APRILIA RS 125 Euro 4 Service Manual
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APRILIA RS 125 Euro 4 Service Manual

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SERVICE STATION MANUAL
2Q000273
RS 125 - Tuono 125 - Euro 4

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Summary of Contents for APRILIA RS 125 Euro 4

  • Page 1 SERVICE STATION MANUAL 2Q000273 RS 125 - Tuono 125 - Euro 4...

  • Page 2: The Value Of Service

    Only by requesting original aprilia spare parts can you be of purchasing products that were developed and tested during the design and development of the vehicle itself. All Aprilia original spare parts undergo quality control procedures to guarantee reliability and durability.
  • 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 scooters.

  • Page 5: Index Of Topics

    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

    RS 125 - Tuono 125 - Euro 4 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: Maintenance Rules

    RS 125 - Tuono 125 - Euro 4 Characteristics KEEP OUT OF THE REACH OF CHILDREN. NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine 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 That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE "RECOMMENDED PRODUCTS" TABLE IN THE SCHEDULED MAIN- TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.

  • Page 11: Serial Number Location

    RS 125 - Tuono 125 - Euro 4 Characteristics Vehicle identification SERIAL NUMBER LOCATION These numbers are necessary for vehicle registration. NOTE ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR- TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY. This number consists of numbers and letters, as in the example shown below.
  • Page 12 RS 125 - Tuono 125 - Euro 4 Characteristics Engine ENGINE Specification Desc./Quantity Engine type Single cylinder 4 stroke Engine capacity 124.2 cm³ (7.58 cu in) Bore x stroke (58 x 47) mm; (2.28 x 1.85) in Compression ratio 12.0 +/- 0.5: 1 Start-up electric Idle speed...
  • Page 13 RS 125 - Tuono 125 - Euro 4 Characteristics ELECTRICAL SYSTEM Specification Desc./Quantity Battery 12V - 6Ah Fuses 30A, 25A, 20A, 15A, 7.5A, 3A Alternator 13V - 235W BULBS Specification Desc./Quantity Low beam light H8 - 12V - 35W High beam light (RS 125) H11 - 12V - 55W High beam light (Tuono 125) H7 - 12V - 55W...

  • Page 14: Fuel System

    RS 125 - Tuono 125 - Euro 4 Characteristics Specification Desc./Quantity Front - inflation pressure, rider + passenger 1.8 bar (180 kPa) (26.11 PSI) Rear 130 / 70 - 17'' 62S Rear - inflation pressure, rider only 1.8 bar (180 kPa) (26.11 PSI) Rear - inflation pressure, rider + passenger 1.9 bar (190 kPa) (27.56 PSI) Supply...

  • Page 15: Front Side

    RS 125 - Tuono 125 - Euro 4 Characteristics Front side RONT LIGHTS pos. Description Type Quantity Torque Notes Headlamp fastener screw M5x14 1.5 Nm (1.11 lb ft) Headlamp fastener screw 1.5 Nm (1.11 lb ft) Turn indicator fastener screw M5x12 3 Nm (2.21 lb ft) Turn indicator cover fastener screw...
  • Page 16 RS 125 - Tuono 125 - Euro 4 Characteristics RONT LIGHTS pos. Description Type Quantity Torque Notes Headlamp fastener screw M5x14 1.5 Nm (1.11 lb ft) Turn indicator fastener screw M5x12 3 Nm (2.21 lb ft) Turn indicator cover fastener screw Self tapping 0.3 Nm (0.22 lb ft) TEERING...
  • Page 17 RS 125 - Tuono 125 - Euro 4 Characteristics TEERING pos. Description Type Quantity Torque Notes Screw fastening top steering yoke to 25 Nm (18.44 lb ft) fork Handlebar fastener nut 48 Nm (35.40 lb ft) Loct. 243 Handlebar U-bolt fastener screws 20 Nm (14.75 lb ft) Ignition switch assembly cover fas- 5 Nm (3.69 lb ft)
  • Page 18 RS 125 - Tuono 125 - Euro 4 Characteristics RONT SUSPENSION pos. Description Type Quantity Torque Notes Screw fastening bottom steering 25 Nm (18.44 lb ft) yoke to fork Screw fastening calliper mounting 20 Nm (14.75 lb ft) bracket RONT SUSPENSION pos.
  • Page 19 RS 125 - Tuono 125 - Euro 4 Characteristics RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel axle nut 78 Nm (57.53 lb ft) Front disc/tone wheel fastener M6x20 12 Nm (8.85 lb ft) Pre-permeated screws Flanged hex head screw fastening M5x16 6 Nm (4.43 lb ft) Loct.
  • Page 20 RS 125 - Tuono 125 - Euro 4 Characteristics RONT MUDGUARD NGINE FAIRING pos. Description Type Quantity Torque Notes Engine fairing fastening screw M5x16 3 Nm (2.21 lb ft) Screw fixing side fairing M6x12 6 Nm (4.43 lb ft) Front mudguard fixing screw M6x25 4.4 Nm (3.25 lb ft) Flanged self-tapping nut...
  • Page 21 RS 125 - Tuono 125 - Euro 4 Characteristics UCTS pos. Description Type Quantity Torque Notes Screw fastening radiator cowl M5x16 2 Nm (1.48 lb ft) Screw fastening upper fairing closing Self tapping 1 Nm (0.74 lb ft) screw, Ø 3.9 Screw fastening radiator cowl M5x20 2 Nm (1.48 lb ft)

  • Page 22: Handlebar And Controls

    RS 125 - Tuono 125 - Euro 4 Characteristics UCTS pos. Description Type Quantity Torque Notes Screw fastening upper ducts to lower Self tapping 2 Nm (1.48 lb ft) ones screw, Ø 3.3 Screws fastening ducts to chassis 6 Nm (4.43 lb ft) ANDLEBAR AND ONTROLS pos.
  • Page 23 RS 125 - Tuono 125 - Euro 4 Characteristics ANDLEBAR AND ONTROLS pos. Description Type Quantity Torque Notes Handlebar U-bolt fastener screws 20 Nm (14.75 lb ft) Handlebar counterweight fastener M5x50 5 Nm (3.69 lb ft) Loctite 243 screw ASHBOARD pos.
  • Page 24 RS 125 - Tuono 125 - Euro 4 Characteristics pos. Description Type Quantity Torque Notes Instrument panel mounting fixing M5x20 2 Nm (1.48 lb ft) screw Instrument panel mounting fixing M6x40 8 Nm (5.90 lb ft) screw ASHBOARD pos. Description Type Quantity Torque...
  • Page 25 RS 125 - Tuono 125 - Euro 4 Characteristics RONT BRAKE MASTER CYLINDER pos. Description Type Quantity Torque Notes Screw fastening front brake master M6x30 11 Nm (8.11 lb ft) cylinder Front brake lever fixing screw 4-7 Nm (2.95-5.16 lb ft) Front brake lever fixing screw 4-7 Nm (2.95-5.16 lb ft) CHAR - 25...

  • Page 26: Clutch Control

    RS 125 - Tuono 125 - Euro 4 Characteristics RONT ALLIPER pos. Description Type Quantity Torque Notes Front calliper fastener screw M10x60 50 Nm (36.88 lb ft) LUTCH CONTROL pos. Description Type Quantity Torque Notes Clutch cable fastener screw 6 Nm (4.43 lb ft) Clutch control fastener screw 10 Nm (7.38 lb ft) Clutch cable fixing nut...
  • Page 27 RS 125 - Tuono 125 - Euro 4 Characteristics OP FAIRING pos. Description Type Quantity Torque Notes Top fairing fastener screw Self tapping 0.4 Nm (0.30 lb ft) screw, Ø 3.9 Top fairing screen fastener screw 1 Nm (0.74 lb ft) Rear view mirror fastener screw M6x30 2 Nm (1.48 lb ft)
  • Page 28 RS 125 - Tuono 125 - Euro 4 Characteristics OP FAIRING pos. Description Type Quantity Torque Notes Instrument panel fastening screws Self tapping 1 Nm (0.78 lb ft) screw, Ø 4.2 Taillight side panels fixing screws Self tapping 2 Nm (1.48 lb ft) screw, Ø...
  • Page 29 RS 125 - Tuono 125 - Euro 4 Characteristics Central part HASSIS Pos. Description Type Quantity Torque Notes Screws fastening the engine to the 50 Nm (36.88 lb ft) cradle Cradle fixing screw 25 Nm (18.44 lb ft) Saddle mounting fixing screw M10x45 50 Nm (36.88 lb ft) Saddle mounting fixing screw...
  • Page 30 RS 125 - Tuono 125 - Euro 4 Characteristics Pos. Description Type Quantity Torque Notes Rear tank fixing screw M8x40 8 Nm (5.90 lb ft) Tank cover fixing screw M6x35 10 Nm (7.38 lb ft) Front tank fixing screw M5x9 3 Nm (2.21 lb ft) Tank U-bolt fixing screw M6x30...
  • Page 31 RS 125 - Tuono 125 - Euro 4 Characteristics IDE FAIRINGS Pos. Description Type Quantity Torque Notes Side fairing fastening screw M5x16 0.8 Nm (0.59 lb ft) Screw fixing side fairing to engine M5x9 3 Nm (2.21 lb ft) closure Side fairing fastening screw Self tapping 0.4 Nm (0.30 lb ft)
  • Page 32 RS 125 - Tuono 125 - Euro 4 Characteristics XHAUST Pos. Description Type Quantity Torque Notes Exhaust fixing clamp 15 Nm (11.06 lb ft) Silencer fixing screw M8x50 25 Nm (18.44 lb ft) Cover fastener screw M5x16 5 Nm (3.69 lb ft) CHAR - 32...
  • Page 33 RS 125 - Tuono 125 - Euro 4 Characteristics ADIATOR pos. Description Type Quantity Torque Notes Radiator fixing screw M6x25 10 Nm (7.38 lb ft) Coolant tank fixing screw M6x20 3.5 Nm (2.58 lb ft) OOTRESTS pos. Description Type Quantity Torque Notes Screw fastening the rider footrest...
  • Page 34 RS 125 - Tuono 125 - Euro 4 Characteristics OOTRESTS pos. Description Type Quantity Torque Notes Screws fastening the rider footrest 25 Nm (18.44 lb ft) Loctite 243 mounting Passenger footrest mounting fasten- 20 Nm (14.75 lb ft) ing screws Screws fastening the rider footrest 25 Nm (18.44 lb ft) With self-locking nut...
  • Page 35 RS 125 - Tuono 125 - Euro 4 Characteristics EAR BRAKING SYSTEM pos. Description Type Quantity Torque Notes Brake lever fixing screw M6x40 12 Nm (8.85 lb ft) Rear brake pump fixing screw M6x30 10 Nm (7.38 lb ft) Brake pump joint fixing screw 10 Nm (7.38 lb ft) Brake calliper fixing screws 25 +/- 2 Nm (18.44 +/-...
  • Page 36 RS 125 - Tuono 125 - Euro 4 Characteristics ENTRAL ODYWORK pos. Description Type Quantity Torque Notes Fairing fastening screw M5x9 3 Nm (2.21 lb ft) Fairing fastening screw M5x12 3 Nm (2.21 lb ft) TAND pos. Description Type Quantity Torque Notes Low nut...
  • Page 37 RS 125 - Tuono 125 - Euro 4 Characteristics pos. Description Type Quantity Torque Notes Stand mounting fixing screw M8x30 25 Nm (18.44 lb ft) Loctite 243 Chain roller fixing screw M8x45 25 Nm (18.44 lb ft) Side stand switch fastening screws M5x25 3 Nm (2.21 lb ft) Stand mounting fixing screw...
  • Page 38 RS 125 - Tuono 125 - Euro 4 Characteristics OCKS pos. Description Type Quantity Torque Notes Tank plug fixing screw M5x16 3 Nm (2.21 lb ft) Tank plug fixing screw M5x30 3 Nm (2.21 lb ft) Screw fastening saddle lock plate M6x30 6 Nm (4.43 lb ft) Ignition lock fixing screw...

  • Page 39: Abs System

    RS 125 - Tuono 125 - Euro 4 Characteristics SYSTEM pos. Description Type Quantity Torque Notes Screw fastening brake pipe to radia- 10 Nm (7.38 lb ft) tor surround Flanged hex head screw fastening M5x25 3.5 Nm (2.58 lb ft) modulator mounting case Flanged hex head screw fastening M6x30...

  • Page 40: Back Side

    RS 125 - Tuono 125 - Euro 4 Characteristics Back side EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper mount fastener screw 58 Nm (42.78 lb ft) Lower fastener screw 58 Nm (42.78 lb ft) Loctite 243 CHAR - 40...

