX 125 Electrical system ELE SYS 37 ...

Page 38: ...Components Key RX SX 125 1 Front headlamp 2 Coil 3 fuses 4 Battery 5 Turn indicators 6 Voltage regulator Electrical system RX SX 125 ELE SYS 38 ...

Page 39: ...urpose of this document is to define cables laying their fastening on the motorcycle and possible criticalities special checks on connections and layouts all this with the aim of obtaining vehicle relia bility Materials used and corresponding quantities The electrical system consists of the following cable harnesses and parts 1 Main Cable Harness 1 Front Tail Light Cable Harness 1 Ground lead 1 Ca...

Page 40: ... a possible disconnection may cause the motorcycle to stop Undoubtedly the connection of the rest of connectors is also important and essential for the correct operation of the vehicle Vehicle sections The wiring distribution is subdivided in three essential sections as indicated in the figure 1 Front section 2 Central section 3 Rear section Front side TABLE A MAIN CABLE HARNESS AND DI ODE POSITIO...

Page 41: ... switch connector TABLE D FRONT 8 Instrument panel connector 9 Key switch connector 10 Front left arrow connector 11 Front right arrow connector 12 Front tail light connector 13 Front headlight connector 14 Clamp 15 Clamp TABLE E FRONT 16 Clamp 17 Rubber cap RX SX 125 Electrical system ELE SYS 41 ...

Page 42: ...TABLE F FRONT Headlight cable harness Place the cable harness in the front inner part Electrical system RX SX 125 ELE SYS 42 ...

Page 43: ... 2 Clamp 3 Regulator connector TABLE B FILTER CASING AND CONTROL UNIT 4 Cable harness to the bolt 5 Fuses position 6 Turn indicators connector 7 Clamps TABLE D FILTER CASING AND CONTROL UNIT 8 Air solenoid connector 9 Generator connector 10 Pick up earth connector 11 Cable harness laying 12 Clamp RX SX 125 Electrical system ELE SYS 43 ...

Page 44: ...sis connector TABLE F ENGINE AND CARBURETTOR Heater connector TABLE G ENGINE AND CARBURETTOR Throttle valve sensor connector TABLE H ENGINE AND CARBURETTOR 17 Clamps 18 Clamp 19 Speed sensor connector 20 Pick up connector 21 Neutral sensor connector 22 Stop switch connector Electrical system RX SX 125 ELE SYS 44 ...

Page 45: ...TABLE I SADDLE PILLAR 23 Cable harness laying 24 Ground eyelets 25 Clamps TABLE J GROUND LEAD FITTING 26 Ground eyelets 27 Faston coil 28 Ground lead 29 Coil RX SX 125 Electrical system ELE SYS 45 ...

Page 46: ...e connector 4 Rear right arrow connector 5 Clamp 6 Cable harness laying TABLE B LICENSE PLATE HOLDER PRE FITTING 7 License plate light cable harness 8 Rear left arrow cable harness 9 Rear light cable harness 10 Rear left arrow cable harness 11 Cable harness laying Electrical system RX SX 125 ELE SYS 46 ...

Page 47: ...TABLE C LICENSE PLATE HOLDER PRE FITTING RX SX 125 Electrical system ELE SYS 47 ...

Page 48: ...TABLE D SPEED SENSOR 12 Cable harness passes together with brake pipe 13 Cable harness passes together with brake pipe 14 Clamp Electrical system RX SX 125 ELE SYS 48 ...

Page 49: ...General wiring diagram Components key 1 MULTIPLE CONNECTORS 2 ECU DIAGNOSIS 3 AIR TEMPERATURE SENSOR 4 ELECTRONIC INSTRUMENT PANEL RX SX 125 Electrical system ELE SYS 49 ...

Page 50: ...ERY 18 FUEL HEATER 19 NEUTRAL POSITION SENSOR 20 SPARK PLUG 21 IGNITION COIL 22 REGULATOR 23 GENERATOR 24 PICK UP 25 AIR SOLENOID 26 THROTTLE SENSOR TPS 27 SPEED SENSOR 28 CDI CONTROL UNIT 29 RIGHT FRONT TURN INDICATOR 30 FRONT HEADLAMP 31 FRONT LEFT TURN INDICATOR 32 DIODE 33 RAVE SOLENOID OPTIONAL Cable colours key Ar orange Az sky blue B blue Bi white G yellow Gr grey M brown N black Electrical...

Page 51: ...ICK UP IN 10 RPM OUT 11 KILL IN 12 GND 13 TPS IN 14 COIL 1 SPEED SENSOR 2 SPEED SENSOR 3 GND SIGNALS Instrument panel pinout 1 LEFT INDICATORS INPUT 2 RIGHT INDICATORS INPUT 3 NEUTRAL INPUT 4 INPUT FOR HIGH BEAM LIGHTS 5 SPEED SENSOR INPUT 6 7 OIL LEVEL SENSOR 8 9 10 11 LIVE 12 RPM INPUT 13 GENERAL GROUND 14 BATTERY RX SX 125 Electrical system ELE SYS 51 ...

Page 52: ...e when the MODE button is released the word END is displayed Pressing the MODE switch fast the km h and Mph words are displayed Hold down the MODE button until dashes are displayed and the current setting is displayed km h or Mph Pressing the MODE switch fast you can shift from km h to Mph After selecting the desired unit of measurement press the MODE button for 3 seconds to set it Electrical syst...

Page 53: ...he screen corresponding to the 2066 mm 81 34 in size for the RX125 is displayed In order to configure the instrument panel press the MODE button until the letters WS are shown on the LCD on the right hand bottom side Now remove and insert the key again The instrument panel will first turn on the warning lights and the active segments on the LCD Afterwards it will display the pre set wheel size val...

Page 54: ...ton then set the key to OFF Resetting the odometer The odometer can be reset only once and within 200 km 124 27 mi remove the key press the MODE button and insert the key again press and hold the MODE button until the letters WS are shown on the LCD on the right hand bottom side 5 sec always holding down the MODE button operate the high beam lights to flash 10 times turn indicators to flash 5 time...

Page 55: ...leased the words NO CLEAR will be displayed Pressing the MODE switch fast you can shift from NO to YES and vice ver sa If YES CLEAR is displayed press the MODE switch and hold it for more than three seconds to reset the service icon Wrench symbol To exit turn the key to OFF CAUTION IF A SCREEN DIFFERENT FROM THOSE DESCRIBED IS DISPLAYED EXIT BY TURNING THE KEY TO OFF RX SX 125 Electrical system EL...

Page 56: ...Ignition circuit Key 1 Instrument panel 2 Key switch 3 Battery 4 fuses 5 CDI control unit Electrical system RX SX 125 ELE SYS 56 ...

Page 57: ...e are not damaged Check the spark plug and replace it if necessary Check the high voltage wire and the spark plug cap Check the coil Check the pick up Check that the 15 A fuses are in good conditions Check the diode Check the start up relay Replace the CDI by another one in proper operating conditions Battery recharge circuit System diagram key RX SX 125 Electrical system ELE SYS 57 ...

Page 58: ...bleshooting Check that the fuses are in good conditions Check the starter button Check the start up relay Check the starter motor Control data Flywheel check Disconnect the alternator cable con nector Start the engine and make it run at 5000 rpm With the pocket tester measure the voltage alternating current among the three yellow cables If the value indica ted by the tester is below 53 V the gener...

Page 59: ... bulb 5 3 kOhm L bulb 4 8 kOhm Undo and remove the screw and re move the protection glass with caution so as not to break the fitting tooth Slightly press the bulb and turn it anti clockwise Take out the bulb from its fitting Upon replacement insert a bulb of equal rating in the bulb holder making the two guiding pins coincide with their guides on the bulb holder RX SX 125 Electrical system ELE SY...

