APRILIA RS4 50 2011 Workshop Manual
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APRILIA RS4 50 2011 Workshop Manual

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MSS RS4 50 MY2011
B043132

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Summary of Contents for APRILIA RS4 50 2011

  • Page 1 MSS RS4 50 MY2011 B043132 RS4 50 MY2011...
  • Page 2 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 required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 This manual provides the main information to carry out regular maintenance operations on your vehicle. This manual is intended to Aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing motorcycles.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    RS4 50 MY2011 Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
  • Page 8 RS4 50 MY2011 Characteristics KEEP OUT OF THE REACH OF CHILDREN DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil CAUTION IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE- HICLE.
  • Page 9 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.

  • Page 10: Vehicle Identification

    RS4 50 MY2011 Characteristics • If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully with a jet of compressed air. • Ensure that the cables are correctly fastened to the internal connector terminals. •...
  • Page 11 RS4 50 MY2011 Characteristics THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISHABLE CRIME. HOWEVER, THE LIMITED WARRANTY FOR NEW VEHICLES WILL BE VOID IF THE VEHICLE IDENTIFICATION NUMBER (VIN) HAS BEEN MODIFIED OR NOT PROMPTLY DETERMINED. Chassis number The chassis number is stamped on the right hand side of the headstock.

  • Page 12: Gear Ratios

    RS4 50 MY2011 Characteristics Engine NGINE Specification Desc./Quantity Type 2-stroke single aluminium cylinder with nickel and silicon car- bide coated bore Cycle two-strokes Total engine capacity 50 cm³ (3.05 cu in) Bore / stroke 39.88 x 40 mm (1.57 x 1.5747 in) Compression ratio 11.5: 1 Electric...

  • Page 13: Electrical System

    RS4 50 MY2011 Characteristics Electrical system LECTRICAL SYSTEM Specification Desc./Quantity Battery 12 V - 4 Ah MF Fuses 7.5 A Alternator 12V - 85W SPARK PLUG Specification Desc./Quantity Standard NGK BR8ES Alternatively CHAMPION RN3C Electrode gap 0.5 mm (0.020 in) BULBS Specification Desc./Quantity...