  • Page 41: Rear Wheel

    RS 125 - Tuono 125 - Euro 4 Characteristics WINGARM pos. Description Type Quantity Torque Notes Nut adjusting swingarm alignment M25x1.5 15 Nm (11.06 lb ft) relative to frame Swingarm pin nut 78 Nm (57.53 lb ft) Chain guide fastener screw Self tapping 1 Nm (0.74 lb ft) Chain guard fastener screw...

  • Page 42: Rear Lights

    RS 125 - Tuono 125 - Euro 4 Characteristics EAR LIGHTS pos. Description Type Quantity Torque Notes Turn indicator fastener screw M5x12 3 Nm (2.21 lb ft) Turn indicator cover fastener screw 0.3 Nm (0.22 lb ft) Hex socket button head screw M5x16 3 Nm (2.21 lb ft) SWP screw...
  • Page 43 RS 125 - Tuono 125 - Euro 4 Characteristics EAR BODYWORK Pos. Description Type Quantity Torque Notes Screw fixing the side fairing to the M4x14 3 Nm (2.21 lb ft) chassis Under-saddle fixing screw M5x9 3 Nm (2.21 lb ft) Screw fixing the side fairing to the M5x9 3 Nm (2.21 lb ft)

  • Page 44: Electrical Components

    RS 125 - Tuono 125 - Euro 4 Characteristics EAR MUDGUARD Pos. Description Type Quantity Torque Notes Screw fastening rear mudguard to Self-tapping 3 Nm (2.21 lb ft) swingarm M4.8x12 LECTRICAL COMPONENTS Pos. Description Type Quantity Torque Notes Screw fixing coil to mounting 20 Nm (14.75 lb ft) Screw fixing coil to mounting M6x12...
  • Page 45 RS 125 - Tuono 125 - Euro 4 Characteristics Pos. Description Type Quantity Torque Notes Voltage regulator fixing screw M6x30 6 Nm (4.43 lb ft) Battery bracket fixing screw M6x20 8 Nm (5.90 lb ft) Horn fixing screw M8x16 8 Nm (5.90 lb ft) ABS sensors fixing screw 6 Nm (4.43 lb ft) Loctite 243...

  • Page 46: Throttle Body

    RS 125 - Tuono 125 - Euro 4 Characteristics YLINDER ISTON Pos. Description Type Quantity Torque Notes Chain tensioner fastener screw M6x16 12 Nm (8.85 lb ft) HROTTLE BODY Pos. Description Type Quantity Torque Notes Sleeve fixing screw M6x20 12 Nm (8.85 lb ft) Sleeve fixing clamp 0.8 Nm (0.59 lb ft) Injector mounting fixing screw...

  • Page 47: Filter Box

    RS 125 - Tuono 125 - Euro 4 Characteristics Pos. Description Type Quantity Torque Notes Cable stay on throttle body 4 Nm (2.95 lb ft) ILTER BOX Pos. Description Type Quantity Torque Notes Air filter box fastening screw 3.5 Nm (2.58 lb ft) CHAR - 47...

  • Page 48: Clutch Cover

    RS 125 - Tuono 125 - Euro 4 Characteristics LUTCH COVER Pos. Description Type Quantity Torque Notes Clutch cover fixing screw M6x35 12 Nm (8.85 lb ft) Oil filter cover M56x1.5 25 Nm (18.44 lb ft) Oil pressure sensor 13 Nm (9.59 lb ft) EAD COVER pos.

  • Page 49: Flywheel Cover

    RS 125 - Tuono 125 - Euro 4 Characteristics LYWHEEL COVER pos. Description Type Quantity Torque Notes Flywheel cover fastener screw 12 Nm (8.85 lb ft) Timing control cap 4 Nm (2.95 lb ft) Oil dipstick M12x1.5 5 Nm (3.69 lb ft) IMING SYSTEM pos.
  • Page 50 RS 125 - Tuono 125 - Euro 4 Characteristics pos. Description Type Quantity Torque Notes Timing system gear fastener screw M8x40 27 Nm (19.91 lb ft) Loctite 243 LUTCH pos. Description Type Quantity Torque Notes Clutch spring screw 4 Nm (2.95 lb ft) Crankshaft primary gear fastener nut 79 Nm (58.27 lb ft) Clutch nut...

  • Page 51: Water Pump

    RS 125 - Tuono 125 - Euro 4 Characteristics TARTER OTOR pos. Description Type Quantity Torque Notes Starter motor fastener screw M6x25 12 Nm (8.85 lb ft) ATER PUMP pos. Description Type Quantity Torque Notes Water pump fastener screw 3.5 Nm (2.58 lb ft) Water pump rotor fastener screw 5 Nm (3.69 lb ft) CHAR - 51...

  • Page 52: Oil Pump

    RS 125 - Tuono 125 - Euro 4 Characteristics pos. Description Type Quantity Torque Notes Oil pump fastener screw M5x35 4 Nm (2.95 lb ft) Loctite 243 Oil cap retainer 25 Nm (18.44 lb ft) EAR SELECTOR pos. Description Type Quantity Torque Notes...

  • Page 53: Engine Crankcase

    RS 125 - Tuono 125 - Euro 4 Characteristics NGINE RANKCASE pos. Description Type Quantity Torque Notes Crankcase retainer screw M6x60 12 Nm (8.85 lb ft) Crankcase retainer screw M6x75 12 Nm (8.85 lb ft) ALVES pos. Description Type Quantity Torque Notes Head fastener screw...

  • Page 54: Ignition Unit

    RS 125 - Tuono 125 - Euro 4 Characteristics pos. Description Type Quantity Torque Notes Camshaft cover fastener screw M6x40 11 Nm (8.11 lb ft) Head fastener screw M8x166 27 Nm + 90° (19.91 lb ft + 90°) Thermostat cover fastener screw M6x20 11 Nm (8.11 lb ft) Head dowels retainer...
  • Page 55 RS 125 - Tuono 125 - Euro 4 Characteristics OMPONENTS OF GEARBOX pos. Description Type Quantity Torque Notes Gear sensor retainer 3 Nm (2.21 lb ft) INKAGE Pos. Description Type Quantity Torque Note Sprocket fastener screws M5x10 4 Nm (2.95 lb ft) Loctite 270 Front sprocket cover fastener screw M5x16...

  • Page 56: Overhaul Data

    RS 125 - Tuono 125 - Euro 4 Characteristics Pos. Description Type Quantity Torque Note Gearbox lever fixing screws 10 Nm (7.38 lb ft) Gearbox lever fixing nut 8 Nm (5.90 lb ft) Gear tie-rod fixing nuts 6 Nm (4.43 lb ft) Overhaul data Assembly clearances Cylinder - piston assy.

  • Page 57: Index Of Topics

    INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 58 RS 125 - Tuono 125 - Euro 4 Special tools PECIAL TOOLS Stores code Description 020911Y Engine installation adapter for RS 125 + 020710Y 866714 Swingarm adjustment 805181B Tool for fitting chain link AP8140266 Dial gauge mount 865259 Flywheel retainer 866380 Water pump tool set S-TOOLS - 58...
  • Page 59 RS 125 - Tuono 125 - Euro 4 Special tools Stores code Description 864868 Flywheel extractor 864567 Camshaft timing adjustment lock pins 864486 Countershaft lock tool 00H05600351 Oil seal guide 020382Y011 Valve removal/installation tool 020287Y Tool for installing seal rings 865261 Piston retainer S-TOOLS - 59...
  • Page 60 RS 125 - Tuono 125 - Euro 4 Special tools Stores code Description 00H05300041 Clutch lock 865260 Camshaft sprocket lock tool 020376Y Adaptor handle 020359Y 42 x 47 mm Adaptor 020358Y 37 x 40 mm Adaptor 020357Y 32 x 35-mm Adaptor 020439Y 17 mm punch for secondary shaft oil seal S-TOOLS - 60...
  • Page 61 RS 125 - Tuono 125 - Euro 4 Special tools Stores code Description 020891Y 25 mm (0.98 in) adapter 020363Y 20 mm diam. punch for crankshaft oil seal 020412Y 15 mm diam. punch for clutch oil seal 020375Y 28x30 mm punch 020483Y 30-mm guide 020364Y...
  • Page 62 RS 125 - Tuono 125 - Euro 4 Special tools Stores code Description 020922Y Diagnostic tool 020955Y PADS cable kit S-TOOLS - 62...

  • Page 63: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 64: Scheduled Maintenance Table

    RS 125 - Tuono 125 - Euro 4 Maintenance Scheduled maintenance table Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum function and performance. Services must be performed as soon as the specified mileage and time intervals are reached. Services must be performed punctually at the correct intervals to maintain the validity of the warranty.
  • Page 65 RS 125 - Tuono 125 - Euro 4 Maintenance Km x 1,000 (mi x 1,000) EVERY EVERY (0.6) (3.7) (7.5) (11.2) (14.9) (18.6) (22.4) (26.1) (29.8) MONTH MONTH Screw tightness Front suspension: oil (5) Indicator lamps Final drive (1)(6) Fuel and oil pipes + filters (2) Brake pipes Labour time (minutes) SCHEDULED MAINTENANCE TABLE RESERVED TO THE USA-LATAM MARKET...

  • Page 66: Recommended Products

    RS 125 - Tuono 125 - Euro 4 Maintenance km (mi) x1000 1 (0.6) 6 (3.7) 12 (7.5) 18 (11.2) 24 (14.9) 30 (18.6) 36 (22.4) 42 (26.1) 48 (29.8) Fuel and oil pipes + filters Brake pipes Labour time (minutes) NOTE AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.

  • Page 67: Spark Plug

    RS 125 - Tuono 125 - Euro 4 Maintenance • If any defects are found, replace the spark plug with a new component of the specified type. • Fit the spark plug with the correct incli- nation and hand-tighten it completely into its seat, then tighten definitively to the specified torque.
  • Page 68 RS 125 - Tuono 125 - Euro 4 Maintenance • From the left hand side of the engine, unscrew and remove the oil dipstick-cap (1). • Wipe the dipstick clean with a clean cloth, then refit and retighten it into the oil filler. •...
  • Page 69 RS 125 - Tuono 125 - Euro 4 Maintenance • Keep the vehicle upright with both wheels on the ground. • Place a container of suitable capacity under the drain plug (2). • Unscrew and remove the drainage plug (2). •...

  • Page 70: Engine Oil Filter

    RS 125 - Tuono 125 - Euro 4 Maintenance Engine oil filter • Remove the bottom fairing and drain the engine oil. • Undo and remove the oil filter cap. • Remove the oil filter. Air filter • The passenger saddle must be removed in order to remove the air filter. •...

  • Page 71: Cleaning Air Filter

    RS 125 - Tuono 125 - Euro 4 Maintenance • Working from behind the tank, lift the filter box cover (3) and remove com- plete with the filter element (4). • Separate the filter element (4) from the filter box cover (3) on a clean, dry sur- face.
  • Page 72 RS 125 - Tuono 125 - Euro 4 Maintenance TO AVOID SPILLING FLUID WHILE TOPPING UP, KEEP THE LEVEL OF THE FLUID IN THE RES- ERVOIR PARALLEL WITH THE EDGE OF THE RESERVOIR ITSELF (IN HORIZONTAL POSITION). DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. FUNNELS OR ANY OTHER IMPLEMENTS USED MUST BE PERFECTLY CLEAN.

  • Page 73: Clutch System

    RS 125 - Tuono 125 - Euro 4 Maintenance • Top up the reservoir (6) with recom- mended brake fluid to above the mini- mum level marking "MIN". CAUTION ONLY FILL TO THE "MAX" LEVEL AFTER FITTING NEW BRAKE PADS. DO NOT FILL TO THE "MAX" LEVEL WITH WORN PADS, AS THIS WILL CAUSE FLUID TO ESCAPE WHEN REPLACING BRAKE PADS.

  • Page 74: Adjusting The Lever

    RS 125 - Tuono 125 - Euro 4 Maintenance 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.

  • Page 75: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 76 RS 125 - Tuono 125 - Euro 4 Electrical system Components arrangement KEY: 1. Engine speed sensor 2. Stop switch 3. Taillight ELE SYS - 76...