Page 60: ... bulb does not turn on Test D the bulb turns on With a tester in diode test function check the val ues between the two male terminals inside the diode as indicated in the figure Correct value measurement A 0 1 Ohm Correct value measurement B infinite If the tester cannot be used as a diode test tool supply 12 V voltage interpose a 12 V 2 W bulb on the positive lead and connect the diode as in dica...

Page 61: ...Lights list Key 1 Instrument panel 2 Horn 3 Diode 4 Left rear turn indicator RX SX 125 Electrical system ELE SYS 61 ...

Page 62: ...ft front turn indicator Troubleshooting Check that the 15 and 20 A fuses are in good conditions Check if the stop light bulb is in good conditions Switches With a tester check the continuity of the switches referring to the specific diagram provided If any malfunction is detected replace the corre sponding switch unit FRONT AND REAR LIGHTS Electrical system RX SX 125 ELE SYS 62 ...

Page 63: ... From battery to ignition switch voltage regulator clock 2 15 A Fuse From ignition switch to all light loads and horn 3 7 5 A Fuse From ignition switch to ignition air solenoid RAVE Full Power solenoid NOTE THERE IS ONE SPARE FUSE Control unit The control unit has been designed for internal self diagnose In case of mal function install a control unit in proper operating conditions on the vehicle R...

Page 64: ... 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 cell or if the off load voltage is lower than 12V the battery surely needs to be replaced Speed sensor Operating voltage Vdc 5 24 V Maximum voltage applicable 26 V Maximum r...

Page 65: ...les The resistance value measured should be between 190 and 300 Ohm If the resistance is infinite or lower than the set value the pick up needs to be replaced Air temperature sensor AIR TEMPERATURE SENSOR Specification Desc Quantity 5 C 41 F 5310 Ohm 10 C 50 F 4134 Ohm 25 C 77 F 2053 Ohm 30 C 86 F 1651 Ohm 40 C 104 F 1090 Ohm 50 C 122 F 738 Ohm Ohm resistance 10 RX SX 125 Electrical system ELE SYS...

Page 66: ...m Secondary 4 3 8 1 kOhm Checking Use a pocket tester to check the coil In every case the continuity of the primary and secondary wind ings must be checked The Ohm reading need not be exact but if the windings are not damaged their continuity must be detected according to the fol lowing Ohm resistance values described above Electrical system RX SX 125 ELE SYS 66 ...

Page 67: ...sensor positive 2 Pin 2 Speed sensor signal 3 Pin 3 Signal ground connection CONNECTOR B Specification Desc Quantity 1 Pin 1 Rave valve 2 Pin 2 K line 3 Pin 3 live 4 Pin 4 Temperature sensor input 5 Pin 5 5V TPS 6 Pin 6 Mil bulb 7 Pin 7 Maj2 Valve 8 Pin 8 Speed output 9 Pin 9 Pick up input 10 Pin 10 RPM output 11 Pin 11 Kill input 12 Pin 12 Ground connection 13 Pin 13 TPS input 14 Pin 14 HV coil R...

Page 68: ...TORS INPUT 2 RIGHT INDICATORS INPUT 3 NEUTRAL INPUT 4 INPUT FOR HIGH BEAM LIGHTS 5 SPEED SENSOR INPUT 6 7 OIL LEVEL SENSOR 8 9 10 11 LIVE 12 RPM INPUT 13 GENERAL GROUND 14 BATTERY 15 16 17 18 EFI WARNING LIGHT Electrical system RX SX 125 ELE SYS 68 ...

Page 69: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 70: ...table belts to the rear frame Remove the central and front side fairings Remove the fuel tank Lift the hoist arm until the belts are linked to the chassis and are taut Remove the complete exhaust Removing the engine from the vehicle Remove the battery 1 from its hous ing Before draining the cooling system prepare a container of suitable capaci ty Empty the cooling system by undoing the front screw...

Page 71: ...emove the three screws and remove the oil pump cover Loosen the set nut Slide off the throttle cable from the oil pump CAUTION UPON REFITTING ADJUST THE THROTTLE CABLE TEN SION BY OPERATING THE NUT ON THE OIL PUMP RX SX 125 Engine from vehicle ENG VE 71 ...

Page 72: ...outlet and pipe Disconnect the spark plug tube Disconnect the thermistor electric con nector Loosen the locking washer completely 2 Loosen the set screw 3 completely Remove the clutch cable 4 from the lever Engine from vehicle RX SX 125 ENG VE 72 ...

Page 73: ... cable from its seat Slide off the clutch cable CAUTION UPON REFITTING CHECK THE CLUTCH LEVER CLEAR ANCE Loosen the fixing screw and move the oil hose guides Detach the oil pipes from the engine crankcase Disconnect the engine oil breather pipe from the crankcase RX SX 125 Engine from vehicle ENG VE 73 ...

Page 74: ...TO FACILITATE SLIDING OFF THE TRANSMISSION PIN ION SLIGHTLY LOOSEN THE DRIVE CHAIN Remove the Seeger ring Slide off the transmission pinion with the chain from the shaft Disconnect the neutral gear sensor Release the cables by removing the clamps indicated Engine from vehicle RX SX 125 ENG VE 74 ...

Page 75: ... Working from the left side of the vehi cle undo the screw while keeping the right hand side nut tightened Release the engine temperature sen sor RX SX 125 Engine from vehicle ENG VE 75 ...

Page 76: ... Disconnect the connections Remove the pipe from the hose guide Remove the carburettor Engine from vehicle RX SX 125 ENG VE 76 ...

Page 77: ... speed sensor CAUTION DUE TO THE ENGINE WEIGHT THE FOLLOWING OPERATIONS REQUIRE THE INTERVENTION OF A SECOND OPERATOR FIRST AGREE ABOUT THE PROCEDURE TO BE FOLLOWED Working from the right side and using the suitable swingarm pin adjustment tool fully loosen the ring nut 5 Loosen the ring nut set bushing 6 Specific tooling AP8101945 Fork pin ring nut RX SX 125 Engine from vehicle ENG VE 77 ...

Page 78: ...ushing 6 Working from the left side undo and remove the swingarm pin and collect the two washers Remove the swingarm from the chas sis Sliding it off from the left side of the vehicle remove the engine from the chassis Installing the engine to the vehicle Move the engine with small alternating movements until it is perfectly aligned with the fixing holes Insert the upper screw fit the washer and t...

Page 79: ...rop erly seating the ring nut set bushing 1 and screwing it another 1 4 of a turn CAUTION GET THE ADEQUATE SWINGARM PIN ADJUSTMENT TOOL Specific tooling AP8101945 Fork pin ring nut Firmly hold the bushing 2 and tighten the ring nut 1 using a special tool Now adjust the rear swingarm pin as follows Using the adequate adjustment tool loosen the ring nut 1 completely working from the upper right side...

Page 80: ...or and tighten the screw Fit the carburettor Replace the clamp and connect the secondary air pipe Place the rear brake pipe and the speed sensor cable and tighten them to the chassis fastening the cable guide Connect the following electric connectors in order Engine from vehicle RX SX 125 ENG VE 80 ...

Page 81: ... System ground connections tighten the screw Connect the neutral gear sensor Replace the clamps RX SX 125 Engine from vehicle ENG VE 81 ...

Page 82: ... Control unit ground connection Pick up Generator Connect the engine temperature sen sor connector Engine from vehicle RX SX 125 ENG VE 82 ...

Page 83: ...ith the chain on the shaft Fit the Seeger ring Fit the pinion protection case and fix it by means of two screws Place the oil pipes on the engine crank case fastening them with the hose guides RX SX 125 Engine from vehicle ENG VE 83 ...

Page 84: ...on tank pipe Reposition the clutch cable in its seat Tighten the gearbox oil filler cap Fit the clutch cable 3 in the clutch lev er Undo the set screw 4 Tighten the locking washer 5 partial ly Check the clutch lever clearance Engine from vehicle RX SX 125 ENG VE 84 ...