  • Page 14: Wheels And Tyres

    RS4 50 MY2011 Characteristics Brakes BRAKES Specification Desc./Quantity Front Ø 300 mm (11.81 in) disc brake Rear Ø 218 mm (8.58 in) disc brake Wheels and tyres WHEEL RIMS Specification Desc./Quantity Type made of light alloy Front 2.75 x 17'' Rear 3.50 x 17'' TYRES...
  • Page 15 RS4 50 MY2011 Characteristics Front side RONT LIGHTS pos. Description Type Quantity Torque Notes Headlamp fixing screw M5x14 2.5 Nm (1.84 lbf ft) Self-tapping screw 1.5 Nm (1.11 lbf ft) Turn indicator fixing screw 1.5 Nm (1.11 lbf ft) CHAR - 15...
  • Page 16 RS4 50 MY2011 Characteristics TEERING pos. Description Type Quantity Torque Notes Upper yoke fastening to sleeve 25 Nm (18.43 lbf ft) Steering retainer nut 48 Nm (35.40 lbf ft) RONT USPENSION pos. Description Type Quantity Torque Notes Screws fastening lower yoke to 25 Nm (8.43 lbf ft) sleeve CHAR - 16...
  • Page 17 RS4 50 MY2011 Characteristics RONT HEEL pos. Description Type Quantity Torque Notes Front wheel spindle nut 78 Nm (8.85 lbf ft) Front disc fixing screw M6x20 12 Nm (8.85 lbf ft) RONT UDGUARD pos. Description Type Quantity Torque Notes Lug fixing screw M5x9 3 Nm (2.21 lbf ft) CHAR - 17...
  • Page 18 RS4 50 MY2011 Characteristics pos. Description Type Quantity Torque Notes Side fairing fixing screw M6x12 6 Nm (4.42 lbf ft) Front mudguard fixing screw M6x25 4.4 Nm (3.24 lbf ft) 5 Nm (3.68 lbf ft) Flanged self- locking nut 6 Nm (4.42 lbf ft) Screws fastening lower fairing to cra- M5x12 3 Nm (2.21 lbf ft)
  • Page 19 RS4 50 MY2011 Characteristics ANDLEBAR AND ONTROLS pos. Description Type Quantity Torque Notes Semi-handlebar retainer M8x30 25 Nm (18.44 lbf ft) Loctite 243 Handlebar counterweight retainer M5x50 5 Nm (3.69 lbf ft) Loctite 243 NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Self-tapping screw...
  • Page 20 RS4 50 MY2011 Characteristics RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Front brake pump fixing screw 5 Nm (3.68 lbf ft) Brake pipe clamp fixing screw M5x16 5 Nm (3.68 lbf ft) RONT ALLIPER pos. Description Type Quantity Torque Notes Front calliper fixing screw...
  • Page 21 RS4 50 MY2011 Characteristics LUTCH CONTROL pos. Description Type Quantity Torque Notes Throttle cable ring fixing screw M6x16 6 Nm (4.42 lbf ft) Throttle control fixing screw M6x20 10 Nm (7.37 lbf ft) INDSHIELD pos. Description Type Quantity Torque Notes Rear view mirror fixing screw Self-t.
  • Page 22 RS4 50 MY2011 Characteristics pos. Description Type Quantity Torque Notes Top fairing glass fixing screw 1 Nm (0.73 lbf ft) Central part CHASSIS pos. Description Type Quantity Torque Notes TCEI screw M8x16 15 Nm (11.06 lbf ft) TCEI screw 25 Nm (18.43 lbf ft) TCEI screw M10x45 50 Nm (36.88 lbf ft)
  • Page 23 RS4 50 MY2011 Characteristics ODYWORK pos. Description Type Quantity Torque Notes Side fairing to chassis fixing screw M4x14 Plastic panel fixing screw M5x12 3 Nm (2.21 lbf ft) Side fairing to chassis fixing screw M5x9 3 Nm (2.21 lbf ft) Side fairing to chassis fixing screw M5x9 3 Nm (2.21 lbf ft)
  • Page 24 RS4 50 MY2011 Characteristics pos. Description Type Quantity Torque Notes Rear tank fixing screw M8x40 25 Nm (18.44 lbf ft) Front tank fixing screw M6x35 10 Nm (7.37 lbf ft) Fastener screw M5x9 3 Nm (2.21 lbf ft) Tank cover fixing screw M5x9 3 Nm (2.21 lbf ft) CHAR - 24...
  • Page 25 RS4 50 MY2011 Characteristics IXER pos. Description Type Quantity Torque Notes Mixing tank fixing screw M6x16 4.4 Nm (3.24 lbf ft) Max 5 N (3.68 lbf ft) AIRINGS pos. Description Type Quantity Torque Notes Side fairing fixing screw M5x9 1.7 Nm (1.25 lbf ft) Max 2 Nm (1.47 lbf CHAR - 25...
  • Page 26 RS4 50 MY2011 Characteristics XHAUST pos. Description Type Quantity Torque Notes Drainage retainer M6x20 10 Nm (7.37 lbf ft) Footrest retainer M8x40 25 Nm (18.43 lbf ft) ADIATOR pos. Description Type Quantity Torque Notes Radiator retainer M6x25 10 Nm (7.37 lbf ft) Expansion tank support fixing screw M6x20 3.5-4 Nm (2.58-2.95 lbf...
  • Page 27 RS4 50 MY2011 Characteristics OOTRESTS pos. Description Type Quantity Torque Notes Rider footrest support fixing screw M8x25 25 Nm (18.43 lbf ft) Loctite 243 Footrest protection fixing screw M5x12 5 Nm (3.69 lbf ft) Passenger footrest fixing screw M8x40 20 Nm (14.75 lbf ft) Rider pedal retainer M8x26 25 Nm (18.44 lbf ft)
  • Page 28 RS4 50 MY2011 Characteristics RAKING YSTEM pos. Description Type Quantity Torque Notes Brake lever fixing screw M6x40 12 Nm (8.85 lbf ft) Rear brake pump fixing screw M6x30 10 Nm (7.37 lbf ft) Brake pump joint retainer 10 Nm (7.37 lbf ft) ENTRAL ODYWORK pos.
  • Page 29 RS4 50 MY2011 Characteristics TAND pos. Description Type Quantity Torque Notes Thin nut M10x1.25 10 Nm (7.38 lb ft) TCEI screw M8x30 25 Nm (18.43 lb ft) Loctite 243 TCEI screw M8x45 25 Nm (18.43 lb ft) LOCKS pos. Description Type Quantity Torque...
  • Page 30 RS4 50 MY2011 Characteristics pos. Description Type Quantity Torque Notes Fuel tank cap retainer M5x30 3 Nm (2.21 lb ft) Saddle lock retainer M6x30 6 Nm (4.42 lb ft) Steering lock retainer M8x20 6.5 Nm (4.79 lb ft) Back side EAR SUSPENSION pos.
  • Page 31 RS4 50 MY2011 Characteristics WINGARM pos. Description Type Quantity Torque Notes Swingarm to chassis adjustment nut M25x1.5 15 Nm (11.06 lbf ft) Swingarm pin nut 78 Nm (57.52 lbf ft) Chainguard fixing screw M 4.8x13 1 Nm (0.74 lbf ft) Chainguard fixing screw Self-tap.
  • Page 32 RS4 50 MY2011 Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut 78 Nm (57.53 lbf ft) Rear disc fixing screw M6x20 12 Nm (8.85 lbf ft) Sprocket fixing screw 12 Nm (8.85 lbf ft) Chain tensor fixing screw 12 Nm (8.85 lbf ft) Loctite 243 EAR LIGHTS...
  • Page 33 RS4 50 MY2011 Characteristics EAR MUDGUARD pos. Description Type Quantity Torque Notes Rear mudguard to swingarm fixing Self-tap. 3 Nm (2.21 lbf ft) Max 4.5 Nm (3.31 screw lbf ft) Engine CHAR - 33...
  • Page 34 RS4 50 MY2011 Characteristics EED VALVE pos. Description Type Quantity Torque Note Reed valve retainer M6x110 8-10 Nm (5.90-7.38 lbf Clamp retainer 0.3 - 0.4 Nm (0.22-0.29 lbf ft) Description Type Quantity Torque Note Oil pump cover retainer M5x80 3.5-4.5 Nm (2.58-3.31 lbf Oil pump retainer M5x80 3.5-4.5 Nm (2.58-3.31 lbf...
  • Page 35 RS4 50 MY2011 Characteristics RANSMISSION AND HAFT pos. Description Type Quantity Torque Note Main axle bearing retainer M5x80 3.5-4.5 Nm (2.58-3.31 lbf ft) Pinion retainer M4x10 2-4 Nm (1.47-2.95 lbf ft) Loctite 243 CHAR - 35...
  • Page 36 RS4 50 MY2011 Characteristics ATER PUMP pos. Description Type Quantity Torque Note Water pump shaft retainer 3.5-4.5 Nm (2.58-3.31 lbf ft) Water pump cover retainer M6x100 8-10 Nm (5.90-7.38 lbf LUTCH pos. Description Type Quantity Torque Note Clutch housing retainer 35-45 Nm (28.81-33.19 lbf ft) Clutch spring retainer...
  • Page 37 RS4 50 MY2011 Characteristics LUTCH COVER pos. Description Type Quantity Torque Note Cover retainer M6x110 8-10 Nm (5.90-7.38 lbf CHAR - 37...
  • Page 38 RS4 50 MY2011 Characteristics pos. Description Type Quantity Torque Note Spark plug retainer M14x125 20-30 Nm (14.75-29.50 lbf ft) Head retainer M6x10 8-10 Nm (5.90-7.38 lbf Head nut retainer 19-22 Nm (14.01-16.23 lbf ft) Thermistor retainer 32-38 Nm (23.60-28.03 lbf ft) DEPRESSION CARBURETTOR pos.
  • Page 39 RS4 50 MY2011 Characteristics TARTER OTOR pos. Description Type Quantity Torque Note Starter motor retainer M6x100 8-10 Nm (5.90-7.38 lbf Countershaft retainer 15-18 Nm (11.06-13.27 lbf ft) CHAR - 39...
  • Page 40 RS4 50 MY2011 Characteristics NGINE RANKCASE pos. Description Type Quantity Torque Note Crankcase retainer M26x100 8-10 Nm (5.90-7.38 lbf EVERS pos. Description Type Quantity Torque Note Gearbox lever fixing screws M6x20 10 Nm (7.73 lbf ft) Gearbox lever fixing screws M6x16 10 Nm (7.73 lbf ft) CHAR - 40...
  • Page 41 RS4 50 MY2011 Characteristics ILTER pos. Description Type Quantity Torque Notes Filter box cover fixing screw M5x12 3 Nm (2.21 lbf ft) Class 8.8 Sleeve fixing clamp 0.5 Nm (0.37 lbf ft) Recommended products chart RECOMMENDED PRODUCTS TABLE Product Description Specifications ENI I-RIDE PG 2T Mixer oil...
  • Page 42 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 43 RS4 50 MY2011 Special tools OOLS Stores 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 S-TOOLS - 43...
  • Page 44 RS4 50 MY2011 Special tools Stores code Description 020455Y 10-mm guide for oil seal on 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...
  • Page 45 RS4 50 MY2011 Special tools Stores code Description 020565Y Flywheel lock calliper spanner AP8106698 Crankcase separator AP8501501 Flywheel extractor AP8140266 Dial gauge mounting 020330Y Stroboscopic light for timing checking 020331Y Digital multimeter S-TOOLS - 45...
  • Page 46 RS4 50 MY2011 Special tools Stores code Description 020333Y Single battery charger 020334Y Multiple battery charger 866714 Swingarm adjustment S-TOOLS - 46...
  • Page 47 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 48: Maintenance Chart

    RS4 50 MY2011 Maintenance Maintenance chart OUTINE MAINTENANCE TABLE km(mi)x1000 1 (0.62) 6 (3.72) 12 (7.45) 18 (11.18) 24 (14.91) 30 (18.64) Months Rear shock absorber Reed valve intake Battery electrolyte level Safety fasteners Spark plug DEPRESSION CARBURETTOR Headlight - adjustment Air filter Final drive kit (1) Clutch control lever...
  • Page 49 NOTE TAKE THE VEHICLE TO AN official aprilia Dealer IF RE- QUIRED. Carburettor - Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning.
  • Page 50 RS4 50 MY2011 Maintenance Specific tooling 020330Y Stroboscopic light for timing check- - With the engine at 3000 rpm, check that the ref- erence position (1) on the magneto flywheel is aligned with the notch on the crankcase (2). IGNITION Specification Desc./Quantity Type...

  • Page 51: Gearbox Oil

    RS4 50 MY2011 Maintenance • Engage the spark plug with the due in- clination and screw it right down by hand, then do it up with the wrench at the prescribed torque. • Fit the cap on the spark plug as far as it will go.
  • Page 52 RS4 50 MY2011 Maintenance • If the oil level does not reach the hole, continue adding small quantities of oil and checking the level via the hole (1) until the specified level is reached. • Once the top up procedure is com- plete, fit and tighten the inspection screw (1) and the filler cap (2).