  • Page 77: Electrical System Installation

    RS 125 - Tuono 125 - Euro 4 Electrical system 4. Injector 5. Battery 6. Main fuses 7. Fan relay 8. Light relay 9. Headlight unit 10.Starter relay 11.Electric fan. 12.Lambda probe 13.Fuel reserve sensor 14.Oil pressure sensor 15.Coil 16.Fuel pump 17.Injection relay 18.Secondary fuses 19.Instrument panel...
  • Page 78 RS 125 - Tuono 125 - Euro 4 Electrical system • 2 turn indicator wiring harnesses • 1 H.V. cable • 1 blinker • 1 start-up relay 12V 80A • 3 relays 12V 30A Small parts and mountings: • 7 large black 290x4.5 (11.42x0.18 in) clamps •...
  • Page 79 RS 125 - Tuono 125 - Euro 4 Electrical system • Check fastening of the chassis - engine ground cable. • Check the flywheel connection. • Check the lambda connection (with security Lock). • Check that lambda probe cable is correctly connected. •...
  • Page 80 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE A3 - Headlight cable routing: RH side 1. Daylight running light (5W). 2. Cable grommet. 3. Low beam light. 4. RH daylight running light wiring harness. 5. RH low beam light wiring harness. TABLE A4 3.
  • Page 81 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE B - ABS SENSOR The ABS sensor must be fastened with the cable fasteners onto the front brake pipe, must pass through the eyelet of the brake calliper bleeding cap and must be curved as shown in the photo- graph.
  • Page 82 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE C2 • Using two rubber clamps, lock together the wiring harness of the RH light switch and the wiring harness of the front brake and the brake pipe. D TABLES - ARCH BRACE TABLE D1 1.
  • Page 83 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE D2 The headlamp wiring harness connector is inside the instrument holder arch brace TABLE E - DETAIL OF LIGHTS 1. Clamps. 2. LH light switch wiring harness. 3. RH light switch wiring harness. The clamps must secure the light switch wiring harnesses to the semi-handlebars.
  • Page 84 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE F - IGNITION SWITCH 1. Ignition switch. 2. Clamp. 3. Ignition switch wiring harness. The clamp must block the ignition switch wiring harness as shown. TABLE G - INSTRUMENT PANEL 1.
  • Page 85 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE H2 1. Voltage regulator wiring harness. CAUTION CHECK THAT THE REGULATOR IS CORRECTLY CON- NECTED. IN THE AREA SHOWN IN RED (REGULATOR CABLE, BE- HIND RADIATOR) THE FLYWHEEL CONNECTION MUST NOT BE SEEN BUT BE CONCEALED BEHIND THE PLAS- TIC COVER.
  • Page 86 RS 125 - Tuono 125 - Euro 4 Electrical system Central part A TABLES - PRE-FITTING OF CHASSIS TABLE A1 1. Retaining clips. 2. Cable guide. TABLE A2 1. Edge clips Place the edge clips between the points indicated on the chassis. TABLE A3 - RH SIDE 1.
  • Page 87 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE A4 - LH SIDE 1. Cable guide 2. Hole for chassis ground. 3. Rubber edge protectors. TABLE B - PRE-FITTING OF FUEL RESERVE SENSOR 1. Fuel pump 2. Fuel reserve sensor WIRING TABLE C 1.
  • Page 88 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE D2 1. Coil connector 2. Coil earth. 3. Circlip. E TABLES - CONNECTION OF MIU (3G) CON- TROL UNIT - INJECTOR- WATER TEMPERA- TURE SENSOR TABLE E1 1. Protective rubber. TABLE E2 1.
  • Page 89 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE E3 1. Connector. 2. Injector. CAUTION CONNECT THE CONNECTOR TO THE INJECTOR AND MAKE SURE IT HAS BEEN CORRECTLY CONNECTED. TABLE E4 CAUTION CONNECT THE WATER TEMPERATURE SENSOR CON- NECTOR AND MAKE SURE THAT IT HAS BEEN CORRECT- LY INSERTED.
  • Page 90 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE F - PRE-FITTING OF RADIATOR FAN 1. Radiator fan. G TABLES - PRE-FITTING OF ABS - PROCE- DURE FOR INSERTION OF ABS CONNECTOR TABLE G1 1. ABS Modulator. 2. ABS modulator support. 3.
  • Page 91 RS 125 - Tuono 125 - Euro 4 Electrical system When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm. if the initial position of the connector and the driving lever is not as shown in "TABLE G2 - Figure 1", the connector will not be properly coupled and the distance measured will be greater (approx.

  • Page 92: Main Wiring Harness

    RS 125 - Tuono 125 - Euro 4 Electrical system TABLE I2 1. Main wiring harness. 2. Cable guide. CAUTION PLACE THE GREY REFERENCE MARKS ON THE WIRING HARNESS IN THE RESPECTIVE CABLE FASTENERS AND CLOSE THEM, POSITIONING THE WIRING HARNESS AS SHOWN IN THE PHOTOGRAPH.
  • Page 93 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE L - CONNECTING THE COIL 1. Coil connector. 2. Ground cable. 3. Circlip. CAUTION MAKE SURE THAT THE CONNECTOR HAS BEEN CON- NECTED AND THE GROUND CABLE FASTENED TO THE CIRCLIP CORRECTLY.
  • Page 94 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE M2 1. Ground cable. CAUTION MAKE SURE THAT THE GROUND CABLE IS FASTENED TO THE CHASSIS CORRECTLY. N TABLES - BATTERY AREA COMPONENTS TABLE N1 1. Turn indicators relay. 2.
  • Page 95 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE N3 1. Start-up relay. TABLE O - REAR BRAKE SENSOR ROUTING 1. Clamp. 2. Rear brake sensor wiring harness. TABLE P - HORN - NEUTRAL SENSOR - STAND SENSOR 1.
  • Page 96 RS 125 - Tuono 125 - Euro 4 Electrical system Q TABLES - LAMBDA PROBE - ENGINE OIL PRESSURE SENSOR TABLE Q1 1. Lambda probe wiring harness. 2. Rubber clamps. 3. Engine oil pressure sensor. CAUTION CHECK THAT THE CAP IS CORRECTLY INSERTED ON THE ENGINE OIL PRESSURE SENSOR.
  • Page 97 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE R - STARTER MOTOR 1. Starter motor ground wiring harness. 2. Starter motor positive wiring harness. CAUTION CHECK THAT THE STARTER MOTOR GROUND CABLE AND POSITIVE CABLE HAVE BEEN FASTENED COR- RECTLY COMPLETE WITH PROTECTIVE CAP.
  • Page 98 RS 125 - Tuono 125 - Euro 4 Electrical system T TABLES - FUEL TANK WIRING HARNESSES TABLE T1 1. Fuel pipe. 2. Clamps. 3. Fuel pump/sensor wiring harness CAUTION CONNECT THE BRANCH OF THE FUEL PUMP WIRING HARNESS TO THE FUEL PIPE WITH TWO CLAMPS IN LINE WITH THE GREY TAPING.
  • Page 99 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE T3 1. Fuel pump wiring harness. 2. Wire holders. CAUTION PASS THE FUEL PUMP WIRING HARNESS ONTO THE LH SIDE OF THE TANK AND INSERT IT IN THE SPECIAL WIRE HOLDERS FITTED PREVIOUSLY.
  • Page 100 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE U 1. Quick shift connector. TABLE V Correct position of battery. Back side TABLE A - PRE-FITTING OF TAILLIGHT 1. Grey taping that indicates the LH rear turn indi- cator cable.
  • Page 101 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE B - REAR HEADLIGHT ASSEMBLY 1. LH rear turn indicator. 2. Faston: light blue and blue cables. 3. LH rear turn indicator wiring harness. 4. RH rear turn indicator. 5.
  • Page 102 RS 125 - Tuono 125 - Euro 4 Electrical system D TABLES - FASTENING OF TAIL FAIRING WIRING HARNESS TABLE D1 1. Main wiring harness connector. Check the position of the connector. TABLE D2 1. Rear speed sensor wiring harness. 2.
  • Page 103 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE D4 1. Rear speed sensor wiring harness. 2. Clamp. 3. Cable fasteners. • The ABS sensor cable must be blocked by the bleeder cap TABLE D5 1. Rear speed sensor connector. ELE SYS - 103...
  • Page 104 RS 125 - Tuono 125 - Euro 4 Electrical system TABLE D6 1. Taillight wiring harness. 2. USB socket connector. 3. Taillight wiring harness. 4. Cable guide. ELE SYS - 104...

  • Page 105: General Wiring Diagram

    RS 125 - Tuono 125 - Euro 4 Electrical system General wiring diagram 1. Multiple connectors 2. MIU G3 control unit 3. Left hand front turn indicator (10W) 4. Front daytime running lights (5W) ELE SYS - 105...
  • Page 106 RS 125 - Tuono 125 - Euro 4 Electrical system 5. Low beam headlight lamp (35W) 6. High beam light bulb (55W) 7. Complete headlamp 8. Right hand front turn indicator (10W) 9. Fan 10.Side stand switch 11.Accessories fuse 12.Instrument cluster 13.Clutch switch 14.Flasher unit 15.Left light switch...

  • Page 107: Checks And Inspections

    RS 125 - Tuono 125 - Euro 4 Electrical system 43.Engine water temperature sensor 44.ECU diagnostics 45.BLUEDASH pre-installation 46.Fall sensor 47.Electronic gearbox (optional) 48.Reserve fuel sensor 49.ABS control unit 50.Front ABS sensor 51.Rear speed sensor 52.USB port 53.- 54.- 55.- 56.- 57.- 58.-...
  • Page 108 RS 125 - Tuono 125 - Euro 4 Electrical system CAUTION BEFORE STARTING ANY TROUBLESHOOTING PROCEDURES ON THE VEHICLE, CHECK THAT THE BATTERY VOLTAGE IS ABOVE 12V. PROCEDURE FOR CHECKING CONNECTOR This procedure consists of the following checks and inspections: 1.
  • Page 109 RS 125 - Tuono 125 - Euro 4 Electrical system Tester: set the tester selector to the "DC voltage" symbol and place the red tester probe on the cable under inspection and the black tester probe on the vehicle ground point (or on the battery negative pole).
  • Page 110 RS 125 - Tuono 125 - Euro 4 Electrical system Engine alarm warning MI • The amber engine alarm warning lamp MI (4) lights continuously in the event of a fault identified by the engine con- trol unit. Check for errors with the di- agnostic tool.
  • Page 111 RS 125 - Tuono 125 - Euro 4 Electrical system • Segments lit when the ignition switch is turned to Key-on. Use the controls to scroll through the display func- tions in the following order: • • TRIP I • TRIP II •...

  • Page 112: Ignition Circuit

    RS 125 - Tuono 125 - Euro 4 Electrical system Ignition circuit Characteristic Spark plug NGK CR9EKB or NGK CR9EB / NGK CR8EB Electrode gap 0.7-0.8 mm (0.027-0.031 in) Battery recharge circuit Key: 1. Multiple connectors 2. Battery 3. Main fuses 4.

  • Page 113: Recharging System

    RS 125 - Tuono 125 - Euro 4 Electrical system RECHARGING SYSTEM • Disconnect the six-way connector (1) (black colour) located behind the left side cover. NOTE THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER "A" Measurement of resistance (with engine off) •...

  • Page 114: Resistance Measurement

    RS 125 - Tuono 125 - Euro 4 Electrical system • Resistance of the wires read on the display = 0.47 Ohm • Effective resistance stage 1 = 0.67-0.47 = 0.20 Ohm • If there is a significant difference between one stage and another (other than 0.20 Ohm), this means that the alternator is defective and must be replaced.
  • Page 115 RS 125 - Tuono 125 - Euro 4 Electrical system stage "2" (outgoing cables from pins 2 and 6), stage "3" (outgoing cables from pins 4 and • Start the engine and carry out the measurement. • If there is a significant difference between one stage and another (other than 15 V), this means that the alternator is defective and must be replaced.
  • Page 116 RS 125 - Tuono 125 - Euro 4 Electrical system OLD SHORT CIRCUIT CURRENT 2000 4000 6000 8000 RMS DC current (Arms) (average of the 3 stage 12 - 18 12 - 18 12 - 18 12 - 18 currents) Voltage on battery poles with engine speed always between 3000 - 5000 RPM •...
  • Page 117 RS 125 - Tuono 125 - Euro 4 Electrical system Start-up system check Key: 1. Multiple connectors 2. MIU G3 control unit 3. Side stand 4. Clutch switch 5. Right light switch 6. Ignition switch 7. Starter motor relay 8. Starter motor 9.

  • Page 118: Checking The Starter Motor

    RS 125 - Tuono 125 - Euro 4 Electrical system CHECKING THE STARTER MOTOR • To carry out the check, power up the motor with a 12 V 9 AH battery. • Win an AC ammeter clamp measure the steady running absorbed current (after 5 seconds).