Page 85: ...con nector Connect the spark plug tube Place the throttle cable in the oil pump Adjust the throttle cable tension by op erating the nut on the oil pump until it is aligned with the two references RX SX 125 Engine from vehicle ENG VE 85 ...

Page 86: ... screws locking nuts are tightened to the prescribed torque Top up coolant Check the drive chain tension and adjust if necessary NOTE CARRY OUT AN OVERALL CHECK ON ALL THE COMPONENTS THAT HAVE UNDERGONE ANY OPERATION ESPECIALLY THAT the electrical cables are correctly fastened with suitable clamps Engine from vehicle RX SX 125 ENG VE 86 ...

Page 87: ... electrical connectors are correctly coupled the pipes and unions are correctly fitted and secured with suitable clamps the throttle and cold start cables slide freely and do not cause the handlebar to rotate RX SX 125 Engine from vehicle ENG VE 87 ...

Page 88: ...INDEX OF TOPICS ENGINE ENG ...

Page 89: ...e gearbox Open the crankcase halves Remove the gaskets from the crank case Take out the countershaft Fix the flywheel side crankcase half on the engine support with the adequate screw and spacer Take out both fork rod RX SX 125 Engine ENG 89 ...

Page 90: ... the desmodrom ic control fixing screw and collect the washer Slide off the three gear forks from the guides of the desmodromic drum con trol Remove the desmodromic drum con trol Remove the O ring Engine RX SX 125 ENG 90 ...

Page 91: ...16 97 mm 0 6681 in Checking the secondary shaft Check the state of the joints and grooves Max admissible deviation A 0 03 mm 0 0012 in Min wear limit B Diam 24 96 mm 0 9827 in Min wear limit C Diam 20 96 mm 0 8260 in Min wear limit C Diam 16 97 mm 0 6681 in Checking the desmodromic drum Check the contact zone on fork 1 and the driving pin 2 of the forks for wear Check the desmodromic drum grooves ...

Page 92: ...ED BY REMOVING THE CLUTCH COVER AND ROTATING THE LONG SHAFT Assembling the gearbox Place the guiding sleeve on the pri mary shaft to avoid damaging the oil seal Heat up the engine crankcase Apply LOCTITE Anti Seize on the bearing seats present on the crank case Fit the bearings in their seats Fit the gear unit Fit the 5th 6th gear fork on the gear pinion of the secondary shaft Place the 2nd 3rd ge...

Page 93: ...ubricate the gear shafts and insert them in their seats paying special at tention that the short gear shaft has its chamfering side facing upwards and that the seeger ring on the long one is properly placed Check that all the gear components slide smoothly Warm up the crankcase Apply LOCTITE Anti Seize to each bearing seat of the countershaft Fit the bearing Fit the countershaft in the bearing RX ...

Page 94: ...UP GEAR Make sure that the gears 3 are not worn The start up gears must be blocked with precision in one direction Removing the starter motor Undo and remove the two fixing screws Remove the starter motor NOTE THE STARTER MOTOR CAN ALSO BE 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 ...

Page 95: ...de Apply MOLYKOTE 111 to all the bear ing housings and the teeth of the start up gear unit Install the start up gear unit together with the thrust washer in the hole with the needle bearing Generator side Removing the flywheel cover Lean the engine on the support in such a way as to place the start up cover facing upwards Undo and remove the six screws fixing the flywheel cover RX SX 125 Engine EN...

Page 96: ... Remove the flywheel cover Magneto flywheel removal Remove the flywheel cover Remove the starter motor gear cover Undo the two M5 screws and remove the external pick up Engine RX SX 125 ENG 96 ...

Page 97: ... The flywheel cam must be fac ing the external pick up making sure that the crankshaft is at TDC When placing the extractor plate make sure that the position of the support pins is correct Undo and remove the M12x1 hexago nal screw and collect the locking wash er RX SX 125 Engine ENG 97 ...

Page 98: ... three M6 stator fixing screws Remove the stator the cable guide and external locking Remove the woodruff key from the crankshaft Installing the flywheel Degrease the crankshaft conic part and the flywheel Place the flywheel matching the grooves on the shaft Place the washer and the magneto fly wheel fixing screw without tightening it Place the flywheel up to the TDC Engine RX SX 125 ENG 98 ...

Page 99: ... fix it with three screws M6 x 16 Specific tooling AP0277455 Extractor plate to separate the crankcase halves Tighten the magneto flywheel fixing nut Place the pick up tighten the two pick up fixing screws and adjust the pick up distance to 0 55 mm 0 217 in RX SX 125 Engine ENG 99 ...

Page 100: ...electric starter device cover on the starter gear Stator installation Insert the woodruff key in the crank shaft Place the stator Tighten the three stator fixing screws Flywheel cover installation Apply a thin layer of SILASTIC 732 RTV on the flywheel cover centring Place the flywheel cover Engine RX SX 125 ENG 100 ...

Page 101: ...he clutch cover Undo and remove the nine screws fix ing the clutch cover Lift the clutch cover using two screw drivers as levers at the prearranged points paying special attention not to damage the seal surfaces and the gas ket Remove the gasket RX SX 125 Engine ENG 101 ...

Page 102: ...C IS USED AS A SPRING AND MUST BE PUT BACK IN PLACE AT THE SAME UPPER POSITION Check that the plain clutch discs 6 are not deformed Max distortion limit 0 15 mm 0 0059 in Check that the coated clutch discs 5 are not worn Max wear limit min thickness 2 8 mm 0 110 in THE UPPER DISC IS USED AS A SPRING AND MUST BE PUT BACK IN PLACE AT THE SAME UPPER POSITION CHECK Clutch bell 1 teeth sides and contro...

Page 103: ...tion that the coated clutch disc placed at the upper end must be fitted in the shortest slots 8 Screw the clutch fixing screws 9 without tightening proceed to the tightening only after the clutch has been fitted THE UPPER DISC IS USED AS A SPRING AND MUST BE PUT BACK IN PLACE AT THE SAME UPPER POSITION Checking the clutch housing Check the worn guiding grooves of the clutch bell 1 max insertion de...

Page 104: ...as exceeded the wear limit Max wear limit A 0 3 mm 0 012 in Assembling the clutch Check that the needle bearings are in stalled on the secondary shaft Install the clutch base Fit the disc pack pre assembled on the clutch base which has been previously placed on the secondary shaft Head and timing Engine RX SX 125 ENG 104 ...

Page 105: ...mbustion chamber in sert together with the O Ring See also Removing the head cover Cylinder head Checking the cylinder head HEAD Clean off any combustion deposits in the combustion chamber as well as scales on the surfaces in contact with the cooling water Make sure the insert in the combustion chamber is not damaged and the spark plug thread is in good conditions Make sure the seal surfaces are s...

Page 106: ...ngs are clean Make sure the cylinder head cover is not damaged Cylinder piston assembly Removing the cylinder Remove the head Working from both sides remove the four fixing screws and collect the wash ers Take out the cylinder with utmost care trying not to damage the piston Remove the gasket on the cylinder base See also Removing the cylinder head Engine RX SX 125 ENG 106 ...

Page 107: ...L INTO THE CRANKCASE NOTE IT IS NOT NECESSARY TO REMOVE BOTH PIN SEEGER RINGS Tap the pin out with a suitable punch CAUTION WHILE TAPPING OUT THE PIN HOLD THE PISTON WITH ONE HAND SO THAT THE CONNECTING ROAD DOES NOT BEND Remove the piston and collect the ball retainer CAUTION WHILE TAPPING OUT THE PIN HOLD THE PISTON WITH ONE HAND SO THAT THE CONNECTING ROAD DOES NOT BEND See also Removing the cy...