  • Page 53: Air Filter

    RS4 50 MY2011 Maintenance • Drain the oil into the container; allow several minutes for oil to drain out com- pletely. • Check and if necessary, replace the drainage plug (1) sealing washer. • Screw and tighten the drainage plug (1).
  • Page 54 RS4 50 MY2011 Maintenance making it slide upwards and back- wards. • Separate the filtering element (4) on the clean and dry surface of the filter box cover (3). COVER THE HOLE WITH A CLEAN CLOTH SO THAT NO FOREIGN ELEMENTS GET INTO THE INLET DUCTS. AIR FILTER CLEANING DO NOT USE SCREWDRIVERS OR ANY OTHER ELEMENT ON THE FILTER.

  • Page 55: Braking System

    RS4 50 MY2011 Maintenance Checking cables and tubes MIXER TIMING • Remove the oil pump cover. • Adjust mixer working on the corre- sponding adjuster screw. • The correct oil flow rate is obtained by aligning the two references. Braking system Level check Periodically check the brake fluid level via the brake fluid reservoir sight glasses (1 - 2) located...
  • Page 56 RS4 50 MY2011 Maintenance Top-up • The following operations refer to one braking system but they are valid for both braking systems: 1. Front brake fluid reservoir (1); 2. Rear brake fluid reservoir (2). CAUTION RISK OF BRAKE FLUID SPILLS. DO NOT PULL THE BRAKE LEVER WHEN THE COVER FIXING SCREWS ARE LOOSE OR, MAINLY, WHEN THE BRAKE FLUID RESER- VOIR COVER HAS BEEN REMOVED.

  • Page 57: Clutch System

    RS4 50 MY2011 Maintenance • In case of excessive travel 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-...
  • Page 58 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 59 RS4 50 MY2011 Electrical system Electrical system installation Scope and applicability The purpose of this document is to define the position of the vehicle cable harness, its routing and how it is fixed on the chassis, tool kit compartment support and the saddle mounting, any potential problems and particular checks to be carried out on the connections and routings in order to reach the objectives of vehicle reliability.
  • Page 60 RS4 50 MY2011 Electrical system • MIX oil reserve sensor connector (check if connected and if there are pins slide off) - CEN- TRAL SECTION, TABLE C. • Check proper connection of transducer cables (CDI) - CENTRAL SECTION, TABLE D. •...
  • Page 61 RS4 50 MY2011 Electrical system TABLE B 9. Clutch odometer 10. Clamps 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.
  • Page 62 RS4 50 MY2011 Electrical system TABLE D - Special 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.
  • Page 63 RS4 50 MY2011 Electrical system TABLE E - Special tool kit compartment sup- port 14. Front headlamp cable harness connector 15. Clamp The clamp must take all the cables inside the tool kit compartment support, especially the main cable harness must be provided with the clamp on the grey sheathing.
  • Page 64 RS4 50 MY2011 Electrical system 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 ELE SYS - 64...
  • Page 65 RS4 50 MY2011 Electrical system TABLE I - Special cable ELE SYS - 65...
  • Page 66 RS4 50 MY2011 Electrical system Central part TABLE A - Pre-fitting chassis 1. Cable retaining clip 2. Cable guide 3. Cable guide ELE SYS - 66...
  • Page 67 RS4 50 MY2011 Electrical system ELE SYS - 67...
  • Page 68 RS4 50 MY2011 Electrical system TABLE B • Fuel reserve sensor TABLE C - Pre-fitting mix oil probe 5. Mix oil sensor 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.
  • Page 69 RS4 50 MY2011 Electrical system TABLE D - Wire connection on transducer (CDI) 8. Transducer (CDI) 9. The yellow cable that stays free on the flywheel cable harness, is connected to the Yellow Red ca- ble that is provided by the Main Cable harness. (see CENTRAL SECTION, TABLE E5, SPECIAL 10.
  • Page 70 RS4 50 MY2011 Electrical system ELE SYS - 70...
  • Page 71 RS4 50 MY2011 Electrical system TABLE E4 If by mistake the resistance (899436) is not well inserted or does not start correctly, the instrument panel will not signal the end of the Mix oil and could cause the engine failure. 17.
  • Page 72 RS4 50 MY2011 Electrical system TABLE G 27. Start-up relay 28. Acid battery exhaust: DO NOT COVER 29. Side stand connection 30. Relay 31. Relay TABLE H 32. The horn cable is put on the 3 indicated clamps. 33. Horn cable 34.
  • Page 73 RS4 50 MY2011 Electrical system TABLE I 34. Neutral cable TABLE J - Special connection low fuel tank sensor 37. Main cable harness 38. Fuel reserve sensor TABLE K - Proper battery positioning Place the battery cables as indicated, to facilitate the test.
  • Page 74 RS4 50 MY2011 Electrical system 3. Faston of 2.8 mm (0.11 in); cable colour: red and blue TABLE B 1. Rear left turn indicator 2. Faston of 2.8 mm (0.11 in); • 2a. Light blue • 2b. Blue 3. Rear right turn indicator •...
  • Page 75 RS4 50 MY2011 Electrical system TABLE C • Breather pipe TABLE D - Tail 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.
  • Page 76 RS4 50 MY2011 Electrical system ELE SYS - 76...
  • Page 77 RS4 50 MY2011 Electrical system General wiring diagram KEY: 1. MULTIPLE CONNECTORS 2. COMPLETE HEADLAMP 3. HIGH-BEAM BULB 4. LOW_BEAM BULB ELE SYS - 77...
  • Page 78 RS4 50 MY2011 Electrical system 5. FRONT POSITION 6. FRONT RIGHT TURN INDICATOR 7. STAND SWITCH 8. INSTRUMENT PANEL (pico) 9. CLUTCH SWITCH LAYOUT 10.- 11.LEFT LIGHT SWITCH 12.HORN 13.Right light switch 14.KEY 15.FRONT STOP SWITCH 16.REAR STOP SWITCH 17.Rear right turn indicator 18.REAR LIGHT 19.LICENSE PLATE LIGHT (only for Switzerland) 20.REAR LEFT TURN INDICATOR...
  • Page 79 RS4 50 MY2011 Electrical system 43.- 44.- 45.- Colour key: Ar Orange Az Sky blue B Blue Bi White G Yellow Gr Grey M Brown N Black R Red Ro Pink V Green Vi Purple Checks and inspections In case the cause of ignition failure or malfunction cannot be easily identified at sight, first of all re- place the control unit by another one in operating conditions.
  • Page 80 RS4 50 MY2011 Electrical system Disconnect the connector on the flywheel cover and measure the resistance between either con- tact and the earth. Specific tooling 020331Y Digital multimeter Ignition circuit • Lift the tank and support it with the ap- propriate supplied supporting stick.
  • Page 81 RS4 50 MY2011 Electrical system - Check the resistance value in the hole Electric characteristic Resistance 4 - 6 kOhm Lights list BULBS Specification Desc./Quantity Low beam light - 12 V - 35 W H4 High beam light - 12 V - 35 W H4 2 daylight running lights 12V - 5W Turn indicator light...
  • Page 82 RS4 50 MY2011 Electrical system • headlamps: it is not ensured that the light intensity is the same as having a normal compo- nent function; • instrument panel: malfunctions can be checked in the screen page of the display and in the instrument panel functions;...
  • Page 83 RS4 50 MY2011 Electrical system NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE. CAUTION ORDINARY DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL TO THE BAT- TERY.
  • Page 84 RS4 50 MY2011 Electrical system 3) Procedure for filling the battery with acid. Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes. Push the container down with enough force to break the seals. The electrolyte should start to flow inside the battery.
  • Page 85 RS4 50 MY2011 Electrical system 12.8 - 13.15 V Bring the battery to full charge, us- ing the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer c - connect the clamps of the battery charger to the battery poles (black clamp to negative pole (-) and...
  • Page 86 RS4 50 MY2011 Electrical system g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge pro- cedure of the new battery, otherwise go to point i...
  • Page 87 RS4 50 MY2011 Electrical system 5. Right turn indicator warning light 6. - 7. High beam warning light 8. Left turn indicator 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.-...
  • Page 88 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 89 RS4 50 MY2011 Engine from vehicle CHASSIS pos. Description Type Quantity Torque Notes TCEI screw M8x16 15 Nm (11.06 lbf ft) TCEI screw 25 Nm (18.43 lbf ft) TCEI screw M10x45 50 Nm (36.88 lbf ft) TE screw M8x40 25 Nm (18.43 lbf ft) TE screw M6x16 12 Nm (8.85 lbf ft)
  • Page 90 RS4 50 MY2011 Engine from vehicle Removing Removing the engine from the vehicle • Remove the necessary components to work freely on the engine, as described in the chapter "Vehicle preparation". • Release the clutch cable and release it from the clamps and from the cable grommet.
  • Page 91 RS4 50 MY2011 Engine from vehicle • Disconnect the coil connector. • Disconnect the horn connector. • Disconnect the temperature sensor. • Disconnect the electrical system con- nector - engine. • Disconnect the coil cable connector - engine. ENG VE - 91...
  • Page 92 RS4 50 MY2011 Engine from vehicle • Unscrew and remove the screw. • Slide off the gearbox lever. • Unscrew and remove the three screws. • Remove the clutch cover. • Unscrew 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.
  • Page 93 RS4 50 MY2011 Engine from vehicle • Operating from both sides, Unscrew and remove the cradle upper fixing screw to the chassis. • Check the proper position of the under- sump stand. • After loosen the ring with the suitable special key, unscrew the swingarm pin by operating both from the left side and from the right one:...
  • Page 94 RS4 50 MY2011 Engine from vehicle Installing the engine to the vehicle • When before removed from the cradle, fasten the engine to it, on the three in- dicated points. ENG VE - 94...
  • Page 95 RS4 50 MY2011 Engine from vehicle • Place the engine on the vehicle, by us- ing the under-sump stand. • Insert the swingarm pin and the corre- sponding washer, from the right side of the vehicle, with a rubber hammer. •...
  • Page 96 RS4 50 MY2011 Engine from vehicle • Operating on both sides of the vehicle position the washers and tighten the screw and the nut. • Fasten the neutral sensor with the screw. • Fitting the clutch cover with the three screws.
  • Page 97 RS4 50 MY2011 Engine from vehicle • Connect 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. ENG VE - 97...
  • Page 98 RS4 50 MY2011 Engine from vehicle • Position the three relays in the seat of the battery support • Tighten 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.
  • Page 99 INDEX OF TOPICS NGINE...
  • Page 100 RS4 50 MY2011 Engine Gearbox RANSMISSION AND HAFT pos. Description Type Quantity Torque Note Main axle bearing retainer M5x80 3.5-4.5 Nm (2.58-3.31 lbf ft) Pinion retainer M4x10 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 ENG - 100...
  • Page 101 RS4 50 MY2011 Engine - Remove the selector See also Splitting the crankcase halves - Take out the two gear shafts simultaneously 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-...
  • Page 102 RS4 50 MY2011 Engine Checking the secondary shaft - Take out the gears and the shim washers of the secondary shaft once the locks 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-...
  • Page 103 RS4 50 MY2011 Engine - Clean and lubricate the main bearings - Replace them if there are signs of abnormal wear, deformations or jams. - Thoroughly clean and degrease all the compo- nents of the gear housing, the selector and the shaft - Reassemble the secondary shaft making sure all components are fitted correctly...
  • Page 104 RS4 50 MY2011 Engine - Remove the gear 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 ENG - 104...