  • Page 119: Horn Control

    RS 125 - Tuono 125 - Euro 4 Electrical system Starter button: on right hand switch set Connector: ... Electrical specifications • Button released: open circuit • Button pressed: closed circuit Diagnostic tool - Parameters and statuses • Starting request - (Absent, Present, Closed Loop, Closed) Diagnostics tool - Logic errors Starter button P0512 - signal not valid...
  • Page 120 RS 125 - Tuono 125 - Euro 4 Electrical system Warning light on: Magnitude range: MOhm CAUTION UPON REFITTING, MAKE SURE THE ELECTRIC CONNEC- TOR IS CORRECTLY COUPLED. Lights list (RS 125) Key: 1. Instrument panel 2. Flasher unit 3. Left light switch 4.
  • Page 121 RS 125 - Tuono 125 - Euro 4 Electrical system 15.Battery 16.Main fuses 17.Secondary fuses 18.MIU G3 control unit 19.Front left turn indicator 20.Light relay 21.Front daylight running light 22.Headlamp 23.Low beam light 24.High beam light 25.Front right turn indicator (TUONO 125) Key: 1.
  • Page 122 RS 125 - Tuono 125 - Euro 4 Electrical system 9. Rear right turn indicator 10.Licence plate light 11.Rear left turn indicator 12.Taillight 13.Starter motor relay 14.Starter motor 15.Battery 16.Main fuses 17.Secondary fuses 18.MIU G3 control unit 19.Front left turn indicator 20.Light relay 21.Front left headlight connector 22.Front right headlight connector...
  • Page 123 RS 125 - Tuono 125 - Euro 4 Electrical system TAILLIGHT • Rear daylight running light /stop light: • License plate light (where applicable): 12 V - 5W HEADLAMP • Low beam light: H8 - 12V - 35W • High beam light (RS 125): H11 - 12V - •...
  • Page 124 RS 125 - Tuono 125 - Euro 4 Electrical system The main fuses are situated at the front of the motorcycle, under the fuel tank and behind the headstock. The 3A fuse is situated under the rear of the fuel tank CAUTION THE 20A, 15A AND 7.5A FUSES INDICATED (H) ARE SPARES.

  • Page 125: Speed Sensor

    RS 125 - Tuono 125 - Euro 4 Electrical system DIAGNOSTIC TOOL:PARAMETERS Battery voltage • Example value with key ON: 12.0 V • Example value with engine on: 14.2 V This is one of the values set by the ECU in the event of recovery mode Battery voltage before prior to Recovery mode •...
  • Page 126 RS 125 - Tuono 125 - Euro 4 Electrical system Electrical circuit diagram - Level in electrical circuit diagram: ABS system Position on vehicle: On LH stanchion of fork, near the brake calliper mounting bracket CAUTION THE DISTANCE BETWEEN THE ABS SENSOR AND THE PHONIC WHEEL MUST BE BETWEEN 0.3 mm (0.012 in) AND 2 mm (0.079 in).
  • Page 127 RS 125 - Tuono 125 - Euro 4 Electrical system - If there is no insulation, restore the wiring harness or replace the sensor. Short-circuit to positive: - Disconnect the sensor connector. - Check the battery supply insulation of the two PINS. - If there is no insulation, restore the wiring harness or replace the sensor.
  • Page 128 RS 125 - Tuono 125 - Euro 4 Electrical system Position of connector (if applicable): Saddle post frame, RH side Pin-out: • PIN1 - Power feed negative/Signal negative (yellow) • PIN2 - Power feed positive/Signal pos- itive (yellow/brown) Diagnostic tool - Parameters and statuses •...

  • Page 129: Engine Rpm Sensor

    RS 125 - Tuono 125 - Euro 4 Electrical system Error cause Possible tone wheel fault due to deformations or dirt. Troubleshooting - Check that the tone wheel is not damaged and is clean. - Check that the number of teeth on the tone wheel is correct. - Check that the tone wheel and the sensor are correctly positioned;...

  • Page 130: Engine Temperature Sensor

    RS 125 - Tuono 125 - Euro 4 Electrical system • Check the electric circuit is in good conditions and the flywheel teeth cleaning and correct positioning of the sensor in its own housing; if it is not, replace it. If it is OK, replace the sensor Engine temperature sensor Function...

  • Page 131: Lambda Sensor

    RS 125 - Tuono 125 - Euro 4 Electrical system Cause of error Open circuit or short circuit to positive: interruption of the circuit or excessive voltage at PIN 13 of the control unit connector. Short circuit to negative: null voltage between PIN 13 and 15 of the control unit connector. Troubleshooting Open circuit: •...
  • Page 132 RS 125 - Tuono 125 - Euro 4 Electrical system reach a high operating temperature: that is why there is a heating circuit inside. Level in electrical circuit diagram Lambda probe, Injection utilities relay Position • Sensor: exhaust duct • Connector: underneath battery, behind headstock, RH side Electrical specifications...
  • Page 133 RS 125 - Tuono 125 - Euro 4 Electrical system • If the wiring harness is intact and the error persists, proceed with the following checks. Short circuit to negative: • Disconnect the sensor connector and the control unit connector. •...

  • Page 134: Fuel Pump

    RS 125 - Tuono 125 - Euro 4 Electrical system Injector coil is excited for the petrol passage to open. Level in electrical circuit diagram Relay for injection utilities, Coils and injectors Electrical specifications • 14.8 Ώ +/- 5% (at 20 °C - 68°F) Pin-out: 1.
  • Page 135 RS 125 - Tuono 125 - Euro 4 Electrical system Fuel pump relay P0230 - shorted to positive / shorted to negative / open circuit. Error cause Shorted to positive: excessive voltage at PIN 22 of the control unit connector. Shorted to negative: null voltage at PIN 2 of the injection relay.
  • Page 136 RS 125 - Tuono 125 - Euro 4 Electrical system Primary: 550 +/- 50 mOhm Secondary: 3.3 +/- 0.3 kOhm Function Allows generation of the electrical discharge on the spark plug, with an increase of voltage. Pin-out: 1. Relay powered (PIN 3 relay side) 2.

  • Page 137: Engine Oil Pressure Sensor

    RS 125 - Tuono 125 - Euro 4 Electrical system • Verify, with the key turned ON, the presence of voltage on the coil connector PIN 1. If no voltage is read, verify the continuity of the cabling between coil and injection relay (No. 35 on the electrical circuit diagram): Coil PIN 1 - relay PIN 3.
  • Page 138 RS 125 - Tuono 125 - Euro 4 Electrical system Position • Sensor: rear / upper side of the gearbox • Connector: on the sensor Electrical specifications • Gear in neutral: closed circuit (0 V on wire from control unit to sensor / switch in continuity). •...
  • Page 139 RS 125 - Tuono 125 - Euro 4 Electrical system Clutch lever sensor Function Indicates the clutch lever position to the control unit Operation / Operating principle In order to start the engine, pull the clutch also with the gear in neutral Level in electrical circuit diagram Start enable switches Position...
  • Page 140 RS 125 - Tuono 125 - Euro 4 Electrical system • If absent, restore the wiring harness. The vehicle starts even without pulling the clutch lever Error cause • Possible malfunction Troubleshooting • Disconnect the terminals from the sensor and check that, with the clutch released, there is continuity between the two PINs.
  • Page 141 RS 125 - Tuono 125 - Euro 4 Electrical system • verify continuity of the grey/yellow cable between the sensor and PIN 19 of the control unit. • If absent, restore the wiring harness, if present, with the stand up, check for continuity be- tween the two PINs on the sensor.

  • Page 142: Run/Stop Switch

    RS 125 - Tuono 125 - Euro 4 Electrical system Open circuit: circuit interruption. Troubleshooting Short-circuit to positive: • Disconnect the fan control relay (No. 42 in electrical circuit diagram), turn the ignition switch to ON and measure the voltage at PIN 1 of the relay connector leading to the wiring harness side: if the voltage is 12V, repair the wiring harness, if the voltage is zero, replace the relay.
  • Page 143 RS 125 - Tuono 125 - Euro 4 Electrical system • RUN position: closed circuit (continui- Pin-out 1. Voltage 0 V with engine kill in STOP; 12V if engine kill in RUN (pink/yellow cable) 2. Always voltage 12 V (with key on) (red/yellow cable) Diagnostic tool - Parameters and statuses •...
  • Page 144 RS 125 - Tuono 125 - Euro 4 Electrical system Function It manages injection/ignition, the system safety checks and the self-diagnosis function. The con- trol unit is Magneti Marelli MIU G3 Level in electrical circuit diagram Diagnostics, ABS system, pre-configuration for BlueDash Position •...
  • Page 145 RS 125 - Tuono 125 - Euro 4 Electrical system 23.Ground 2 (power) (blue) 24.Fan relay output (purple-black) 25.Warning lamp output (purple-brown) 26.Can "H" (NC) (X4) 27.Can "L" (NC) (X3) 28.Speed sensor input (S) (blue-orange) 29.Pick-up input (+) (X2) 30.Engine speed output (pink-black) 31.Lambda probe heater output (green-yellow) 32.Water pump output (NC) 33.Lights relay output (purple-red)
  • Page 146 RS 125 - Tuono 125 - Euro 4 Electrical system Diagnostic tool - Parameters and statuses This screen page shows the parameters meas- ured by the several sensors (engine revs, engine temperature, etc.) or values set by the control unit (injection time, ignition advance);...
  • Page 147 RS 125 - Tuono 125 - Euro 4 Electrical system • RUN/OFF Switch - (RUN-OFF) • Start enable - (NO, YES) • Checking of Probe1 value (...) • Lambda probe - (---, Not enabled, Not active (start), Not active (heat.), Not active (rich), Operating, Not active (lean), Fault •...
  • Page 148 RS 125 - Tuono 125 - Euro 4 Electrical system Diagnostic tool - Errors screen page This display shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO). Diagnostic tool - Electrical errors Air pressure sensor P0105 - short circuit to positive / open circuit, short circuit to negative, signal not valid...
  • Page 149 RS 125 - Tuono 125 - Euro 4 Electrical system • This indication appears only if the Level 2 safety has reset the engine (C gravity). The in- strument panel does not indicate the presence of this error even in the ATT status. Troubleshooting •...
  • Page 150 RS 125 - Tuono 125 - Euro 4 Electrical system • Once the throttle body or the injection control unit is replaced, it is necessary to connect to the diagnostic tool selecting FUEL INJECTION and carry out the operation "THROTTLE POSITIONER AUTODETECTION"...
  • Page 151 RS 125 - Tuono 125 - Euro 4 Electrical system • Riduzione del numero di cavi: la linea CAN viaggia su doppino tra i vari nodi. • I nodi sono capaci inoltre di isolare gli errori senza causare il breakdown del sistema (Faults- Confination).

  • Page 152: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...

  • Page 153: Vehicle Preparation

    RS 125 - Tuono 125 - Euro 4 Engine from vehicle Vehicle preparation • Rest the vehicle on its stand • Support the vehicle rear part using belts and hoist. • Drain off the cooling system. • Beforehand, remove the lug, the side fairings, the battery, the fuel tank, the side fairings, the drive chain, the air filter box, the radiator and the expansion tank.
  • Page 154 RS 125 - Tuono 125 - Euro 4 Engine from vehicle • Remove the rubber plug and loosen the screw. • Disconnect the starter motor cable. • Unscrew and remove the two fixing screws. • Remove the pinion cover. • Undo and remove the fixing screw.
  • Page 155 RS 125 - Tuono 125 - Euro 4 Engine from vehicle • Water temperature connector. • Disconnect the neutral sensor connec- • Remove the oil temperature sensor. • Remove the oil temperature sensor. ENG VE - 155...
  • Page 156 RS 125 - Tuono 125 - Euro 4 Engine from vehicle • Remove the battery compartment. • Remove the coil. • Remove the clamp. • Remove the breather pipe. • Remove the screw. • Remove the cable guide. ENG VE - 156...
  • Page 157 RS 125 - Tuono 125 - Euro 4 Engine from vehicle • Disconnect the injector connector. • Remove the main cable grommet. • Working on both sides, unscrew and remove the two fastener screws. • Remove the screw that fastens the ABS modulator support to the engine. •...
  • Page 158 RS 125 - Tuono 125 - Euro 4 Engine from vehicle • Operating from both sides, remove the pass through screws and collect the retaining nuts. • Operating from both sides, remove the upper fixing screws. • Working from the right side, slide off the pin.
  • Page 159 RS 125 - Tuono 125 - Euro 4 Engine from vehicle Installing the engine to the vehicle • Place the ring nut and tighten it to the prescribed torque. Specific tooling 866714 Swingarm adjustment • Insert the swingarm pin from the right side and slide it until it reaches the oth- er side.
  • Page 160 RS 125 - Tuono 125 - Euro 4 Engine from vehicle • On the LH side, place the washer on the swingarm pin and start the nut. • Check that the washer and nut are on the swingarm pin. • Working on both sides, tighten the nuts to the prescribed torque.
  • Page 161 RS 125 - Tuono 125 - Euro 4 Engine from vehicle • Place the cable guide. • Tighten the screw to the prescribed tor- que. • Place the breather pipe and secure it with the clamp. • Connect the ground and fix it with the screw.
  • Page 162 RS 125 - Tuono 125 - Euro 4 Engine from vehicle • Connect the horn. • Connect the oil temperature sensor. • Connect the neutral sensor. CAUTION TAKE CARE NOT TO LOSE THE INSULATING RUBBER HOOD OR THE PLASTIC WASHER FITTED BETWEEN THE CONNECTOR AND THE NEUTRAL SENSOR BULB.
  • Page 163 RS 125 - Tuono 125 - Euro 4 Engine from vehicle • Position and reconnect the chain. • Put in place the gear lever and tighten the screw to the specified torque. • Put in place the pinion cover and tight- en the two screws to the specified tor- que.
  • Page 164 RS 125 - Tuono 125 - Euro 4 Engine from vehicle • Connect the starter motor ground wire and tighten the screw to the specified torque. • Reattach the clutch cable, making sure to insert it in the cable grommet. •...