Page 108: ...ke sure the piston is not damaged or shows signs of pressure or galling SLIGHT SCORINGS CAN BE ELIMINATED BY RUBBING THEM WITH EMERY CLOTH GRAIN 600 800 Clean the piston crown and the bottom side as well as the piston ring grooves CLEAN THE RING GROOVES THOROUGHLY WITH A SCRAPER OR PREFERABLY WITH A PIECE OF AN OLD PISTON RING Clearance between piston and wall Cylinder diam Piston diam Nominal cle...

Page 109: ...wear limit 0 8 mm 0 032 in TO MEASURE THE DISTANCE BETWEEN THE ENDS OF A PISTON RING PLACE THE RING IN THE CYLINDER USING THE PISTON AS A PUSHING TOOL AND CHECK THE DIS TANCE WITH A THICKNESS GAUGE Fitting the piston Position the cylinder base gasket THE CRANKCASE GASKET SHOULD NOT PROTRUDE OR RECESSED COMPARED WITH THE CYLINDER BASE SURFACE SO AS TO AVOID COOLANT LEAKING INTO THE CRANKCASE Place ...

Page 110: ...NKCASE WITH A CLEAN CLOTH SO THAT THE SEEGER RINGS DO NOT FALL INTO THE CRANKCASE Place the second seeger ring FOR SAFETY REASONS COVER THE CRANKCASE WITH A CLEAN CLOTH SO THAT THE SEEGER RINGS DO NOT FALL INTO THE CRANKCASE Installing the cylinder Use the wrench for piston rings MAKE SURE THE PISTON RINGS ARE FITTED WITH THEIR ENDS BESIDE THE FIXING PIN IN THE GROOVE APPLY OIL FOR TWO STROKE ENGI...

Page 111: ... cylinder diameter at TDC The bottom section of the cylinder sur face undergoes only slight wear If the cylinder TDC area is very worn it is no longer bright rough and sharp it can be inferred that the engine has been working fed on a fuel with too much sulphur Cylinder A Diam 54 000 54 010 mm 2 12597 2 12637 in Diam 54 060 mm 2 12834 in Cylinder AB Diam 54 010 54 015 mm 2 12637 2 12657 in Diam 54...

Page 112: ...t types of piston rings which are identified with their part number PISTON code 294583 chrome plated PISTON RING code 215670 PISTON code 294587 chromium ceramic PISTON RING code 215720 PISTON code 294589 chromium ceramic PISTON RING code 215820 PISTON code 294588 chromium ceramic PISTON RING new type code 215825 IF A PISTON SHOWS SIGNS OF EXCESSIVE WEAR AS IT HAS BEEN FUNCTIONING WITH LOW QUALITY ...

Page 113: ...e head cover already fitted with the thermostat Tighten crosswise the four screws fix ing the head cover Crankcase crankshaft Splitting the crankcase halves Remove the snap ring of the crankshaft and that of the countershaft RX SX 125 Engine ENG 113 ...

Page 114: ... Remove the control gear from the crankshaft Remove the two countershaft gears with a suitable tool Remove the gear shaft and collect the thrust washer Engine RX SX 125 ENG 114 ...

Page 115: ...ve the screw fixing the lever Remove the lever and collect the spring the spacer and the washer Undo and remove the nine screws fix ing the crankcase halves Undo and remove the support screw RX SX 125 Engine ENG 115 ...

Page 116: ...rubber mallet being careful that the crank case half gets detached evenly Be ex tremely careful not to tap the seal surfaces Check the thrust washer of the main shaft When detaching the crankcase the washer may get glued inside the crankcase halves Once the crankcase halves have been detached remove the extracting tool before the crankcase halves are fully apart Specific tooling AP0277455 Extracto...

Page 117: ...nkcase halves the ball bearings and all the bearing gaskets with a non ag gressive detergent DO NOT USE DEGREASERS OR SOLVENTS Clean all the seal surfaces BE CAREFUL NOT TO DAMAGE THE SEAL SURFACES WHEN CLEANING THEM Check that the crankcase halves show no signs of cracks or any kind of damage Check that the oil flow in the main bearings is not obstructed clear the passage with com pressed air if ...

Page 118: ...RFACE TO AVOID DAMAGING THE SEAL SURFACES FLYWHEEL SIDE CRANKCASE HALF Take out the oil seal 2 and the ball bearing 3 of the crankshaft with a suit able punch 4 BEHIND THE BALL BEARING THERE ARE SOME SHIM WASHERS FOR THE AXIAL CLEARANCE OF THE CRANK SHAFT 5 ALSO REPLACE THE OIL SEAL IF THE BALL BEARING IS REPLACED Fit the oil seal of the crankshaft using a punch 6 THE BALL BEARING OF THE CRANKSHAF...

Page 119: ...0276370 Split bushing AP0276372 Split bushing The ball bearings of the secondary shaft and those of the countershaft can be taken out using the specific extractor for bearings THE REAR SIDE OF THE BALL BEARING RETAINER SHOULD BE FACING OUTWARDS The needle bearing for the gears of the starter motor can be pulled using a specific extractor for bearings CLUTCH SIDE CRANKCASE HALF Pre warm the crankca...

Page 120: ...e punch Refit fol lowing the same procedure THE CLOSED SIDE OF THE RETAINER OF THE BEARING ON THE SECONDARY SHAFT 15 SHOULD BE FACING OUTWARDS WHEREAS IT SHOULD BE FACING INWARDS FOR THE BEARING ON THE MAIN SHAFT 16 Remove the M5 countersunk screw 17 and the locking washer and take out the ball bearing 19 of the coun tershaft Follow the same procedure to refit the bearing fixing the M5 counter sun...

Page 121: ...OUNTERSHAFT GEAR ON THE CRANKSHAFT MUST BE REPLACED AFTER 15 000 KM Installing the crankshaft UPON REFITTING ALWAYS REPLACE THE GASKETS THE SAFETY CIRCLIPS THE O RINGS AND THE OIL SEALS REMOVED Pre warm the crankcase at 90 100 C 194 212 F Fix the flywheel side crankcase half to the support and tighten the screw and the spacer If necessary fit the shim washers nee ded to the flywheel side crankcase...

Page 122: ...or screw in the extractor plate Insert the crankshaft in the tapping of the extractor screw by turning the shaft clockwise until it stops Push the crankshaft fully into the crankcase by turning the extractor screw anticlockwise While fitting the crankshaft keep the connecting rod in the direction of the cylinder axis Once the fitting is complete undo and remove the screws fixing the extractor plat...

Page 123: ...half ALWAYS USE NEW GASKETS NOTE THE CRANKCASE GASKET MAY BE GREASED TO KEEP IT IN POSITION THE CRANKCASE GASKET MUST MATCH ALL THE HOLES ON THE CRANKCASE OPERATE WITH CAUTION SO THAT THE COUPLING DOES NOT LEAK Fix again the crankcase to the support by tightening the bolts Screw both crankcase halves with new M6 Allen screws TIGHTEN THE SCREWS CROSSWISE STARTING GRADU ALLY FROM THE CRANKCASE CENTR...

Page 124: ... MOVE SMOOTHLY ENGAGE 3rd GEAR AND TURN THE SHAFT TO LEFT AND RIGHT UNTIL THE LATCH TOUCHES THE RELEVANT PIN ON THE DESMODROMIC DRUM THERE SHOULD BE THE SAME CLEARANCE ON BOTH SIDES IF CLEARANCES DIFFER FOLD THE TAB AS REQUIRED Place the two countershaft control gears MAKE SURE ALL THE MARKS ARE ALIGNED Engine RX SX 125 ENG 124 ...

Page 125: ...ring of the crank shaft control and that of the counter shaft control NEVER REUSE OLD SEEGER RINGS WHEN USING A SEEGER RING BE CAREFUL NOT TO OVER STRETCH IT MAKE SURE THE RINGS ARE FULLY INSERTED IN THE GROOVES Lubrication Oil pump RX SX 125 Engine ENG 125 ...