  • Page 105: Starter Motor

    RS4 50 MY2011 Engine Checking the gear selector - Check that the selector shaft is not worn or dam- aged - Mount the components following the removal procedure but in reverse order - Apply one drop of Loctite 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-...
  • Page 106 RS4 50 MY2011 Engine Removing the starter motor - Remove the flywheel cover. - Unscrew the two screws to remove the bendix supporting plate - Slide the bendix form its seat and take the shim washers - Remove the electrical connections to the starter motor - Unscrew the two screws to remove the starter motor...
  • Page 107 RS4 50 MY2011 Engine Generator side Magneto flywheel removal - Remove the gear pedal - Unscrew the three fixings screws and remove the left crankcase cover - Lock the magneto flywheel with the aid of a spe- cific calliper spanner. Unscrew the flywheel fixing screw and collect the spacer Specific tooling 020565Y Flywheel lock calliper spanner...
  • Page 108 RS4 50 MY2011 Engine - Unscrew the three fixings screws and remove the stator from stator plate - Unscrew the three fixing screws of the plate in order to detach the stator electrical 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...
  • Page 109 RS4 50 MY2011 Engine - Connect the stator connector and fix the wire to the chassis by means of the clamps - Make sure the cable support inside the crankcase is correctly positioned so that the cables do not get into contact with the flywheel rotor - Mount the flywheel checking the proper insertion of the key in the slot on the crankshaft...
  • Page 110 RS4 50 MY2011 Engine LUTCH COVER pos. Description Type Quantity Torque Note Cover retainer M6x110 8-10 Nm (5.90-7.38 lbf LUTCH pos. Description Type Quantity Torque Note Clutch housing retainer 35-45 Nm (28.81-33.19 lbf ft) Clutch spring retainer M5x80 3.5-4.5 Nm (2.58-3.31 lbf ft) Removing the clutch cover - Remove the oil pump...
  • Page 111 RS4 50 MY2011 Engine Disassembling the clutch - Remove the crankcase right cover - Undo the 5 screws fixing the clutch spring and lift the internal clutch cover - Remove the 4 clutch plates and the three steel discs - Straighten the bevelled washer See also Removing the clutch cover...

  • Page 112: Checking The Clutch Plates

    RS4 50 MY2011 Engine Checking the clutch plates - Check the clutch plate - 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:...
  • Page 113 RS4 50 MY2011 Engine Checking the clutch housing Carry out a visual inspection of the clutch jaws. Replace the component if there are signs of ther- mal fatigue, reduced surface hardness or irregular jaw wear. Check the components of the clutch bell are in good conditions: - Clutch plate seats - Rivets and connecting plugs to crown gears...
  • Page 114 RS4 50 MY2011 Engine Checking the springs - Check the clutch spring - Measure the length of each spring when exten- Characteristic Spring serviceability limit: 31 mm (1.2205 in) Assembling the clutch - Fit the shim washer and the clutch bushing - Fit the clutch housing.
  • Page 115 RS4 50 MY2011 Engine - Fit the star washer - Fit the disc thrust plate, the bevelled washer and the fixing nut - Lock the plate with the specific tool and tighten the fixing nut - Fold the locking washer to secure the nut Specific tooling 00H0530004.1 Clutch locking tool - Lubricate the clutch plates with new oil...

  • Page 116: Installing The Clutch Cover

    RS4 50 MY2011 Engine Installing the clutch cover - Insert the bolts on the clutch cover - Fit a new gasket on the crankcase right cover - Make sure the faying surfaces of the crankcase and cover are clean and not damaged - Align the tappet (1) with the clutch lever on the cover - Place the clutch cover, turn the clutch control until it coincides with the tappet...