  • Page 165: Index Of Topics

    INDEX OF TOPICS NGINE...
  • Page 166 RS 125 - Tuono 125 - Euro 4 Engine Gearbox EAR SELECTOR pos. Description Type Quantity Torque Notes Selector sprocket fastener screw 4 Nm (2.95 lb ft) Lever fastener screw 9 Nm (6.64 lb ft) Clutch lever fastener screw 9 Nm (6.64 lb ft) Gear shift selector pin fixing 9 Nm (6.64 lb ft) ENG - 166...
  • Page 167 RS 125 - Tuono 125 - Euro 4 Engine OMPONENTS OF GEARBOX pos. Description Type Quantity Torque Notes Gear sensor retainer 3 Nm (2.21 lb ft) Diagram Filtro olio • Place a recipient with a capacity of at least 900 cm³ (54.91 cu.in) under the drain plug (1) on the clutch side.

  • Page 168: Gearbox Shafts

    RS 125 - Tuono 125 - Euro 4 Engine • Remove the oil filter (4) and clean thor- oughly before refitting. NOTE CHECK AND, IF NECESSARY, REPLACE THE FILTER SEAL WASHER Gearbox shafts Disassembling the gearbox • Remove the desmodromic drum •...
  • Page 169 RS 125 - Tuono 125 - Euro 4 Engine Removing the primary shaft CAUTION THE PRIMARY SHAFT CANNOT BE DISASSEMBLED. IF NECESSARY, REPLACE THE ENTIRE PRIMARY SHAFT. Removing the secondary shaft CAUTION FIT NEW CIRCLIPS WHEN REASSEMBLING Disassemble the secondary shaft as follows: •...
  • Page 170 RS 125 - Tuono 125 - Euro 4 Engine • Remove the spacer washer (4) • Remove the fifth speed gear (5). • Remove the circlip (6). • Remove the spacer washer (7) ENG - 170...
  • Page 171 RS 125 - Tuono 125 - Euro 4 Engine • Remove the third speed gear (8). • Remove the fourth speed gear (9). • Remove the sixth speed gear (10). • Remove the spacer washer (11) ENG - 171...
  • Page 172 RS 125 - Tuono 125 - Euro 4 Engine • Remove the spacer washer (12) • Remove the second speed gear (13). • Remove the bush (14). • Remove the shim washer (15) ENG - 172...
  • Page 173 RS 125 - Tuono 125 - Euro 4 Engine Desmodromic demounting • Remove the fork carrier shaft (1) • Remove the desmodromic shaft (2) • Remove the forks (3) Checking the desmodromic drum Check the desmodromic shaft and drum for any signs of damage, scratches or wear, and replace if necessary.

  • Page 174: Starter Motor

    RS 125 - Tuono 125 - Euro 4 Engine • Check that the fork moves uniformly and without impediment; check for damage, dents and signs of wear on the roller (1) and on the teeth (2) of the fork. • Replace the fork if necessary.

  • Page 175: Removing The Starter Motor

    RS 125 - Tuono 125 - Euro 4 Engine Removing the starter motor • Undo and remove the two fixing screws (1). • Remove the starter motor (2). NOTE THE STARTER MOTOR CAN ALSO BE REMOVED IF THE ENGINE IS FITTED TO THE VEHICLE. Generator side LYWHEEL COVER pos.
  • Page 176 RS 125 - Tuono 125 - Euro 4 Engine GNITION UNIT pos. Description Type Quantity Torque Notes Flywheel rotor fixing nut M14x1.5 86 Nm (63.43 lb ft) Rotor fastener screw 12 Nm (8.85 lb ft) Stator clamping screws 6 Nm (4.43 lb ft) Pick-Up clamping screw 3.5 Nm (2.58 lb ft) Removing the flywheel cover...
  • Page 177 RS 125 - Tuono 125 - Euro 4 Engine Rimozione rotore • Remove the starter motor gear. • Fit the specific tool. • Undo and remove the hex socket screw. Specific tooling 865259 Flywheel retainer • Retrieve the washer. • Fit the tool and pull out the rotor.

  • Page 178: Removing The Stator

    RS 125 - Tuono 125 - Euro 4 Engine • Remove the rotor. • Remove the key. Removing the stator • Remove the two screws fastening the plate securing the stator cable • Remove the two screws fastening the stator ENG - 178...
  • Page 179 RS 125 - Tuono 125 - Euro 4 Engine • Remove the stator. Freewheel removal • Undo and remove the indicated retain- er screw with the relative plate. • Remove the freewheel. ENG - 179...
  • Page 180 RS 125 - Tuono 125 - Euro 4 Engine Clutch side LUTCH COVER Pos. Description Type Quantity Torque Notes Clutch cover fixing screw M6x35 12 Nm (8.85 lb ft) Oil filter cover M56x1.5 25 Nm (18.44 lb ft) Oil pressure sensor 13 Nm (9.59 lb ft) ENG - 180...

  • Page 181: Removing The Clutch Cover

    RS 125 - Tuono 125 - Euro 4 Engine LUTCH pos. Description Type Quantity Torque Notes Clutch spring screw 4 Nm (2.95 lb ft) Crankshaft primary gear fastener nut 79 Nm (58.27 lb ft) Clutch nut 40 Nm (29.50 lbf ft) Removing the clutch cover •...

  • Page 182: Disassembling The Clutch

    RS 125 - Tuono 125 - Euro 4 Engine Disassembling the clutch • Unscrew and remove the six screws by loosening them 1/4 of a turn at a time; operate in stages and diagonally, and retrieve the washers and the clutch springs.

  • Page 183: Checking The Clutch Plates

    RS 125 - Tuono 125 - Euro 4 Engine • Remove the shim and the clutch hous- ing. • Remove the shim. Checking the clutch plates Characteristic Driving plates thickness 2.85 - 2.95 mm (0.112 - 0.116 in) Number of driving plates Driven plates thickness 1.46 - 1.53 mm (0.057 - 0.06 in) Number of driven plates...

  • Page 184: Checking The Clutch Housing

    RS 125 - Tuono 125 - Euro 4 Engine Checking the clutch housing Check the primary driven gear for damage and wear and, if necessary, replace the primary driven gear and the clutch bell all together. Make sure there is not excessive noise during op- eration;...

  • Page 185: Assembling The Clutch

    RS 125 - Tuono 125 - Euro 4 Engine Checking the springs • Check the springs for damage and, if necessary, replace the them all togeth- • Measure the clutch spring length when unloaded; if necessary, replace the springs all together. Characteristic Minimum wear limit in the release position of the individual clutch springs...
  • Page 186 RS 125 - Tuono 125 - Euro 4 Engine • Insert the clutch hub. • Screw in the retainer nut locking the rotation of the clutch housing with the specific tool. Specific tooling 00H05300041 Clutch lock • Lift one side of the lock tab. •...
  • Page 187 RS 125 - Tuono 125 - Euro 4 Engine Crankcase NGINE RANKCASE pos. Description Type Quantity Torque Notes Crankcase retainer screw M6x60 12 Nm (8.85 lb ft) Crankcase retainer screw M6x75 12 Nm (8.85 lb ft) ENG - 187...
  • Page 188 RS 125 - Tuono 125 - Euro 4 Engine RANKSHAFT Pos. Description Type Quantity Torque Notes Gear fixing screw 40 Nm (29.50 lb ft) Balancing countershaft removal • Before taking out the balancing coun- tershaft the clutch cover and flywheel cover must be removed.
  • Page 189 RS 125 - Tuono 125 - Euro 4 Engine Balancing countershaft fitting • Insert the countershaft from the alter- nator side. • Insert the gear aligning its reference to the primary gear. • Using the specific tool, tighten the nut remember first to place the washer.
  • Page 190 RS 125 - Tuono 125 - Euro 4 Engine • Remove the primary gear unscrewing and removing the nut. • Collect the washer. • Remove the countershaft gear. • Remove the primary remaining gears. • Remove the head and cylinder. •...
  • Page 191 RS 125 - Tuono 125 - Euro 4 Engine • Remove the base gear of the main shaft. • Remove the cotter. • Remove the oil pump unscrewing the three fixing screws. • Collect the gasket. • Remove the gear spider screw, un- screwing and removing the fixing screw.

  • Page 192: Bearing Removal

    RS 125 - Tuono 125 - Euro 4 Engine • Moving from the left side of the engine, remove the flywheel and all of its com- ponents beforehand. • Unscrew and remove the six screws on the outside of the crankcase (1). •...

  • Page 193: Right Crankcase

    RS 125 - Tuono 125 - Euro 4 Engine List of extractors to be used with sleeve 020376Y: RIGHT CRANKCASE • Insertion of main shaft bearing: 020439Y+020359Y Removal of the main shaft bearing: 020358Y • Insertion of desmo bearing: 020439Y+020357Y Removal of desmo bearing: 020891Y •...
  • Page 194 RS 125 - Tuono 125 - Euro 4 Engine Bushing selection USHING SEAT DIAMETER ON CRANKCASE Specification Desc./Quantity Class 1 MIN 36.500 mm (1.4370 in) MAX 36.508 mm (1.4373 in) Class 2 MIN 36.508 mm (1.4373 in) MAX 36.516 mm (1.4376 in) RANKSHAFT DIAMETER Specification Desc./Quantity...
  • Page 195 RS 125 - Tuono 125 - Euro 4 Engine • Insertion of secondary shaft roller bearing cage: 020363Y Removal of the secondary shaft roller bearing cage: use universal extractor • Insertion of countershaft roller bearing cage: 020483Y Removal of countershaft roller bear- ing cage: 020364Y NOTE: insertion of the roller bearing cages in line with the crankcase is recommended from the inside to the outside.
  • Page 196 RS 125 - Tuono 125 - Euro 4 Engine • Fit the selector star. • Fit and tighten the screw. • Fit a new oil pump gasket. • Fit the oil pump, screwing the three screws. • Insert the countershaft gear and posi- tion the washer.
  • Page 197 RS 125 - Tuono 125 - Euro 4 Engine • Insert the pump drive gear. • Insert the washer and apply the fixing seeger. • Insert the timing chain gear, paying at- tention to the direction. The engraving must face upward. •...
  • Page 198 RS 125 - Tuono 125 - Euro 4 Engine • Fit the rest of the primary gears. • Tighten the fixing nut. • Remove the countershaft locking tool. • Fit the gear selector. Head and timing EAD COVER pos. Description Type Quantity Torque...
  • Page 199 RS 125 - Tuono 125 - Euro 4 Engine ALVES pos. Description Type Quantity Torque Notes Head fastener screw M6x130 12 Nm (8.85 lb ft) Drainage side stud bolt retainer M8x40 12 Nm (8.85 lb ft) Camshaft cover fastener screw M6x40 11 Nm (8.11 lb ft) Head fastener screw...

  • Page 200: Removing The Head Cover

    RS 125 - Tuono 125 - Euro 4 Engine IMING SYSTEM pos. Description Type Quantity Torque Notes Chain tensioner pad fastener screw M6x16 10 Nm (7.38 lb ft) Loctite 243 Timing system gear fastener screw M8x40 27 Nm (19.91 lb ft) Loctite 243 Removing the head cover •...
  • Page 201 RS 125 - Tuono 125 - Euro 4 Engine • Remove the spark plug. Removing the timing control • Turn the crankshaft from the hole on the cover (1) • Take the piston to TDC. • The sign (2) must be aligned with the sign (3).

  • Page 202: Cylinder Head

    RS 125 - Tuono 125 - Euro 4 Engine • Remove the spring. • Unscrew and remove the two screws (6) and remove the entire tensioner control. • Lock the timing gear using the specific tool. Specific tooling 865260 Camshaft sprocket lock tool •...
  • Page 203 RS 125 - Tuono 125 - Euro 4 Engine Removing the overhead camshaft • Remove the two pins from the cam tower. • Remove the eight screws (1). • Remove the cam tower (2). • Remove the two camshafts (intake side and exhaust side).