Page 126: ...livery 1 and intake 2 pipes do not leak or have pores at their connecting points Replace if re quired Clean the oil reservoir the oil reservoir filter and the oil intake pipe Always replace the oil pump when damaged or leaking After installing the flexible pipe of the oil pump adjust it so that when in idle position the marks on the pump lever 3 are aligned with the pump 4 seat BLEEDING Purge the ...

Page 127: ...atalytic converter is not able to activate the post combustion reaction freely Thanks to the secondary air system SAS the post combustion reaction is immediately activated outside the combustion chamber reducing CO and HC first and thanks to the heat produced it accelerates the thermal adjustment of the catalytic converter The SAS takes advantage of the pres sure fluctuation at the exhaust At the ...

Page 128: ...M AS THE VEHICLE WORKS REGULARLY ALSO WITH THE SYSTEM DEACTIVATED BUT GIVEN THESE CONDITIONS THE HARMFUL EMIS SIONS INCREASE LACK OF AIR CIRCULATION MAY AL SO RESULT IN OVERHEATING AND THIS IN TURN COULD DAMAGE THE SAS COUPLINGS AND PIPING TO BLOCK AIR CIRCULATION USE SUITABLE SYSTEMS ONLY USING PLUGS TO BLOCK THE AIR INTAKE IN THE FILTER HOUSING MAY DAMAGE THE SECONDARY AIR SYSTEM DUE TO OVERHEAT...

Page 129: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 130: ...Circuit diagram Key 1 Fuel tank 2 Fuel cock 3 Oil mixer tank 4 Oil reservoir cap 5 Oil level gauge Carburettor Removing Remove the fuel tank Undo the two screws Power supply RX SX 125 P SUPP 130 ...

Page 131: ... the throttle valve but keep it connected to the throttle cable Remove the screw Remove the cold start control but keep it connected to the cable Disconnect connectors 1 and 2 RX SX 125 Power supply P SUPP 131 ...

Page 132: ... Working from the right side remove the fuel pump 3 vacuum hose and the fuel hose 4 Loosen the clamps Power supply RX SX 125 P SUPP 132 ...

Page 133: ... to the left Remove the carburettor To refit follow the procedure described above but in reverse order Be very careful about the correct position of the fuel pipes CAUTION IF FUEL HOSES ARE INCORRECTLY POSITIONED THIS MAY RESULT IN CRUSHED HOSES AND THEREFORE IRREGULAR FUNCTIONING AND OR SERIOUS ENGINE DAMAGE RX SX 125 Power supply P SUPP 133 ...

Page 134: ...ng the carburettor Remove the two screws and slide off the throttle valve throttle valve posi tion sensor unit Remove the heater Remove the float chamber cap Remove the maximum nozzle cap Power supply RX SX 125 P SUPP 134 ...

Page 135: ... the start up nozzle Remove the throttle valve position sen sor Carburettor refitting Make sure that the TPS gear 5 is fully turned clockwise the control arm 6 should be at the fully extended posi tion RX SX 125 Power supply P SUPP 135 ...

Page 136: ... THE AXONE DIAGNOSIS TOOL Ignition Axone use for ignition system ignition CAUTION UNLESS OTHERWISE SPECIFIED THE VALUES INDICATED ARE ONLY EXAMPLES ISO screen page ISO DISPLAY Specification Desc Quantity Mapping SX125_28 Map reading active 1 2 indicates whether the control unit is standard 1 or it has been modified for racing on tracks 2 Hardware code APG01 Serial number 12 Central unit hardware v...

Page 137: ...E AIM OF ENSURING THE ENGINE HAS BEEN THOR OUGHLY CHECKED ERRORS DISPLAY Specification Desc Quantity EEPROM checksum error Signal not valid Control unit internal error Data zone EEPROM not valid default values reset Control unit internal error Crankshaft position sensor Circuit open An interruption has been detected between pin 9 and pin 3 of the small connector in the control unit Crankshaft posi...

Page 138: ... Intake manifold valve shorted to positive High voltage has been detected at pin 7 detected only at en gine start up If Map 2 is active the error is deactivated Intake manifold valve Open circuit or shorted to voltage Too low or no voltage has been detected at pin 7 If Map 2 is active the error is deactivated Air temperature sensor Short circuit to ground Too low or no voltage has been detected at...

Page 139: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 140: ...les 5 Rim 6 Front wheel radius 7 Front wheel radius 8 Front wheel radius 9 Front wheel radius 10 Hub 11 Wheel spacer 12 Bearings spacer 13 Hub bearing 14 Oil seal 15 Bare front wheel 16 TSPEI screw 17 Brake disc 18 Magnet Suspensions RX SX 125 SUSP 140 ...

Page 141: ...OPERATOR KEEP THE HANDLEBAR STEADY AND ENGAGED SO THAT THE STEERING IS LOCKED Undo and remove both front calliper fixing screws Remove the brake calliper CAUTION DO NOT ACTUATE THE FRONT BRAKE LEVER AFTER REMOVING THE WHEEL OTHERWISE THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEAT RESULTING IN BRAKE FLUID LEAKAGE Working from the right side loosen both screws Working from the right side unscrew a...

Page 142: ...ont wheel CAUTION CHECK THAT ALL THE PARTS ARE IN GOOD CONDITIONS ESPECIALLY THOSE MENTIONED BELOW BEARINGS Turn the internal ring manually it must rotate smoothly continuously and silently There must be no axial clearance The bearings presenting these problems must be replaced GASKETS Check that the gaskets are in good conditions replace them if they show signs of damage or excessive wear Suspens...

Page 143: ...he bearings the value is not within the specified limit Maximum radial and axial eccentricity 2 mm TYRE Check the tyre conditions Installing the front wheel Spread a thin layer of lubricating grease all along the wheel pin CAUTION UPON REFITTING PAY ATTENTION NOT TO DAMAGE THE BRAKE HOSES DISCS AND PADS CAUTION POSITION THE SPACER WITH THE LARGER DIAMETER SIDE FACING THE FORK RIGHT STEM Fit the sp...

Page 144: ... PADS Slide the brake calliper on the disc and position it with the fixing holes aligned with the holes on the support CAUTION UPON REFITTING THE CALLIPER REPLACE ITS FIXING SCREWS WITH NEW SCREWS OF THE SAME TYPE Screw and tighten both calliper fixing screws Operating the front brake lever press the handlebar repeatedly to send the fork fully down In this way the fork stems will be correctly adju...

Page 145: ...CHECK THAT THE BRAKING SYSTEM OPERATES CORRECTLY CAUTION AFTER REFITTING PULL THE BRAKE LEVER REPEATEDLY AND CHECK THAT THE BRAKING SYSTEM OPERATES CORRECTLY Check that the wheel is centred Front fork Diagram Key 1 Complete cap 2 O ring 3 Complete sleeve 4 Sliding bushing 5 Guide bushing cap 6 Sealing ring 7 Snap ring RX SX 125 Suspensions SUSP 145 ...

Page 146: ...eft pumping member rod 26 Left pumping member 27 Cap 28 Left piston 29 Nut 30 Right pumping member assembly 31 Left pumping member assembly 32 TE flanged screw 33 Stem right wheel holder 34 Stem left wheel holder 35 Spring 36 Preloading pipe 37 Sealing washer 38 TCE screw 39 Thickness 40 Thickness 41 Thickness Removing the fork legs CAUTION POSITION THE OPTIONAL FRONT SERVICE STAND HIGH CAUTION Su...

Page 147: ...lock clamp placed on the brake pipe on left stem protection Release the brake pipe from the left stem protection Undo both stem protection fixing screws Remove the stem protection Remove the front wheel Loosen the screw on the upper plate Loosen both lower plate screws RX SX 125 Suspensions SUSP 147 ...