  • Page 117: Removing The Cylinder Head

    RS4 50 MY2011 Engine pos. Description Type Quantity Torque Note Spark plug retainer M14x125 20-30 Nm (14.75-29.50 lbf ft) Head retainer M6x10 8-10 Nm (5.90-7.38 lbf Head nut retainer 19-22 Nm (14.01-16.23 lbf ft) Thermistor retainer 32-38 Nm (23.60-28.03 lbf ft) Removing the cylinder head - Remove the coolant rubber pipes connecting the pump and the radiator and collect the coolant...
  • Page 118 RS4 50 MY2011 Engine Removing the cylinder - Empty the coolant out the system - Remove the cylinder head - Remove the cylinder by slowly sliding it upwards - Remove the base gasket - Put a piece of old cloth in the cylinder housing hole on the crankcase so that no object can fall in See also Removing the...
  • Page 119 RS4 50 MY2011 Engine Checking the cylinder - Measure the openings of the piston elastic seal- ing rings by placing a feeler gauge in the cylinder Characteristic Maximum allowable piston ring opening: 0.35 mm (0.0138 in) - Check cylinder for wear with a bore meter. - Carry out measurements following the perpen- dicular axis and at three different heights of the cylinder.
  • Page 120 RS4 50 MY2011 Engine CLASS D Specification Desc./Quantity Nominal cylinder diameter (D) 39.905 mm (1.57106 in) Piston diameter (D) 39.8525 - 39.8575 mm (1.568991 - 1.569188 in) Piston nominal diameter (D) 39.855 mm (1.56909 in) Cylinder diameter (D) 39.9025 - 39.9075 (1.57096 - 1.571157 in) CAUTION COUPLING CLEARANCE IN THE FITTING: 0.045 - 0.055 mm (0.0017716 - 0.0021653 in)
  • Page 121 RS4 50 MY2011 Engine Installing the cylinder - Lubricate both the cylinder and the piston faying surfaces and the sealing circlips - Carefully fit the cylinder in the piston being careful to press the sealing circlips in their positions - Fit a new head gasket and refit the cylinder head - Mount the head cover - Fit a new spark plug - Connect again the temperature sensor connec-...

  • Page 122: Installing The Cylinder Head

    RS4 50 MY2011 Engine BASE GASKET Measure top dead center (mm)(in) Gasket thickness (mm) (in) 2.15 + 2.35 (0.08464 +0.09252) 0.70 +/- 0.04 (0.02756 +/- 0.0015748) 1.75 + 1.95 (0.06889 + 0.07677) 0.30 +/- 0.04 (0.01181 +/- 0.0015748) 1.95 + 2.15 (0.07677 + 0.08464) 0.50 +/- 0.04 (0.01968 +/- 0.0015748) Installing the cylinder head To refit, carry out the removal operations but in reverse order:...
  • Page 123 RS4 50 MY2011 Engine NGINE RANKCASE pos. Description Type Quantity Torque Note Crankcase retainer M26x100 8-10 Nm (5.90-7.38 lbf Splitting the crankcase halves MAIN TRANSMISSION GEAR 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...
  • Page 124 RS4 50 MY2011 Engine • Remove the gear with the shim. See also Magneto flywheel removal - Dismount the primary drive gear with the specific tool Specific tooling 0.0H.056.0.032.1 Primary drive pinion extractor CRANKCASE OPENING - Remove the engine from the chassis. - Remove the thermodynamic unit (cylinder, head and piston).
  • Page 125 RS4 50 MY2011 Engine - Warm up at about 60°C (140°F) the seats of the crankshaft, main shaft, secondary shaft on the left hand side - Separate the two crankcase halves with the spe- cific tool CAUTION NEVER USE A LEVER OR A SCREWDRIVER TO SEPA- RATE THE CRANKCASE HALVES.
  • Page 126 RS4 50 MY2011 Engine Inspecting the crankshaft components - Thoroughly clean and degrease the crankshaft and then check it - Use a feeler gauge to check the clearance be- tween the big end and the half shaft Characteristic Serviceability limit: 0.8 mm (0.0315 in) - Use a dial gauge to check the clearance between the connecting rod and the crankpin on X and Y...
  • Page 127 RS4 50 MY2011 Engine - Refit the crankcase by warming up the shaft seats at about 60°C (140°F) - Tighten the screws to the prescribed torque - Make sure the crankshaft and the gear work free- ly after having refitting the crankcase Recommended products ENI I-RIDE PG 2T Mixer oil As an alternative for recommended oils, use top...

  • Page 128: Oil Pump

    RS4 50 MY2011 Engine • Lock the magneto flywheel with the aid of a specific tool and tighten the fixing nut of the gear to the specified torque Specific tooling 020565Y Flywheel lock calliper spanner Lubrication Oil pump Description Type Quantity Torque Note...
  • Page 129 RS4 50 MY2011 Engine Removing - Remove the start-up pedal - Remove the rear brake pedal - Detach the sleeve connecting the radiator to the hydraulic pump 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...
  • Page 130 RS4 50 MY2011 Engine Inspection - Remove the pump - Make sure that the pump drive rotates freely - Check the sealing rings are in good conditions. Replace them if they are damaged or deformed - The oil pump is an essential safety element for proper engine operation.
  • Page 131 RS4 50 MY2011 Engine Installing - Mount the oil pump shaft following the same pro- cedure as for removal but in reverse order - It is crucial to check that the shim washers are correctly mounted - Mount the transmission and the driving gear - Fit a new oil seal in the clutch lever seat on the cover - Fit the clutch lever...
  • Page 132 RS4 50 MY2011 Engine - Fit the clutch wire, the clamp and the lever - Turn the clutch control clockwise with a screw- driver and then fit the clutch lever and its screws - 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...
  • Page 133 INDEX OF TOPICS P SUPP OWER SUPPLY...
  • Page 134 RS4 50 MY2011 Power supply EED VALVE pos. Description Type Quantity Torque Note Reed valve retainer M6x110 8-10 Nm (5.90-7.38 lbf Clamp retainer 0.3 - 0.4 Nm (0.22-0.29 lbf ft) P SUPP - 134...
  • Page 135 RS4 50 MY2011 Power supply DEPRESSION CARBURETTOR pos. Description Type Quantity Torque Note Carburettor chamber retainer 1 Nm (0.73 lbf ft) Starter cover retainer 1 Nm (0.73 lbf ft) Precautions WARNING IF THE MOTORCYCLE IS NOT USED FOR OVER 1 MONTH, DRAIN ALL THE FUEL IN THE CAR- BURETTOR CHAMBER.
  • Page 136 RS4 50 MY2011 Power supply - Remove the carburettor from the engine - Remove the reed 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 P SUPP - 136...
  • Page 137 RS4 50 MY2011 Power supply - Mount the valve following the removal procedure but in reverse order, make sure the plate limiting the reed valve opening has been 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.
  • Page 138 RS4 50 MY2011 Power supply - Compress the throttle valve return spring - Remove the safety cap of the throttle valve and remove the throttle control cable from the throttle - Remove the fixing plate of the starter control by undoing the screws indicated in the photograph - Remove the starter control - Remove the air flow set screw as indicated in the...
  • Page 139 RS4 50 MY2011 Power supply CARBURETTOR FITTING - Clean thoroughly all the carburettor components 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 P SUPP - 139...
  • Page 140 RS4 50 MY2011 Power supply - Use scales to check the float weight. Weight: 3.5 g (0.123 oz). - Replace the float if higher weight values are found - Check that the tapered pin is in good 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...
  • Page 141 RS4 50 MY2011 Power supply - Check that the stop is correctly positioned on the tapered pin notch - The stop must be on the third notch from the top - Move up the stop to obtain a leaner mixture - Move it down to obtain a richer mixture Thus, carburetion can adapt to different climatic condi- tions...