  • Page 204: Removing The Valves

    RS 125 - Tuono 125 - Euro 4 Engine • Remove the head (4). Removing the valves • Remove the head. • Place the head on supporting surface. • Number the valves and their bucket tappets in order to position them cor- rectly upon refitting.
  • Page 205 RS 125 - Tuono 125 - Euro 4 Engine • Remove both cotter pins. • Release the valve springs. • Remove the cap and the valve spring. Checking the overhead camshaft • Check the camshaft bearings for signs of abnormal wear. Characteristic Standard diameter - Bearing A 19.980 - 19.959 mm (0.7866 - 0.7858 in)

  • Page 206: Valve Check

    RS 125 - Tuono 125 - Euro 4 Engine Valve check • Measure the width of the sealing surface on the valve seats and on the valves themselves. • If the sealing surface on the valve is wider than the specified limit, damaged in one or more points or curved, replace the valve with a new one.
  • Page 207 RS 125 - Tuono 125 - Euro 4 Engine • Remove the chain tensioner. • Undo and remove the eight screws and remove the cam tower. • Remove the timing chain and the gears of the camshaft of the valves in ques- tion.
  • Page 208 RS 125 - Tuono 125 - Euro 4 Engine • Fit the camshaft, the gears and the chain in their correct positions, using the references located on the flywheel side of the crankcase. • Fit the cam tower and tighten the eight screws to the prescribed torque. •...

  • Page 209: Checking The Cylinder Head

    RS 125 - Tuono 125 - Euro 4 Engine Inspecting the valve housings • Remove any carbon deposits from the valve guides. • Measure the inside diameter of each valve guide. • Measure according to the thrust direction at three different heights. Characteristic Intake guide - standard diameter 4.012 mm (0.1579 in)

  • Page 210: Installing The Valves

    RS 125 - Tuono 125 - Euro 4 Engine • Check that the camshaft bushings are not worn. • Check that the head cover surface, the intake manifold and the exhaust manifold are not worn. Installing the valves • Lubricate the valve guides with engine oil. •...

  • Page 211: Checking The Chain

    RS 125 - Tuono 125 - Euro 4 Engine Checking the chain • Check that the guide slider and the ten- sioner pad are not excessively worn. • Check that the chain assembly, the camshaft driving pulleys and the sprocket wheel are not worn. •...

  • Page 212: Disassembling The Piston

    RS 125 - Tuono 125 - Euro 4 Engine • Remove the water hose clamp (3). • Remove the cylinder (4). • Remove the gasket (5). Disassembling the piston • Apply the tool under the piston (1). • Cover the base of the cylinder with a cloth.

  • Page 213: Checking The Piston

    RS 125 - Tuono 125 - Euro 4 Engine • Remove the pin (3). • Remove the piston (4). Checking the piston • Measure the pin seat diameter on the piston. • Calculate the pin - piston coupling clearance. • Measure the piston outside diameter, perpendicular to the pin axis.
  • Page 214 RS 125 - Tuono 125 - Euro 4 Engine Characteristic Piston / cylinder Piston pin hole - standard: 15.003 - 15.008 mm (0.5907 - 0.5908 in) Maximum piston / cylinder coupling clearance after use - top ring: 0.075 mm (0.0029 in) - middle ring: 0.065 mm (0.0025 in) - oil scraper: 0.25 mm (0.0098 in) Standard piston / cylinder coupling clearance...

  • Page 215: Anelli Di Tenuta

    RS 125 - Tuono 125 - Euro 4 Engine Inspecting the wrist pin • Check the pin outside diameter. Characteristic Minimum diameter: 14.995 mm (0.590 in) Standard diameter: 15.0000 +0/-0.0030 mm (0.00012 in) Inspecting the piston rings ANELLI DI TENUTA Specification Desc./Quantity Compression ring (top)

  • Page 216: Fitting The Piston

    RS 125 - Tuono 125 - Euro 4 Engine Fitting the piston • Install the piston and the piston pin on the connecting rod, orienting the piston with the arrow facing towards the ex- haust side. • Fit the retainer circlip. •...

  • Page 217: Base Gasket Selection

    RS 125 - Tuono 125 - Euro 4 Engine Installing the cylinder • Fit a new cylinder base gasket of the chosen thickness. • Refit the cylinder as indicated in the figure using the specific clamp tighten- er tool. NOTE BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL.
  • Page 218 RS 125 - Tuono 125 - Euro 4 Engine • Screw but do not tighten both central long screws (3) and position the wash- ers. • Screw but do not tighten both central long screws (2) and position the wash- ers.
  • Page 219 RS 125 - Tuono 125 - Euro 4 Engine • Position the cam tower cap. • Screw but do not and tighten the eight screws. • Place the pins in their positions on the overhead camshafts. Specific tooling 864567 Camshaft timing adjustment lock pins •...
  • Page 220 RS 125 - Tuono 125 - Euro 4 Engine • Check the valve clearance and adjust it if required. • Refit the tappet cover. Lubrication pos. Description Type Quantity Torque Notes Oil pump fastener screw M5x35 4 Nm (2.95 lb ft) Loctite 243 Oil cap retainer 25 Nm (18.44 lb ft)
  • Page 221 RS 125 - Tuono 125 - Euro 4 Engine • Remove the pump gear. • Remove the pump gear. • Separate the components to inspect them. Inspection • Measure distance between rotors with a feeler gauge at the positions shown in the picture.
  • Page 222 RS 125 - Tuono 125 - Euro 4 Engine Radial clearance (2) between points of the rotor: 0.08 mm (0.003 in) Radial clearance (3) between rotor 1 and the pump body: 0.04 mm (0.0015 in) Radial clearance (3) between rotor 2 and the pump body: 0.05 mm (0.0019 in) Installing •...

  • Page 223: Index Of Topics

    INDEX OF TOPICS P SUPP OWER SUPPLY...

  • Page 224: Circuit Diagram

    RS 125 - Tuono 125 - Euro 4 Power supply Circuit diagram Key: 1. Fuel tank 2. Fuel pump 3. Fuel pump ring nut 4. Fuel pump gasket 5. Fuel pipe 6. Fuel level probe Fuel pump P SUPP - 224...
  • Page 225 RS 125 - Tuono 125 - Euro 4 Power supply Removing Remove and empty the fuel tank. • Remove the fuel hose (4). • Loosen the ring nut (3) and slide off the gasket (2). • Remove the pump (1). See also Fuel tank Injection...
  • Page 226 RS 125 - Tuono 125 - Euro 4 Power supply Diagram P SUPP - 226...
  • Page 227 RS 125 - Tuono 125 - Euro 4 Power supply 1. ECU control unit position 2. Ignition switch 3. Fuel pump 4. Instrument panel 5. Air temperature sensor 6. Throttle valve position sensor 7. Injector 8. Coolant temperature sensor 9. Lambda probe position 10.Engine speed sensor 11.Electric fan P SUPP - 227...

  • Page 228: Removing The Throttle Body

    RS 125 - Tuono 125 - Euro 4 Power supply Removing the throttle body • Remove the filter box. • Loosen and remove the nut and un- hook the throttle cable. • Disconnect the connector. • Undo and remove the screw and re- move the cable guide.
  • Page 229 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 230: Front Suspension

    RS 125 - Tuono 125 - Euro 4 Suspensions Front RONT SUSPENSION pos. Description Type Quantity Torque Notes Screw fastening bottom steering 25 Nm (18.44 lb ft) yoke to fork Screw fastening calliper mounting 20 Nm (14.75 lb ft) bracket SUSP - 230...
  • Page 231 RS 125 - Tuono 125 - Euro 4 Suspensions RONT SUSPENSION pos. Description Type Quantity Torque Notes Screw fastening bottom steering 25 Nm (18.44 lb ft) yoke to fork Screw fastening calliper mounting 20 Nm (14.75 lb ft) bracket Screw fastening bottom steering 25 Nm (18.44 lb ft) yoke to fork RONT WHEEL...
  • Page 232 RS 125 - Tuono 125 - Euro 4 Suspensions TEERING pos. Description Type Quantity Torque Notes Screw fastening top steering yoke to 25 Nm (18.44 lb ft) fork Handlebar fastener nut 48 Nm (35.40 lb ft) SUSP - 232...

  • Page 233: Removing The Front Wheel

    RS 125 - Tuono 125 - Euro 4 Suspensions TEERING pos. Description Type Quantity Torque Notes Screw fastening top steering yoke to 25 Nm (18.44 lb ft) fork Handlebar fastener nut 48 Nm (35.40 lb ft) Loct. 243 Handlebar U-bolt fastener screws 20 Nm (14.75 lb ft) Ignition switch assembly cover fas- 5 Nm (3.69 lb ft)

  • Page 234: Checking The Front Wheel

    RS 125 - Tuono 125 - Euro 4 Suspensions • Pull the axle out completely and re- move the collar. • Remove the wheel. Checking the front wheel FRONT WHEEL BEARINGS Check the bearings installed on the wheel. CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR.

  • Page 235: Installing The Front Wheel

    RS 125 - Tuono 125 - Euro 4 Suspensions ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE. SEALS • Check the condition of the seals; replace if damaged or excessively worn. ALWAYS REPLACE BOTH SEALS TOGETHER. ALWAYS REPLACE THE SEALS WITH COMPONENTS OF THE SAME TYPE. WHEEL AXLE •...

  • Page 236: Front Fork

    RS 125 - Tuono 125 - Euro 4 Suspensions Front fork Removing the fork legs The following instructions describe the procedure for removing one fork but are applicable for both forks. • Support the front of the vehicle, fasten- ing a suitable strap to the handlebar and to a hoist.
  • Page 237 RS 125 - Tuono 125 - Euro 4 Suspensions • Fit the fork in the vice using the special Teflon grips. • Unscrew and remove the cap • Remove the internal piston and, lower- ing the lock washer, remove the two half cylinders SUSP - 237...
  • Page 238 RS 125 - Tuono 125 - Euro 4 Suspensions • 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 239: Checking The Components

    RS 125 - Tuono 125 - Euro 4 Suspensions • Remove the oil seal from the sleeve, taking care not to damage it Checking the components SPARE WHEEL HOLDER STEM • Check that the sliding surface is not scratched or scored. Any scoring can be removed by sanding with damp sandpaper (grain 1).
  • Page 240 RS 125 - Tuono 125 - Euro 4 Suspensions • Check for damage and/or cracks; if it is damaged, replace it. • Check the condition of the sliding bush- ings (1). • If there is evidence of excessive wear or damage, replace the component concerned.
  • Page 241 RS 125 - Tuono 125 - Euro 4 Suspensions • Insert the retainer ring • 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 242: Installing The Fork Legs

    RS 125 - Tuono 125 - Euro 4 Suspensions Installing the fork legs • Fit the fork tube complete with stan- chion into the bottom and top steering yokes. • Insert the wheel axle into both stan- chions to align the holes. •...

  • Page 243: Removing The Rear Wheel

    RS 125 - Tuono 125 - Euro 4 Suspensions • Lower the hoist arm. CAUTION BEFORE RELEASING THE BELTS MAKE SURE THAT THE OPTIONAL REAR STAND IS COR- RECTLY POSITIONED. • Correctly install the lower shield, the mudguard, the front wheel and the brake callipers. •...
  • Page 244 RS 125 - Tuono 125 - Euro 4 Suspensions DURING REMOVAL, TAKE CARE NOT TO DAMAGE THE PIPE, THE DISC AND THE BRAKE PADS. CAUTION THE SPECIFIC REAR SUPPORT STAND IS NEEDED TO REMOVE THE REAR WHEEL. • Place the vehicle on the specific rear stand.

  • Page 245: Checking The Rear Wheel

    RS 125 - Tuono 125 - Euro 4 Suspensions Checking the rear wheel CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR. REAR WHEEL BEARINGS Check the bearings installed on the wheel. CHECKING ROTATION •...

  • Page 246: Installing The Rear Wheel

    RS 125 - Tuono 125 - Euro 4 Suspensions the indicated limits after replacing the bearings, replace the wheel (2). Characteristic Maximum radial (A) eccentricity: 0.6 mm (0.0236 in) Maximum lateral (B) eccentricity: 0.5 mm (0.0197 in) CROWN GEAR • Check the condition of the teeth of the crown gear (3).

  • Page 247: Shock Absorbers

    RS 125 - Tuono 125 - Euro 4 Suspensions Shock absorbers EAR SUSPENSION pos. Description Type Quantity Torque Notes Upper mount fastener screw 58 Nm (42.78 lb ft) Lower fastener screw 58 Nm (42.78 lb ft) Loctite 243 SUSP - 247...
  • Page 248 RS 125 - Tuono 125 - Euro 4 Suspensions Removing • Remove both central side fairings. • Place the vehicle on its optional front service stand. • Support the vehicle rear part using belts and hoist. • Place a support under the swingarm, so that it stays in neutral position.

  • Page 249: Index Of Topics

    INDEX OF TOPICS CHAS HASSIS...
  • Page 250 RS 125 - Tuono 125 - Euro 4 Chassis HASSIS Pos. Description Type Quantity Torque Notes Screws fastening the engine to the 50 Nm (36.88 lb ft) cradle Cradle fixing screw 25 Nm (18.44 lb ft) Saddle mounting fixing screw M10x45 50 Nm (36.88 lb ft) Saddle mounting fixing screw...