Page 148: ...roughly CAUTION BEFORE CARRYING OUT THE OPERATIONS BELOW GET A 440 cm 26 85 cu in CONTAINER TO COLLECT THE OIL Place the sleeve in a vice fitted with protection shoes CAUTION THE WHEEL HOLDER STEM SLEEVE UNIT CONTAINS OIL DO NOT TURN IT OVER OR TILT IT TOO MUCH WHEN REMOVING IT Unscrew and remove the upper cap of the shock absorber rod With an open wrench keep the lock nut firm on the shock absorb...

Page 149: ... pipe Remove the spring Drain the oil off the stem being careful not to slide the stem sleeve For easy drainage of the oil inside the cartridge pump it several times with the stem in vertical position RX SX 125 Suspensions SUSP 149 ...

Page 150: ...tted with protection jaws to avoid damaging it Loosen the fixing screw and remove the guide of the stem cover Hold the sleeve and firmly slide it off the stem Screw the sleeve in a vice fitted with protection jaws so as to avoid dam ages With a plain slot screwdriver remove the dust guard being careful not to damage the sleeve rim The dust guards removed can not be reused Suspensions RX SX 125 SUS...

Page 151: ...f its circumference without damaging the oil seal and the sleeve rim To take out the sliding bushings and the plastic spacer hit the sleeve end hard on a wooden surface keeping the sleeve perpendicular to the surface To take out the sliding bushings and the plastic spacer hit the sleeve end hard on a wooden surface keeping the sleeve perpendicular to the surface RX SX 125 Suspensions SUSP 151 ...

Page 152: ...oid damaging it With the cartridge rod firmly in place unscrew and remove the bottom screw and its gasket Remove the cartridge from the fork stem and properly clean all the com ponents with a suitable detergent Checking the components WHEEL HOLDER STEM Suspensions RX SX 125 SUSP 152 ...

Page 153: ...rwise replace it Check that the sliding bushings are in good conditions If there are signs of excessive wear or damage replace the affected component CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS TAKING CARE NOT TO SCRATCH THEIR SUR FACE Replace the following components with new ones sealing ring dust guard O ring gasket on the cap Reassembling the fork Check the components CAUTION BE EXTREMELY CARE...

Page 154: ...t the sliding bushing 1 use the spacer 2 to push it into the sleeve Then fit another sliding bushing 3 if required use a buffer of suitable diam eter to push in into the sleeve Suspensions RX SX 125 SUSP 154 ...

Page 155: ... 5 with a layer of oil Insert on the fork stem the dust guard 6 the snap ring 7 the oil seal 5 and the guide bushing cap 4 Pay attention to the direction in which the dust guard 6 and the oil seal 5 should be placed RX SX 125 Suspensions SUSP 155 ...

Page 156: ...few times Measure the air gap between the oil level and the rim THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS Characteristic Oil level from sleeve rim without the spring and with stem at the end of the stroke 150 mm 5 9 in Slowly move the cartridge upwards and downwards rod so that it is filled with oil Do so until pulli...

Page 157: ... member rod and the spring Screw the spring until it is fully inserted into the sleeve end Place the spring preloading pipe Screw the upper locking cap on the pumping member stem Screw the fork upper cap up to the pumping member stem Place the upper cap on the sleeve tak ing care not to damage the O ring Tighten the upper cap to the prescribed torque RX SX 125 Suspensions SUSP 157 ...

Page 158: ...he wheel holder stem on the lower and upper plates Insert the wheel pin through both stems to align the holes Tighten the screw that locks the lower plate to the sleeve Tighten the screw that blocks the upper plate to the sleeve Suspensions RX SX 125 SUSP 158 ...

Page 159: ... Slide off the wheel pin Mount the front wheel Fit the front brake calliper and tighten the two fixing screws Steering bearing Key 1 Headstock cap 2 Washer RX SX 125 Suspensions SUSP 159 ...

Page 160: ...w 14 U bolt Adjusting play Unscrew and remove the four screws and collect the washers Remove both U bolts Undo and remove both upper plate screws Tap the bottom side to push upwards the upper plate together with handlebar and ignition switch steering lock Move the upper plate forwards place a piece of cloth to avoid damaging the instrument panel Suspensions RX SX 125 SUSP 160 ...

Page 161: ...fterwards tighten the ring nut again to the prescribed torque restoring the clearance Reposition the upper plate and adjust it adequately Lubricate the thread and the bushing base in contact with the oil Tighten the upper bushing Loosen the bushing and tighten it again to the prescribed torque RX SX 125 Suspensions SUSP 161 ...

Page 162: ...E THE HANDLEBAR ROTATES SMOOTHLY TO AVOID DAMAG ING THE SLIDING GUIDES AND COMPROMISING VEHI CLE HANDLING Rear Key 1 Rear tyre 2 Air chamber 3 Wheel flap 4 Rear wheel rim 5 Wheel radius 6 Wheel radius 7 Wheel radius 8 Wheel radius 9 Nipples 10 Rear hub Suspensions RX SX 125 SUSP 162 ...

Page 163: ...Crown 18 Low self locking nut 19 Curved spring washer 20 TSPEI screw 21 Chain with master link 22 Bare rear wheel 23 Bearings spacer 24 Hub bearing Removing the rear wheel Rest the vehicle on the specific OP TIONAL stands Unscrew and remove the nut and re trieve the washer RX SX 125 Suspensions SUSP 163 ...

Page 164: ...lect the centring shim washers and slide off the wheel backwards Checking the rear wheel CAUTION CHECK THAT ALL THE PARTS ARE IN GOOD CONDI TIONS ESPECIALLY THOSE MENTIONED BELOW BEARINGS GASKETS WHEEL PIN RIM ANTI VIBRATION BUFFER Check that the anti vibration buffer is not damaged and or excessively worn Replace the buffer if nec essary Suspensions RX SX 125 SUSP 164 ...

Page 165: ...VENT EARLY WEAR OF NEW COMPONENTS Installing the rear wheel Position the rear wheel Position the chain Working on both sides insert the centring shim washers Working from the left side insert the wheel axle CAUTION DO NOT INVERT THE RIGHT AND THE LEFT CHAIN TENSIONERS Working on the right side position the washer and screw but do not tighten the wheel axle fixing nut Adjust the chain tension opera...

Page 166: ... connection rod 3 Double connecting rod 4 TCEI M10x55 screw 5 10 5x21x2 washer 6 M10 Flanged self locking nut 7 TE flanged M10x61 screw 8 D18x24x3 oil seal 9 Roller casing 10 L 36 pin 11 Spacer 12 TCEI M12x107 screw Suspensions RX SX 125 SUSP 166 ...

Page 167: ...THREAD IF SUCH DISTANCE IS EXCEEDED THERE WILL BE SOME JERKING WHILE RIDING EVEN ON SOME SLIGHTLY UNEVEN ROADS Operate on the set nut 1 shock ab sorber spring preloading adjustment CAUTION TURN THE SET NUT 1 GRADUALLY ONE TURN AT A TIME TRY RIDING THE VEHICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED REAR SHOCK ABSORBER ADJUSTMENT Specification Desc Quantity By tightening the set nut ...

Page 168: ...bsorber is in neutral position Working from the vehicle left side un screw and remove the link rod screw and collect the nut from the right side Working from the left side unscrew and remove the rear shock absorber fixing screw and collect the nut from the opposite side Carefully place the fork upper part Undo the upper screw and remove it from the left side Slide the rear shock absorber down ward...

Page 169: ...y on the shock absorber Insert the shock absorber lower screw from the right side Working from the opposite side tighten the nut 2 Place the double connecting rod in its seat on the chassis From the left side insert the nut fixing the connecting rod assembly plus the washer in the chassis Working from the opposite side tighten the nut 3 Remove the support between the swingarm and the saddle post f...