  • Page 142: Adjusting The Idle Speed

    RS4 50 MY2011 Power supply - If the throttle valve is replaced, fit another with the standard settings indicated on the top surface as shown in the photograph - Re-assemble the whole carburettor - Refit the carburettor to the engine, connect the fuel pipes again, the mixer oil intake pipes and the vacuum pipe for the fuel cock control Adjusting the idle speed...
  • Page 143 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 144 RS4 50 MY2011 Suspensions EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper retainer 58 Nm (42.78 lbf ft) Lower retainer 58 Nm (42.78 lbf ft) Loctite 243 EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut 78 Nm (57.53 lbf ft) Rear disc fixing screw M6x20...
  • Page 145 RS4 50 MY2011 Suspensions pos. Description Type Quantity Torque Notes Sprocket fixing screw 12 Nm (8.85 lbf ft) Chain tensor fixing screw 12 Nm (8.85 lbf ft) Loctite 243 TEERING pos. Description Type Quantity Torque Notes Upper yoke fastening to sleeve 25 Nm (18.43 lbf ft) Steering retainer nut 48 Nm (35.40 lbf ft)

  • Page 146: Removing The Front Wheel

    RS4 50 MY2011 Suspensions RONT USPENSION pos. Description Type Quantity Torque Notes Screws fastening lower yoke to 25 Nm (8.43 lbf ft) sleeve RONT HEEL pos. Description Type Quantity Torque Notes Front wheel spindle nut 78 Nm (8.85 lbf ft) Front disc fixing screw M6x20 12 Nm (8.85 lbf ft)
  • Page 147 RS4 50 MY2011 Suspensions • Unscrew and remove the wheel axle fixing nut and collect the washer. • Loosen the lock screw of the calliper mounting bracket. • Extracting the wheel, slide off the pin from the right side of the vehicle, pay- ing attention to the speed sensor collar.
  • Page 148 RS4 50 MY2011 Suspensions Wheel axle bending limit (1): 0.2 mm TYRES • Check the tyres for wear; If they are damaged, replace them. WHEEL RIMS • Check the wheel deformation. • If there are bends or damages, replace • Check the wheel deformation limits.

  • Page 149: Installing The Front Wheel

    RS4 50 MY2011 Suspensions • Check the spacer. • Replace together with the retaining ring if there are scorings or signs of de- terioration. Installing the front wheel • Follow the steps described in the front wheel removal in reverse, be very careful when po- sitioning the components and the corresponding tightening torque.
  • Page 150 RS4 50 MY2011 Suspensions The following operations only refer to one fork, but they apply to both. • Support the vehicle at the front, by fas- tening a suitable belt to the handlebar and a crane. • Position a support under-sump stand and the rear stand.
  • Page 151 RS4 50 MY2011 Suspensions • Fit the fork in the vice using the special Teflon grips. • 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.
  • Page 152 RS4 50 MY2011 Suspensions • Remove the stem from the vice and drain off the oil inside it into the collec- tion container. • Reposition the stem in the vice using the specific Teflon shoes. • Remove the dust gaiter, taking care for the surface of the stem and the integrity of the dust gaiter.
  • Page 153 RS4 50 MY2011 Suspensions • Undo and remove the piston retaining screw on the foot of the fork • Remove the complete piston MINGXING FORK CAUTION THE FOLLOWING PROCEDURES ARE FOR A SINGLE WHEEL CARRIER STANCHION/SLEEVE ASSEMBLY, BUT ARE APPLICABLE TO BOTH. •...
  • Page 154 RS4 50 MY2011 Suspensions • Remove the internal piston and, lower- ing the lock washer, remove 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.
  • Page 155 RS4 50 MY2011 Suspensions • Reposition the stem in the vice using the specific Teflon shoes. • Remove the dust gaiter, taking care for the surface of the stem and the integrity of the dust gaiter. • Remove the retainer ring. •...
  • Page 156 RS4 50 MY2011 Suspensions • If over the value, replace the stem. Bending limit: 0.2 mm CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BE- CAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS. • Replace the following components with new ones: - sealing ring;...
  • Page 157 RS4 50 MY2011 Suspensions • Check that there are no damages and/ or cracks; otherwise, replace it. • Check that the sliding bushings (1) for good conditions. • If there are signs of excessive wear or damage, replace the affected compo- nent.
  • Page 158 RS4 50 MY2011 Suspensions • Insert the oil seal in the sleeve • After inserting the dust gaiter in the stem as well as the retainer ring, insert the stem itself in the sleeve • Position the retainer and push the dust gaiter into its seat •...
  • Page 159 RS4 50 MY2011 Suspensions • Screw the cap on the piston and tighten • Screw the cap on the sleeve MINGXING FORK CAUTION THE FOLLOWING PROCEDURES ARE FOR A SINGLE WHEEL CARRIER STANCHION/SLEEVE ASSEMBLY, BUT ARE APPLICABLE TO BOTH. • Insert the oil seal in the sleeve •...
  • Page 160 RS4 50 MY2011 Suspensions • Position the retainer and push the dust gaiter into its seat • Insert the retainer ring • Position the two half cylinders and lock them in place with the retainer ring • Position the fork vertically in a vice •...

  • Page 161: Installing The Fork Legs

    RS4 50 MY2011 Suspensions • Screw the cap on the sleeve Installing the fork legs The following operations are described for the Paioli fork, but are identical for the operation with the fork model Mingxing, except where specified. • Insert the sleeve together with the wheel holder stem on the lower and upper plates.
  • Page 162 RS4 50 MY2011 Suspensions • Tighten the screws that lock the lower plate to the holding pipes to the pre- scribed torque. • Tighten completely the screws that lock the upper plate to the holding pipes to the prescribed torque. •...

  • Page 163: Removing The Rear Wheel

    RS4 50 MY2011 Suspensions • Tighten the two screws on the front headlamp clamp. • Fasten the brake piping to the left sheath. • Slide off the wheel axle. • Mount the front wheel. • Fit the front brake calliper and tighten the two fixing screws. See also Removing the front wheel...
  • Page 164 RS4 50 MY2011 Suspensions BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS, ALLOW THE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE. CAUTION UPON REMOVING, PAY ATTENTION NOT TO DAMAGE THE BRAKE HOSES, DISCS AND PADS. CAUTION TO REMOVE THE REAR WHEEL, GET THE APPROPRIATE REAR SERVICE STAND (OPTIONAL).

  • Page 165: Checking The Rear Wheel

    RS4 50 MY2011 Suspensions • Slide the rear wheel completely off and check the mechanical components. Checking the rear wheel CAUTION CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ES- PECIALLY THOSE LISTED AS FOLLOWS. BEARINGS, GASKETS, WHEEL PIN, RIM. FLEXIBLE COUPLING Check that the anti-vibration buffer is not damaged and/or excessively worn.