  • Page 251: Swinging Arm

    RS 125 - Tuono 125 - Euro 4 Chassis Swinging arm WINGARM pos. Description Type Quantity Torque Notes Nut adjusting swingarm alignment M25x1.5 15 Nm (11.06 lb ft) relative to frame Swingarm pin nut 78 Nm (57.53 lb ft) Chain guide fastener screw Self tapping 1 Nm (0.74 lb ft) Chain guard fastener screw...
  • Page 252 RS 125 - Tuono 125 - Euro 4 Chassis • Working on both sides, loosen the nuts fastening the swingarm pivot bolt. • On the LH side, undo and remove the nut and retrieve the washer. • On the RH side of the vehicle, undo and remove the nut and retrieve the washer.
  • Page 253 RS 125 - Tuono 125 - Euro 4 Chassis Pinion INKAGE Pos. Description Type Quantity Torque Note Sprocket fastener screws M5x10 4 Nm (2.95 lb ft) Loctite 270 Front sprocket cover fastener screw M5x16 4 Nm (2.95 lb ft) Gearbox lever fixing screws 10 Nm (7.38 lb ft) Gearbox lever fixing nut 8 Nm (5.90 lb ft)

  • Page 254: Drive Chain

    RS 125 - Tuono 125 - Euro 4 Chassis • Rotate the pinion lock plate to remove it the from the shaft. • Remove the pinion Inspection • Check the state of the teeth of the front and rear sprockets. If excessively worn, replace: the rear sprocket, front sprocket and drive chain.
  • Page 255 RS 125 - Tuono 125 - Euro 4 Chassis Removing • Support the vehicle with the optional rear stand. • Loosen the chain tension, by unscrew- ing the rear adjuster screws. • Identify the master link; slide off the clip. •...
  • Page 256 RS 125 - Tuono 125 - Euro 4 Chassis • Check that the measurement notches between the mobile part and the fixed part of the instrument match (1/2 step) New chain: • the notch of the mobile measuring in- strument coincides with the first notch on the right of the fixed part of the in- strument Chain to be replaced:...

  • Page 257: Specific Tooling

    RS 125 - Tuono 125 - Euro 4 Chassis • Insert the new fork from the rear • Insert the connecting plate at the point of the dowels • Place the tool on the chain, inserting the centring dowel between the chain rollers •...
  • Page 258 RS 125 - Tuono 125 - Euro 4 Chassis The spring has been inserted in its housing cor- rectly when it measures a maximum of 9.4 mm (0.37 in). Adjusting To check chain deflection: • Shut off the engine. • Rest the vehicle on the side stand.

  • Page 259: Chain Tensioner

    RS 125 - Tuono 125 - Euro 4 Chassis If, after checking the deflection, it is necessary to adjust the chain tension, follow the instructions given below. • Place the vehicle on the specific rear support stand. • On both sides of the vehicle, loosen the nut (1) completely.
  • Page 260 RS 125 - Tuono 125 - Euro 4 Chassis TAND pos. Description Type Quantity Torque Notes Low nut M10x1.25 10 Nm (7.38 lb ft) Loctite 243 Stand mounting fixing screw M8x30 25 Nm (18.44 lb ft) Loctite 243 Chain roller fixing screw M8x45 25 Nm (18.44 lb ft) Side stand switch fastening screws...
  • Page 261 RS 125 - Tuono 125 - Euro 4 Chassis • If necessary, replace the spring. Installing • Fit the spring (1) on the chain tensioner bracket (2), positioning correctly. • Fit the bush (3) with the machined end on the outer side as shown in the fig- ure.
  • Page 262 RS 125 - Tuono 125 - Euro 4 Chassis Pedaline OOTRESTS pos. Description Type Quantity Torque Notes Screw fastening the rider footrest M8x25 25 Nm (18.44 lb ft) Loctite 243 mounting Footrest protection fastening screw M5x12 5 Nm (3.69 lb ft) Passenger footrest bracket fastening M8x40 20 Nm (14.75 lb ft)
  • Page 263 RS 125 - Tuono 125 - Euro 4 Chassis OOTRESTS pos. Description Type Quantity Torque Notes Screws fastening the rider footrest 25 Nm (18.44 lb ft) Loctite 243 mounting Passenger footrest mounting fasten- 20 Nm (14.75 lb ft) ing screws Screws fastening the rider footrest 25 Nm (18.44 lb ft) With self-locking nut...

  • Page 264: Brake Lever

    RS 125 - Tuono 125 - Euro 4 Chassis • Remove the footpeg mount (4). REMOVING THE RIGHT HAND SIDE RIDER FOOTPEG: FOOTPEG GUARD: • After disconnecting the rear brake master pump, remove the two fastener screws (5) of the footpeg guard, taking care not to lose the washers.
  • Page 265 RS 125 - Tuono 125 - Euro 4 Chassis • Remove the screw (8) fastening the brake lever, holding the nut to prevent it from turning. • Remove the bush (9), the spring wash- ers (10) and the spacer washer (11). FOOTPEGS: NOTE THE PROCEDURE DESCRIBED AS FOLLOWS IS THE SAME FOR BOTH FOOTPEGS...
  • Page 266 RS 125 - Tuono 125 - Euro 4 Chassis • Remove the footpeg (14) and the re- turn spring (15). LEFT HAND SIDE RIDER FOOTPEG: • Working on the left hand side of the motorcycle, remove the circlip (1) re- taining the gear lever control rod.

  • Page 267: Gear Lever

    RS 125 - Tuono 125 - Euro 4 Chassis REMOVING THE LEFT HAND SIDE RIDER FOOTPEG: FOOTPEG GUARD: • Remove the two screws (4) fastening the footpeg guard, taking care not to lose the washers. • Remove the footpeg guard (5). GEAR LEVER: •...

  • Page 268: Side Stand

    RS 125 - Tuono 125 - Euro 4 Chassis Stand TAND pos. Description Type Quantity Torque Notes Low nut M10x1.25 10 Nm (7.38 lb ft) Loctite 243 Stand mounting fixing screw M8x30 25 Nm (18.44 lb ft) Loctite 243 Chain roller fixing screw M8x45 25 Nm (18.44 lb ft) Side stand switch fastening screws...
  • Page 269 RS 125 - Tuono 125 - Euro 4 Chassis • Slide off the nut and remove the cable grommet. • Slide off the stand together with the plate. Exhaust XHAUST Pos. Description Type Quantity Torque Notes Exhaust fixing clamp 15 Nm (11.06 lb ft) Silencer fixing screw M8x50 25 Nm (18.44 lb ft)
  • Page 270 RS 125 - Tuono 125 - Euro 4 Chassis Removing the tail pipe • Undo and remove the two upper stay- screws and collect the relative nuts and washers. • Beforehand, remove the side fairings and the fairing lug. • Loosen the clamp.

  • Page 271: Removing The Exhaust Manifold

    RS 125 - Tuono 125 - Euro 4 Chassis Removing the exhaust manifold • Unscrew and remove the two screws. • Remove the manifold. • Remove the muffler. • Lift the saddle and disconnect the lambda probe connector. See also Removing the tail pipe CHAS - 271...

  • Page 272: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 273 RS 125 - Tuono 125 - Euro 4 Braking system RONT BRAKE MASTER CYLINDER pos. Description Type Quantity Torque Notes Screw fastening front brake master M6x30 11 Nm (8.11 lb ft) cylinder Front brake lever fixing screw 4-7 Nm (2.95-5.16 lb ft) Front brake lever fixing screw 4-7 Nm (2.95-5.16 lb ft) BRAK SYS - 273...

  • Page 274: Rear Braking System

    RS 125 - Tuono 125 - Euro 4 Braking system RONT ALLIPER pos. Description Type Quantity Torque Notes Front calliper fastener screw M10x60 50 Nm (36.88 lb ft) EAR BRAKING SYSTEM pos. Description Type Quantity Torque Notes Brake lever fixing screw M6x40 12 Nm (8.85 lb ft) Rear brake pump fixing screw...
  • Page 275 RS 125 - Tuono 125 - Euro 4 Braking system EAR BRAKING SYSTEM pos. Description Type Quantity Torque Notes Peg fixing screw 8 Nm (5.90 lb ft) Brake lever fixing pin 25 Nm (18.44 lb ft) Pre-permeated Pin spring coupling 5 Nm (3.69 lb ft) Loctite 243 Rear brake pump fixing screw...

  • Page 276: Abs System

    RS 125 - Tuono 125 - Euro 4 Braking system SYSTEM pos. Description Type Quantity Torque Notes Screw fastening brake pipe to radia- 10 Nm (7.38 lb ft) tor surround Flanged hex head screw fastening M5x25 3.5 Nm (2.58 lb ft) modulator mounting case Flanged hex head screw fastening M6x30...
  • Page 277 RS 125 - Tuono 125 - Euro 4 Braking system SYSTEM pos. Description Type Quantity Torque Notes Flanged hex head screw fastening M5x25 3.5 Nm (2.58 lb ft) modulator mounting case Flanged hex head screw fastening M6x30 10 Nm (7.38 lb ft) modulator mounting case Hex socket button head screw fas- 10 Nm (7.38 lb ft)

  • Page 278: Operating Diagram

    RS 125 - Tuono 125 - Euro 4 Braking system • PIN 15 (Blue) - Hwvc 3 (-) • PIN 16 (Blue/Orange) - Wso_R • PIN 17 (Blue/Yellow) - ABS indicator light • PIN 18 (Red/White) - Battery positive for ABS pump motor Operating diagram BRAK SYS - 278...

  • Page 279: Abs Operation

    RS 125 - Tuono 125 - Euro 4 Braking system ABS functional diagram key 1. Front system circuit. 2. Front brake master cylinder. 3. Front brake control lever. 4. ABS control unit. 5. Front brake calliper. 6. Front brake circuit inlet solenoid valve (normally open). 7.
  • Page 280 RS 125 - Tuono 125 - Euro 4 Braking system C - Maintaining pressure: the pressure in the calliper (5) remains low until total recovery of the correct wheel speed state / wheel grip. The system returns the fluid taken from the calliper (5) to the section of circuit between the brake master cylinder (2) and the ABS inlet valve (6 ).
  • Page 281 RS 125 - Tuono 125 - Euro 4 Braking system When sensors (3) detect a significant speed difference between the rear and the front wheels (for example, when rearing up on the back wheel), the ABS system could take this as a dangerous situation. In this case, 2 things may occur: - the ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the same speed of the other wheel;...
  • Page 282 RS 125 - Tuono 125 - Euro 4 Braking system • Remove the screw (3) that fastens the modulator support to the engine. • Remove the two screws (4) that fasten the modulator support to the chassis. • Remove the protective casing (5) of the control unit connector (6) and discon- nect •...
  • Page 283 RS 125 - Tuono 125 - Euro 4 Braking system • Operating from the LH side of the mo- torcycle, remove the ABS modulator with support • Release the relays (9) on the sides from the battery support and remove the support fastener screw (10).
  • Page 284 RS 125 - Tuono 125 - Euro 4 Braking system • Move the support aside. • Disconnect the fuse supports from the two brackets on the headstock. • After releasing the front ABS sensor wiring harness from the brake pipe, re- move the two brake calliper fastener screws (18).
  • Page 285 RS 125 - Tuono 125 - Euro 4 Braking system • Remove the two brake pump fastener screws (19). • Disconnect the front brake sensor (20) of the brake pump. • Remove the clamp (21) and the cable fastener (22) to release the brake pump. •...
  • Page 286 RS 125 - Tuono 125 - Euro 4 Braking system • Remove the complete ABS system. REMOVAL OF MODULATOR / ABS CONTROL UNIT • Remove the modulator as described above. • Mark the pipes so that they can be cor- rectly re-installed on the new modula- tor.
  • Page 287 RS 125 - Tuono 125 - Euro 4 Braking system MORE OIL IS REQUIRED TO BLEED THE ABS SYSTEM THAN A CONVENTIONAL SYSTEM. FOR THIS REASON, CAREFULLY CHECK THE OIL LEVEL IN THE BRAKE TANK. • If even after bleeding, the front brake lever feels "spongy", the secondary circuit in the ABS control unit must be bled.

  • Page 288: Contact Technical Service

    RS 125 - Tuono 125 - Euro 4 Braking system The ABS system is disabled! The system operates perfectly just as any other braking system without ABS. The detection of malfunctions may require more or less time according to the type of failure. Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist within a given time.
  • Page 289 RS 125 - Tuono 125 - Euro 4 Braking system ECU INFO screen page Diagnostic tool - Control unit info screen page In this screen page are read the general data re- garding the control unit, for example: type of soft- ware, control unit programming data, etc.
  • Page 290 RS 125 - Tuono 125 - Euro 4 Braking system When turning the wheel or acting on the brake, a variation of parameters must be detected. ACTIVATION screen page On this screen page, you can delete the errors from the memory of the controller and you can en- able some systems controlled by the control unit.