Page 170: ...move the nut 3 Slide off the screw from the opposite side and collect the washer Remove the complete suspension connecting rod assembly unit CONNECTING ROD ASSEMBLY REMOVAL Remove the complete suspension connecting rod assembly unit Unscrew and remove the nut 4 Slide off the screw from the opposite side and collect the washer Remove the single connecting rod Remove the right bushing 5 and the left...

Page 171: ...ecific extractor take out the ball retainer 18 CAUTION WASH ALL THE PARTS WITH CLEAN DETERGENT Checking CAUTION CHECK THAT NO COMPONENT IS NOTICEABLY DISTORTED DAMAGED CRACKED AND OR DENTED REPLACE ALL DAMAGED COMPONENTS BALL RETAINER Turn the ball retainers manually they must rotate smoothly continuously and silently There must be no axial clearance Replace the ball retainers that present these p...

Page 172: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 173: ...arm 2 Chain guard 3 Chain guide slider 4 Slider cap 5 TCB M4 8x13 screw 6 Swing arm pin 7 22x28x16 Roller casing 8 Sealing ring 9 D15x22x1 knurled washer 10 M14x1 5 lower nut 11 Swing arm pin bushing RX SX 125 Chassis CHAS 173 ...

Page 174: ...RONT AND BELTS ATTACHED TO AN OPTIONAL HOIST FROM THE REAR Fasten the belts to the chassis at the engine upper support Lift the hoist arm until the belts are taut Remove the chain Remove the rear wheel Working from the left side unscrew and remove the nut 1 and collect the washer Slide off the screw from the opposite side Remove the connecting rod assembly from the swingarm Undo and remove the int...

Page 175: ...remove the screw and re move the speed sensor Loosen the screw fixing the chassis on the engine 4 to facilitate removing the swingarm Working from the right side fully loos en the ring nut 5 with the specific box spanner Loosen the ring nut set bushing 6 Specific tooling AP8101945 Fork pin ring nut RX SX 125 Chassis CHAS 175 ...

Page 176: ...the swingarm Take out the two O rings 9 Using a buffer of suitable diameter take out the two roller casings 10 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 smoothly continuously and silently There must be no axial clearance Replace the roller casings tha...

Page 177: ...ffer of suitable diameter as semble the two new roller casings 3 centring them axially in their housing Fit the two O rings 2 Fit both needle bearing 4 bushings inside the swingarm Fit the external plastic washers 1 CAUTION DUE TO THE REARCARRIAGE WEIGHT THE FOLLOWING OPERATIONS REQUIRE THE INTER VENTION OF A SECOND OPERATOR Place the swingarm on the chassis Move it into position so that the holes...

Page 178: ...l tool Specific tooling AP8101945 Fork pin ring nut Now adjust the rear swingarm as fol lows Loosen the pin 1 working from the left side Working from the right side fully loosen the ring nut 6 with the specific box spanner Tighten the set bushing 6 to the prescribed tor que Use the specific box spanner to tighten the ring nut 7 Tighten the pin Tighten the chassis fixing screw 8 on the engine Chass...

Page 179: ... 9 Position the brake hoses on the swing arm Fasten the internal brake pipe clamp with the screw 10 Fasten the brake hose guide with the screw 11 Mount the rear wheel Assemble the chain Lower the hoist arm Release the belts from the chassis Install the fuel tank Place the speed sensor Drive chain RX SX 125 Chassis CHAS 179 ...

Page 180: ...ke sure that the chain pinion and crown do not present Damaged rollers Loose pins Dry rusty flattened or jammed chain links Excessive wear Excessively worn or damaged pinion or crown teeth CAUTION IF THE CHAIN ROLLERS ARE DAMAGED AND OR THE PINS ARE LOOSE THE ENTIRE CHAIN UNIT PINION CROWN AND CHAIN SHOULD BE REPLACED LUBRICATE THE CHAIN ON A REGULAR BASIS PARTICULARLY IF YOU DETECT DRY OR RUSTY P...

Page 181: ...ends of the 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 backslash Stop the engine Place the vehicle on its stand Set the gear level to neutral Check that the vertical oscillation between t...

Page 182: ...SERVICE STAND OPT TO ADJUST THE CHAIN If chain tension needs adjusting after the check Place the scooter on its rear service stand OPT Loosen the nut 1 completely WHEEL CENTRING IS CARRIED OUT USING IDENTIFIA BLE FIXED REFERENCES 2 3 IN THE TENSIONER MOUNTS ON THE SWING ARMS BEFORE THE WHEEL PIN Loosen both lock nuts 4 Actuate on the set screws 5 and ad just the chain backlash checking that the re...

Page 183: ... collect the nut 6 Undo and remove the screw 3 and collect the rubber ring 5 Remove the upper chain guide slider 4 Undo and remove the two lower screws 2 Remove the lower chain guide slider 1 Exhaust KEY 1 Muffler RX SX 125 Chassis CHAS 183 ...

Page 184: ...ncer plate 13 M6x12 TE flanged screw 14 6 4X11X0 5 spring washer 15 6 6x18x1 6 washer 16 Insulating washer 17 Central exhaust pipe 18 Silencer gasket 19 Lower self locking nut 20 Pull screw 21 Plate 22 Washer Removing the tail pipe Rotating it on the screw move the fair ing that covers the chassis Undo and remove the front fixing screw of the silencer pipe and collect the washer Chassis RX SX 125 ...

Page 185: ...e off the silencer backwards See also Side body panels Removing the exhaust manifold Undo and remove the screw that fixes the muffler to the chassis and collect the washer Release the two cylinder attachment springs Release the secondary air pipe sealing clamp and slide off the pipe RX SX 125 Chassis CHAS 185 ...

Page 186: ...e electric control unit that receives the engine rotation signal from the primary circuit frequency CAUTION FITTING THE EXHAUST VALVE ON 11 KW HOMOLOGATED VEHICLES RENDERS SUCH CER TIFICATION INVALID IT CAN ONLY BE USED FOR RACING OR ON RACETRACKS AND CIR CUITS NOT OPEN TO THE PUBLIC RAVE operation The exhaust valve opens between 500 and 2500 rpm for the valve stem self cleaning It closes between ...

Page 187: ...el Replace the regulator with another one in proper operating conditions Replace the EFI control unit with an other one in proper operating condi tions CAUTION THE RAVE VALVE CHECKING FUNCTION IS ACTIVATED WHEN THE EFI CONTROL UNIT JUMPER IS CUT OFF SOLENOID Check that the piston moves freely Measure the resistance between the wires with a tester Correct value 2 2 Ohm 10 Start the vehicle go over ...

Page 188: ...xible cable from the cyl inder Turn the stem valve 3 seat by 180 and disconnect the flexible cable 4 If the exhaust valve is blocked at the opening position due to combustion deposits Push the valve stem 3 housing back with a screwdriver CAUTION PAY ATTENTION NOT TO DAMAGE THE SEAL SUR FACE Turn the stem valve 3 seat by 180 and disconnect the flexible cable 4 Remove the stem valve 3 housing and co...

Page 189: ...d remove both screws 8 from the battery housing frame Remove the whole RAVE valve Checking GASKETS Check that the valve gasket 1 and the O ring 2 fitted to the valve seat are not worn or damaged EXHAUST VALVE Clean off any combustion deposits from the exhaust valve 3 and from the valve duct in the cylinder Make sure that the exhaust valve is not worn or damaged RX SX 125 Chassis CHAS 189 ...

Page 190: ...ver version re move the fixed guillotine by undoing the two screws 1 and collect the washers before fitting the RAVE valve TOTAL Insert the exhaust valve unit with the gasket 5 in the cylinder CAUTION REPLACE THE GASKET 5 AT EVERY REFITTING OPER ATION Fit the exhaust valve unit by means of the two screws 1 with the fixed guillotine washers Fit the control unit with the two screws 2 on the battery ...