  • Page 166: Installing The Rear Wheel

    RS4 50 MY2011 Suspensions Installing the rear wheel • Follow the removal steps but in reverse order, be careful to adequately position the spacers on the left side as indicated in the figure. • Tighten the nuts to the prescribed tor- que.
  • Page 167 INDEX OF TOPICS CHAS HASSIS...
  • Page 168 RS4 50 MY2011 Chassis WINGARM pos. Description Type Quantity Torque Notes Swingarm to chassis adjustment nut M25x1.5 15 Nm (11.06 lbf ft) Swingarm pin nut 78 Nm (57.52 lbf ft) Chainguard fixing screw M 4.8x13 1 Nm (0.74 lbf ft) Chainguard fixing screw Self-tap.
  • Page 169 RS4 50 MY2011 Chassis XHAUST pos. Description Type Quantity Torque Notes Drainage retainer M6x20 10 Nm (7.37 lbf ft) Footrest retainer M8x40 25 Nm (18.43 lbf ft) TAND pos. Description Type Quantity Torque Notes Thin nut M10x1.25 10 Nm (7.38 lb ft) TCEI screw M8x30 25 Nm (18.43 lb ft)

  • Page 170: Drive Chain

    RS4 50 MY2011 Chassis • Operating on both sides, loosen the swingarm pin tightening nut. • Working on the left side, unscrew and remove the nut and collect the washer. See also Removal Removing the rear wheel Removing • Working from the right side of the ve- hicle, unscrew and remove the nut and retrieve the washer.
  • Page 171 RS4 50 MY2011 Chassis CAUTION REPLACE THE ENTIRE UNIT IF THE CHAIN IS PARTICU- LARLY WORN. See also Adjusting inspection Also check the following parts and make sure that the chain, pinion and crown do not present: - Damaged rollers. - Loose pins.
  • Page 172 RS4 50 MY2011 Chassis Adjusting To check clearance: • Shut off the engine. • Rest the vehicle on its stand. • Engage neutral gear. • Check vertical oscillation, midway be- tween pinion and sprocket, in the lower chain length. • If the chain clearance is less than 18 mm (0.71 in) or exceeds 22 mm (0.87 in), adjust the chain.

  • Page 173: Side Stand

    RS4 50 MY2011 Chassis CAUTION GET A SPECIFIC REAR SERVICE STAND (OPT) TO AD- JUST THE CHAIN. Stand Side stand • Rest the vehicle on the optional rear stand. Stand rod removal • With closed stand, release the spring • Unscrew and remove the nut (2).
  • Page 174 RS4 50 MY2011 Chassis • If necessary, unscrew and remove the three screws and remove the rear cov- Removing the manifold - tail pipe • Remove the fairing and the lug. • Unscrew and remove the stay-bolts and collect the nut. •...
  • Page 175 RS4 50 MY2011 Chassis • Extracting the exhaust, unscrew both front fixing screws at the head. • Slide off the complete exhaust. • If necessary, remove the muffler and the cover. • If necessary, unscrew and remove the three screws and remove the central exhaust cover.
  • Page 176 RS4 50 MY2011 Chassis • Unscrew and remove the front nut, re- trieve the screw. • Remove the exhaust manifold. See also Removing the tail pipe CHAS - 176...
  • Page 177 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 178 RS4 50 MY2011 Braking system RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Front brake pump fixing screw 5 Nm (3.68 lbf ft) Brake pipe clamp fixing screw M5x16 5 Nm (3.68 lbf ft) RONT ALLIPER pos. Description Type Quantity Torque Notes...
  • Page 179 RS4 50 MY2011 Braking system RAKING YSTEM pos. Description Type Quantity Torque Notes Brake lever fixing screw M6x40 12 Nm (8.85 lbf ft) Rear brake pump fixing screw M6x30 10 Nm (7.37 lbf ft) Brake pump joint retainer 10 Nm (7.37 lbf ft) Rear brake calliper CAUTION THE MOTORCYCLE MAY BE FITTED WITH AN A.J.P.
  • Page 180 RS4 50 MY2011 Braking system Removal • Release the chain. • Loosen the wheel axle, acting on the nut, from the right side of the vehicle and on the pin, from the left side. • Move the rear wheel. • Move the rear brake calliper plate until the end and slide it one off.
  • Page 181 RS4 50 MY2011 Braking system Installing • Place the complete calliper on the spe- cific lodging on the swingarm. • Connect the drive chain after position- ing the wheel and insert the retaining • Insert the washer, the nut and fix the pin at the prescribed torque •...
  • Page 182 RS4 50 MY2011 Braking system • Unscrew and remove both calliper fixing screws (2). • Slide off the front brake calliper. See also Bleeding the braking system Rear brake disc Removal • Remove the wheel. • Unscrew and remove the six disc fixing screws. •...
  • Page 183 RS4 50 MY2011 Braking system • Check the decentralisation with a mi- crometer by placing it on the disc (A) and turning the wheel. • If the decentralisation exceeds the serviceability limit, replace the disc. Decentralisation of the disc: 0.2 mm Front brake disc Removal •...

  • Page 184: Front Brake Pads

    RS4 50 MY2011 Braking system • Check the decentralisation with a mi- crometer by placing it on the disc (A) and turning the wheel. • If the decentralisation exceeds the serviceability limit, replace the disc. Decentralisation of the disc: 0.2 mm Front brake pads Removal A.J.P.
  • Page 185 RS4 50 MY2011 Braking system • On the front brake 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. •...

  • Page 186: Rear Brake Pads

    RS4 50 MY2011 Braking system • 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 CALLIPER IT MAY BE NECESSARY TO CARRY OUT THE CORRESPONDING BLEEDING.
  • Page 187 RS4 50 MY2011 Braking system Bleeding the braking system NOTE IF AIR CONTINUES TO COME OUT DURING THE BLEED OPERATION EXAMINE ALL THE FIT- TINGS: IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS.
  • Page 188 RS4 50 MY2011 Braking system OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a container to collect the fluid.

  • Page 189: Changing The Brake Fluid

    RS4 50 MY2011 Braking system • Insert the transparent plastic pipe in the rear brake calliper bleed valve and insert the other end of this pipe into a container to collect the fluid. • Remove the rear brake fluid reservoir cap. •...
  • Page 190 RS4 50 MY2011 Braking system IF THE BRAKE LEVER STARTS WITHOUT THE CALLIPER IT MAY BE NECESSARY TO CARRY OUT THE CORRE- SPONDING BLEEDING. Front brake pump • Unscrew and remove the screw and, by disconnecting the hoses, collect the brake oil in the tank, in an adequate container.
  • Page 191 RS4 50 MY2011 Braking system Rimozione • Unscrew the screw, disconnect the pipe, collect the break fluid in an ade- quate container. • Unscrew and remove the two screws and collect the corresponding nuts. • Unscrew and remove the nut, retriev- ing the nut.
  • Page 192 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 193 RS4 50 MY2011 Cooling system ATER PUMP pos. Description Type Quantity Torque Note Water pump shaft retainer 3.5-4.5 Nm (2.58-3.31 lbf ft) Water pump cover retainer M6x100 8-10 Nm (5.90-7.38 lbf COOL SYS - 193...