Page 191: ...e exhaust valve unit with the gasket 5 in the cylinder CAUTION REPLACE THE GASKET 5 AT EVERY REFITTING OPERATION Tighten the two exhaust valve unit screws 1 with their washers CAUTION AFTER FITTING THE EXHAUST VALVE UNIT CHECK With the valve fully open the valve stem end should be at the same level with the exhaust port To do so it is necessary to remove the exhaust flange make sure that the exhau...

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

Page 193: ...r 2 Radiator cap 3 LH Radiator 4 T shaped bushing 5 11 5x23x9 3 rubber cap 6 Clip M6 7 Radiators water pipe 8 Radiator pump pipe 9 D24 24 5x8 6 clic clamp 10 Head radiator pipe 11 d 7x11 fuel pipe RX SX 125 Cooling system COOL SYS 193 ...

Page 194: ...Remove both front side fairings Place a container of suitable capacity underneath the sleeve Release the clamp Slide off the sleeve Empty the liquid into the container Open the radiator cap to facilitate drainage Unscrew and remove the drainage plug 1 indicated by the mark OUT Unscrew and remove the radiator plug to facilitate draining the coolant CAUTION DO NOT DISPOSE OF THE FLUID INTO THE ENVIR...

Page 195: ...ON DO NOT DISPOSE OF THE FLUID INTO THE ENVIRONMENT See also Side body panels Water pump Remove the water pump control gear Undo and remove the M5 fixing screw Slide off the water pump gear RX SX 125 Cooling system COOL SYS 195 ...

Page 196: ...f the water pump control wheel which must be aligned with the reference on the crankcase when refitting Removing the radiator Remove both front side fairings Place a container of suitable capacity underneath the sleeve Release the clamp Slide off the sleeve Empty the liquid into the container Open the radiator cap to facilitate drainage Cooling system RX SX 125 COOL SYS 196 ...

Page 197: ...s between the aluminium tube and the rubber hose in the radiator Remove the right and left delivery pipes Remove the radiator breather pipe Working on both sides undo the two screws and collect the spacer RX SX 125 Cooling system COOL SYS 197 ...

Page 198: ... on both sides of the chassis undo and remove the two screws and collect the washers and remove the ra diator CAUTION THE RADIATORS ARE INTERCONNECTED THROUGH THE LOWER PIPE Cooling system RX SX 125 COOL SYS 198 ...

Page 199: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 200: ...THE GLOVE BOX TOOLKIT COMPARTMENT Fit the saddle making sure to position the corresponding rear hooks correct ly Lower and press the saddle to trip the lock BEFORE RIDING MAKE SURE THAT THE SADDLE IS CORRECTLY LOCKED INTO POSITION Headlight assy Undo and remove both screws on the upper plate Undo and remove the two screws fas tening the mudguard and collect the nuts and washers from the bottom Bod...

Page 201: ...fitting slots on the mudguard Remove the rubber cap and discon nect the instrument panel connector Disconnect the front headlight bulb connectors Taillight assy Remove the tail and the rear side fair ings Disconnect the turn indicators connec tors 1 license plate light 2 rear light 3 Remove the clamp 4 RX SX 125 Bodywork BODYW 201 ...

Page 202: ...ight undo and take out the screw and carefully slide off the light with cables REAR LIGHT If necessary remove the rear light un do and take out both screws and collect the washers Slide off the rear light with cables care fully Side body panels CENTRAL FAIRING The following operations refer to only one fair ing but are valid for both Unscrew and remove the screw and collect the collar Bodywork RX ...

Page 203: ...t the collar Undo and remove the lower screw Remove the central side fairing FRONT FAIRING Remove saddle central fairings and tank cover Undo and remove the right side screw and collect the nut from the left side RX SX 125 Bodywork BODYW 203 ...

Page 204: ...ove the front side fairing CHASSIS COVER They are placed in the central area on both sides of the vehicle For regular operations remove the three clamps and turn the cover according to visibil ity requirements acting on the lower screw slightly loose If necessary remove them from the vehicle Remove the three retaining clamps Bodywork RX SX 125 BODYW 204 ...

Page 205: ...Air box Support the vehicle with a suitable under sump stand Support the scooter rearcarriage with a hoist and suitable belts Remove the saddle Remove both central fairings Remove the six chassis side cover clamps and loosen the lower screws to rotate the cover rightwards Working from the right side undo and remove the screw and collect the collar and the rubber ring RX SX 125 Bodywork BODYW 205 ...

Page 206: ...undo and re move the screw and collect the wash er Remove the clamp and slide off the piping Loosen the clamp and release the sleeve Undo and remove the two screws and move the control unit sideways Bodywork RX SX 125 BODYW 206 ...

Page 207: ...lamp Release the fuses housing from the fil ter casing sliding it upwards Release the relay from the filter casing sliding it rightwards Disconnect the connector Remove the chassis clamp RX SX 125 Bodywork BODYW 207 ...

Page 208: ...THE MOTORCYCLE AND PLACE IT ON THE GROUND LOWERING THE HOIST Slide the filter casing upwards Fuel tank TANK COVER Remove the saddle Undo and remove the two screws Undo and remove the front screw Disconnect the fuel vapour recovery pipe Unscrew and remove the fuel tank cap Remove the fuel tank cover and screw the cap again See also Bodywork RX SX 125 BODYW 208 ...

Page 209: ...emove the two screws pay ing attention to the corresponding col lars and spacers Lift the tank from the side and close the fuel supply valve Disconnect the fuel pump connector Loosen the clamp and detach the pipe See also Side body panels RX SX 125 Bodywork BODYW 209 ...

Page 210: ...nd collect the nuts 1 and washers Unscrew and remove the four screws 2 and collect the washers Slide off the front mudguard forwards paying attention to the front fitting slots Mixture oil tank Remove saddle central right and left fairings and right chassis cover Remove the clamp Bodywork RX SX 125 BODYW 210 ...

Page 211: ...oir in the container REFITTING EACH TIME THE MIX OIL RESERVOIR IS DRAINED REFILL AND BLEED Mount the mix oil reservoir following the same removal procedure but in re verse order Undo and remove the three pump screws on the LHS of the vehicle and remove the cover Remove the bleed screw indicated Pour oil in the reservoir until air bubbles are no longer formed in the pipe RX SX 125 Bodywork BODYW 21...

Page 212: ...first and then the positive red one Remove the battery breather pipe Remove the battery from its housing and put it away on a level surface in a cool and dry place CAUTION ONCE REMOVED THE BATTERY MUST BE PUT AWAY IN A SAFE PLACE OUT OF THE REACH OF CHILDREN Tail guard Remove the saddle and the central side fairings Undo and remove the two screws Undo and remove the two lower screws Bodywork RX SX...

Page 213: ... To detach the rear fairings from the tail section check the fittings alongside the rim from the lower side of the tail Remove fairings and tail RX SX 125 Bodywork BODYW 213 ...

Page 214: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 215: ... 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 Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning...

Page 216: ...E OF CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK MEDICAL ATTENTION IMMEDIATELY IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK MEDICAL ATTENTION IMMEDIATELY BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WO...

Page 217: ...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 pressure check Installation of mirrors and any possible accessories NE...

Page 218: ...82 Clutch 31 101 104 Coolant 194 D Display 137 F Fork 145 146 150 153 158 Fuel 205 208 Fuses 63 G Gearbox oil 26 H Headlight 33 200 Horn 60 I Identification 10 Instrument panel M Maintenance 8 25 R Recommended products 17 S Shock absorber Shock absorbers 166 Spark plug 25 Stand ...

Page 219: ...T Tank 205 208 210 Transmission 12 Tyres 14 W Warning lights ...

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