  • Page 194: Coolant Replacement

    RS4 50 MY2011 Cooling system ADIATOR pos. Description Type Quantity Torque Notes Radiator retainer M6x25 10 Nm (7.37 lbf ft) Expansion tank support fixing screw M6x20 3.5-4 Nm (2.58-2.95 lbf Coolant replacement CAUTION DO NOT USE YOUR VEHICLE IF THE COOLANT IS BELOW THE MINIMUM LEVEL. CHECK THE COOLANT LEVEL PERIODICALLY OR AFTER LONG TRIPS.
  • Page 195 RS4 50 MY2011 Cooling system Removal - Remove the clutch cover - The longer screws are highlighted in the figure - Remove the crankcase cover gasket and clean off any rests of old gaskets that may remain on the crankcase or the cover See also Removing the clutch cover...
  • Page 196 RS4 50 MY2011 Cooling system - First unscrew the fixing nut and then the rotor. Remove the driving gear - Slide out the hydraulic 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...
  • Page 197 RS4 50 MY2011 Cooling system - Fit new oil seals on the hydraulic pump shaft with the aid of the specific tool - Fit the first oil seal with its rim facing inside, and the second with the rim facing outside Specific tooling 020441Y Oil seal punch - Mount the pump rotor and fixed it by tightening...
  • Page 198 RS4 50 MY2011 Cooling system Removing the radiator • Remove the expansion tank and the radiator cowl. • Slide off the fastening clamp of the heater pipe. • Release the hoses from the five clamps that fasten it to the chassis. •...
  • Page 199 RS4 50 MY2011 Cooling system • Unscrew and remove both screws fix- ing from the radiator to the chassis. • Sliding it off the fitting slots, remove the radiator. Radiator installation • Install the radiator following the removal operations but in reverse order. •...
  • Page 200 RS4 50 MY2011 Cooling system • Loosen the clamp and slide off the ho- ses. See also Side fairings 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.
  • Page 201 INDEX OF TOPICS BODYW ODYWORK...
  • Page 202 RS4 50 MY2011 Bodywork EAR MUDGUARD pos. Description Type Quantity Torque Notes Rear mudguard to swingarm fixing Self-tap. 3 Nm (2.21 lbf ft) Max 4.5 Nm (3.31 screw lbf ft) INDSHIELD pos. Description Type Quantity Torque Notes Rear view mirror fixing screw Self-t.
  • Page 203 RS4 50 MY2011 Bodywork EAR LIGHTS pos. Description Type Quantity Torque Notes Turn indicator retainer 3 Nm (2.21 lbf ft) Turn indicator cover retainer 0.3 Nm (0.22 lbf ft) NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Self-tapping screw M5x4 2.5 Nm (1.84 lbf ft) BODYW - 203...
  • Page 204 RS4 50 MY2011 Bodywork pos. Description Type Quantity Torque Notes Instrument panel fixing screw M5x20 2 Nm (1.47 lbf ft) AIRINGS pos. Description Type Quantity Torque Notes Side fairing fixing screw M5x9 1.7 Nm (1.25 lbf ft) Max 2 Nm (1.47 lbf BODYW - 204...
  • Page 205 RS4 50 MY2011 Bodywork ENTRAL ODYWORK pos. Description Type Quantity Torque Notes Fairing upper fixing screw M5x9 3 Nm (2.21 lbf ft) Fairing lower fixing screw M4x14 RONT LIGHTS pos. Description Type Quantity Torque Notes Headlamp fixing screw M5x14 2.5 Nm (1.84 lbf ft) Self-tapping screw 1.5 Nm (1.11 lbf ft) Turn indicator fixing screw...
  • Page 206 RS4 50 MY2011 Bodywork IR DEFLECTORS pos. Description Type Quantity Torque Notes Radiator frame screw M5x16 2 Nm (1.47 lbf ft) Max 2.5 N (1.84 lbf Front fixing screw Self-t. 3.9 1 Nm (0.74 lbf ft) TCEI screw M5x20 2 Nm (1.47 lbf ft) Max 2.5 N (1.84 lbf Flanged TBEI screw M5x16...

  • Page 207: Instrument Panel

    RS4 50 MY2011 Bodywork Instrument panel • Remove the windshield. • Lift the instrument panel and discon- nect the connector. • Disconnect the two connectors from the turn indicator and remove the in- strument panel from the support. See also Headlight fairing INSTRUMENT PANEL SUPPORT REMOVAL •...
  • Page 208 RS4 50 MY2011 Bodywork Headlight assy. • Remove the top fairing. • Disconnect the two tail light connec- tors. • Unscrew and remove the four fixing screws at the top fairing. • Remove the headlight assembly. See also Headlight fairing Headlight fairing •...
  • Page 209 RS4 50 MY2011 Bodywork • Unscrew and remove the two top fair- ing side screws. • Unscrew and remove the two screws on the front fairing. • Disconnect the instrument panel con- nector. • Remove the windshield. BODYW - 209...
  • Page 210 RS4 50 MY2011 Bodywork Front wheelhouse • Remove the fairing from the side of the wheel housing that you want to re- move. • Operating from the left shield, unscrew and remove the regulator fixing screw, collecting the nut and the washer. •...
  • Page 211 RS4 50 MY2011 Bodywork • Disconnect the connector. See also Tail guard • Take off the rear light unit, by removing it from the hooks. Footrest PASSENGER FOOTREST The following procedures only refer to one foot- rest, but they are applicable to both. •...
  • Page 212 RS4 50 MY2011 Bodywork Side fairings The following operations only refer to one fairing, but they apply to both. • Rest the vehicle on its stand. • Remove the side fairing. • Unscrew and remove the two screws (1) and collect the corresponding washers.
  • Page 213 RS4 50 MY2011 Bodywork • Unscrew and remove the two lower screws. • 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.
  • Page 214 RS4 50 MY2011 Bodywork • Remove the lock 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.
  • Page 215 RS4 50 MY2011 Bodywork • Operating from the right side, unscrew and remove the central screw. • Working on the left side, unscrew and remove the two screws. • Remove the rear mudguard. Lower cowl • Remove the side fairings. •...

  • Page 216: Fuel Tank

    RS4 50 MY2011 Bodywork Side fairings • Unscrew and remove the central screw. • Unscrew and remove the front screw, following 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.
  • Page 217 RS4 50 MY2011 Bodywork • After having removed the passenger saddle, collect the supporting rod of the fuel tank. • Lift the tank and support it appropriate- • Slide off the clamp and fuel pipes, be careful with the fuel in the pipes and in the cock.
  • Page 218 RS4 50 MY2011 Bodywork • Slide off the fuel breather pipe. • Operating from both sides, unscrew and remove the screw and collect the nut on the internal side. • Keeping the tank in position, lower it by removing the supporting rod. •...

  • Page 219: Front Mudguard

    RS4 50 MY2011 Bodywork Front mudguard • Slide off the cable 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.
  • Page 220 RS4 50 MY2011 Bodywork • Unscrew and remove the four mixer pump cover screws and slide off the cover. • Loosen the clamp and detach the pipe from the pump CAUTION CLOSE THE PIPE WITH A COVER OR A CLAMP TO AVOID THAT OIL COMES OUT.
  • Page 221 RS4 50 MY2011 Bodywork Radiator cover • Unscrew and remove the central screw. • Unscrew and remove the two upper screws. • Retrieve the corresponding washers. • Unscrew and remove the two lower screws. • Slide off the radiator cover. •...
  • Page 222 RS4 50 MY2011 Bodywork Tail guard • The following procedures refer to the left side 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. •...
  • Page 223 INDEX OF TOPICS PRE DE DELIVERY...

  • Page 224: Road Test

    RS4 50 MY2011 Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...
  • Page 225 RS4 50 MY2011 Pre-delivery - Front and rear suspension efficiency - Abnormal noise level Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering - Possible leaks - Radiator electric fan operation (if present) Functional inspection...
  • Page 226 Air filter: 53 Battery: 81 Brake: 179, 181–184, 186, 189, 190 Brake calliper: 179, 181 Brake disc: 182, 183 Brake fluid: 189 Brake pads: 184, 186 Brake pump: 190 Bulbs: Carburettor: 48, 135 Chain: 89, 164, 170 Clutch: 57, 104, 109–114, 116, 124, 131, 195, 197 Connectors: 86 coolant: 194, 200 Coolant: 194, 200...
  • Page 227 Identification: 10 Instrument panel: 207 License plate holder: 212 Magneto flywheel: 107, 124 Maintenance: 8, 48 Maintenance Table: Mirrors: 206 Mudguard: 150, 214, 219 Primary shaft: 101 Radiator: 89, 198, 221 Rear wheel: 163, 165, 166, 170 Recommended products: 41 Secondary shaft: 102 Shock absorbers: 166 Side fairings: 212...

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