  • Page 291: Braking System

    RS 125 - Tuono 125 - Euro 4 Braking system P.A.D.S. characteristic. Value/example Units of Notes measure ment Rear wheel speed sensor electrical C1031 Short circuit or open circuit to negative or short diagnosis circuit to positive Rear wheel speed sensor functional C1032 Signal not plausible diagnosis...
  • Page 292 RS 125 - Tuono 125 - Euro 4 Braking system • Go to the page Error codes. • Select an error and show the Ambient parameter error(where provided). • Repeat the operation by selecting each error and showing the corresponding Ambient pa- rameter error (where provided).

  • Page 293: Configuration Errors

    RS 125 - Tuono 125 - Euro 4 Braking system SETTINGS screen page This screen is used to adjust some control unit pa- rameters. ADJUSTMENTS Diagnostic tool characteristics Value/example Units of Notes measure ment Disabling of VR-shut down Enabling of VR-shut down EVAC and wires ABS bleeding phase 1 ABS bleeding phase 2...

  • Page 294: Rear Brake Calliper

    RS 125 - Tuono 125 - Euro 4 Braking system C1089 Configuration error Cause of error The configuration stored in the ABS control unit does not correspond to the configuration in the vehicle it is installed on. Troubleshooting Check the control unit mapping and reset the vehicle configuration. CAN LINE ERRORS U2921 Controller error U2922 Line failure (busoff)

  • Page 295: Front Brake Calliper

    RS 125 - Tuono 125 - Euro 4 Braking system • Remove the rear brake calliper. • Unscrew the coupling from the rear brake calliper after placing a container for collecting the brake fluid. CAUTION WHEN FITTING THE REAR BRAKE CALLIPER TIE THE ABS SENSOR CABLE TO THE BLEED PROTECTION CAP.

  • Page 296: Disc Inspection

    RS 125 - Tuono 125 - Euro 4 Braking system • Remove the tone wheel. • Remove the brake disc. Disc Inspection This procedure must be performed with the brake disc installed on the wheel. • Check the disc for wear by measuring the minimum thickness with a micro- meter in different points.

  • Page 297: Front Brake Disc

    RS 125 - Tuono 125 - Euro 4 Braking system Installing • Fit the brake disc and tone wheel in the respective seat. • Fit the six fastener screws and tighten to specified torque. NOTE FIRST HAND-TIGHTEN TIGHTEN ALL THE SCREWS, THEN TIGHTEN TO THE DEFINITIVE TORQUE IN A CROSSED PATTERN IN THE SEQUENCE A-D-B-E-C-F CAUTION...
  • Page 298 RS 125 - Tuono 125 - Euro 4 Braking system • Remove the brake disc. Disc Inspection This procedure must be performed with the brake disc installed on the wheel. • Check the disc for wear by measuring the minimum thickness with a micro- meter in different points.

  • Page 299: Front Brake Pads

    RS 125 - Tuono 125 - Euro 4 Braking system ALL TRACES OF THE OLD THREAD-LOCK SEALANT HAVE BEEN ELIMINATED. Front brake pads Removal • Working on the front brake calliper, on the left side of the vehicle, unscrew and remove the two screws fixing the brake calliper.

  • Page 300: Rear Brake Pads

    RS 125 - Tuono 125 - Euro 4 Braking system • Remove the brake pads. • Check the brake pads. • Measure the thickness of the brake pads. If either one is under the service limit, replace them. Service limit 1.5 mm (0.05 in). WARNING IF THE BRAKE LEVER IS OPERATED WITH THE CLAMP EXTRACTED IT MIGHT BE NECESSARY TO CARRY OUT THE CORRESPONDING BLEEDING.
  • Page 301 RS 125 - Tuono 125 - Euro 4 Braking system • Measure the thickness of the brake pads. If either one is under the service limit, replace them. Service limit 1.5 mm (0.05 in). WARNING IF THE BRAKE LEVER IS OPERATED WITH THE CLAMP EXTRACTED IT MIGHT BE NECESSARY TO CARRY OUT THE CORRESPONDING BLEEDING.
  • Page 302 RS 125 - Tuono 125 - Euro 4 Braking system NOTE THE FOLLOWING OPERATIONS REFER TO ONE FRONT BRAKE CALLIPER ONLY, BUT ARE VALID FOR BOTH. THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE PURG- ING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID.

  • Page 303: Changing The Brake Fluid

    RS 125 - Tuono 125 - Euro 4 Braking system CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON- DITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED. THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED.

  • Page 304: Front Brake Pump

    RS 125 - Tuono 125 - Euro 4 Braking system • Drain the system as for the bleeding procedure, proceeding till reaching the indicated level in the inspection glass. • Place the gasket and the cover and tighten the two fixing screws. WARNING IF THE BRAKE LEVER IS OPERATED WITH THE CLAMP EXTRACTED IT MIGHT BE NECESSARY TO CARRY OUT THE CORRESPONDING BLEEDING.
  • Page 305 RS 125 - Tuono 125 - Euro 4 Braking system Installing Where you need to replace the front brake lever: • Carry out a complete inspection of the piston and the cylinder to check the braking system is working properly. Make sure no other component is dam- aged.

  • Page 306: Rear Brake Pump

    RS 125 - Tuono 125 - Euro 4 Braking system • The measurement must be carried out at the indicated point. CAUTION LIFT THE FRONT WHEEL AT THE END OF THE OPERATION AND CHECK THAT IT SPINS FREE- LY WITH THE BRAKE LEVER IN REST POSITION. CHECK THAT THE BRAKE LEVER HAS FREE STROKE WITHIN THE LIMITS PRESCRIBED IN THE ASSEMBLY PHASE.
  • Page 307 RS 125 - Tuono 125 - Euro 4 Braking system • Unscrew and remove the two screws, and retrieve the respective nuts. • Unscrew and remove the nut, and re- trieve the screw. • Remove the rear brake pump. • To reassemble, repeat the procedure described above in reverse order.
  • Page 308 RS 125 - Tuono 125 - Euro 4 Braking system • Remove the two brake pump fixing screws. • Unscrew the coupling and disconnect the oil pipes from brake pump in order to remove it. BRAK SYS - 308...

  • Page 309: Index Of Topics

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 310 RS 125 - Tuono 125 - Euro 4 Cooling system ADIATOR pos. Description Type Quantity Torque Notes Radiator fixing screw M6x25 10 Nm (7.38 lb ft) Coolant tank fixing screw M6x20 3.5 Nm (2.58 lb ft) ATER PUMP pos. Description Type Quantity Torque...
  • Page 311 RS 125 - Tuono 125 - Euro 4 Cooling system Circuit diagram key: 1. Breather pipe 2. Radiator - expansion tank pipe 3. Cooling liquid reservoir 4. Cap 5. Clamp 6. Clamp D16-24x8 7. D10.1 clamp 8. Water radiator 9. Cap 10.TCEI screw M6x20 11.6.6x18x1.6 washer 12.Elastic plate M6...

  • Page 312: Electric Fan

    RS 125 - Tuono 125 - Euro 4 Cooling system 19.Electric fan 20.Washer 21.Pin 22.Washer 23.Screw 24.Screw Electric fan • Remove the radiator • Undo and remove the three screws and collect the washers; remove the electric fan. See also Removing the radiator Coolant replacement...
  • Page 313 RS 125 - Tuono 125 - Euro 4 Cooling system • Release the clamp. Remove the pipe and drain the coolant into a container of adequate capacity. CAUTION DO NOT DISPOSE OF THE FLUID INTO THE ENVIRONMENT. FILLING THE COOLING SYSTEM •...

  • Page 314: Specific Tooling

    RS 125 - Tuono 125 - Euro 4 Cooling system • Remove the clutch cover; • Heat the clutch cover to facilitate extraction of the water pump spindle assembly; • Support the clutch cover on a press and with the specific tool "B", remove the water pump shaft group, acting from the external part to the internal one.
  • Page 315 RS 125 - Tuono 125 - Euro 4 Cooling system ALWAYS REPLACE THE BEARINGS, THE OIL SEAL, AND THE SEALING RING, WHENEVER IT IS NECESSARY TO REMOVE THE WATER PUMP. • Place the new bearings on the press and with the specific tool "B" push the shaft until it stops;...

  • Page 316: Removing The Radiator

    RS 125 - Tuono 125 - Euro 4 Cooling system • Place the gear paying attention that the operation is oriented to the cover; • Use the specific tool "B" as an endstop in order to push the gear, with the press, until it is in line with the shaft.
  • Page 317 RS 125 - Tuono 125 - Euro 4 Cooling system • Lift the fuel tank and disconnect the electric fan connector. See also Removing the expansion tank • Unscrew the radiator cover and let it connect to the hoses. • Loosen the clamp with a screwdriver.

  • Page 318: Removing The Expansion Tank

    RS 125 - Tuono 125 - Euro 4 Cooling system • Sliding it off the fitting slots, remove the radiator. • Remove the electric fan if necessary. Radiator installation • Install the radiator following the removal operations but in reverse order. •...

  • Page 319: Installation

    RS 125 - Tuono 125 - Euro 4 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 •...
  • Page 320 INDEX OF TOPICS BODYW ODYWORK...
  • Page 321 RS 125 - Tuono 125 - Euro 4 Bodywork EAR LIGHTS pos. Description Type Quantity Torque Notes Turn indicator fastener screw M5x12 3 Nm (2.21 lb ft) Turn indicator cover fastener screw 0.3 Nm (0.22 lb ft) Hex socket button head screw M5x16 3 Nm (2.21 lb ft) SWP screw...
  • Page 322 RS 125 - Tuono 125 - Euro 4 Bodywork EAR BODYWORK Pos. Description Type Quantity Torque Notes Screw fixing the side fairing to the M4x14 3 Nm (2.21 lb ft) chassis Under-saddle fixing screw M5x9 3 Nm (2.21 lb ft) Screw fixing the side fairing to the M5x9 3 Nm (2.21 lb ft)
  • Page 323 RS 125 - Tuono 125 - Euro 4 Bodywork OCKS pos. Description Type Quantity Torque Notes Tank plug fixing screw M5x16 3 Nm (2.21 lb ft) Tank plug fixing screw M5x30 3 Nm (2.21 lb ft) Screw fastening saddle lock plate M6x30 6 Nm (4.43 lb ft) Ignition lock fixing screw...
  • Page 324 RS 125 - Tuono 125 - Euro 4 Bodywork OCKS pos. Description Type Quantity Torque Notes Tank plug fixing screw M5x16 3 Nm (2.21 lb ft) Tank plug fixing screw M5x30 3 Nm (2.21 lb ft) Screw fastening saddle lock plate M6x30 6 Nm (4.43 lb ft) Ignition lock fixing screw...
  • Page 325 RS 125 - Tuono 125 - Euro 4 Bodywork IDE FAIRINGS Pos. Description Type Quantity Torque Notes Side fairing fastening screw M5x16 0.8 Nm (0.59 lb ft) Screw fixing side fairing to engine M5x9 3 Nm (2.21 lb ft) closure Side fairing fastening screw Self tapping 0.4 Nm (0.30 lb ft)
  • Page 326 RS 125 - Tuono 125 - Euro 4 Bodywork IDE FAIRINGS Pos. Description Type Quantity Torque Notes Side fairing fastening screw 3 Nm (2.21 lb ft) Screw fastening inner fairing 3 Nm (2.21 lb ft) Pos. Description Type Quantity Torque Notes Rear tank fixing screw M8x40...
  • Page 327 RS 125 - Tuono 125 - Euro 4 Bodywork OP FAIRING pos. Description Type Quantity Torque Notes Top fairing fastener screw Self tapping 0.4 Nm (0.30 lb ft) screw, Ø 3.9 Top fairing screen fastener screw 1 Nm (0.74 lb ft) Rear view mirror fastener screw M6x30 2 Nm (1.48 lb ft)
  • Page 328 RS 125 - Tuono 125 - Euro 4 Bodywork OP FAIRING pos. Description Type Quantity Torque Notes Instrument panel fastening screws Self tapping 1 Nm (0.78 lb ft) screw, Ø 4.2 Taillight side panels fixing screws Self tapping 2 Nm (1.48 lb ft) screw, Ø...
  • Page 329 RS 125 - Tuono 125 - Euro 4 Bodywork UCTS pos. Description Type Quantity Torque Notes Screw fastening radiator cowl M5x16 2 Nm (1.48 lb ft) Screw fastening upper fairing closing Self tapping 1 Nm (0.74 lb ft) screw, Ø 3.9 Screw fastening radiator cowl M5x20 2 Nm (1.48 lb ft)
  • Page 330 RS 125 - Tuono 125 - Euro 4 Bodywork EAR MUDGUARD Pos. Description Type Quantity Torque Notes Screw fastening rear mudguard to Self-tapping 3 Nm (2.21 lb ft) swingarm M4.8x12 RONT MUDGUARD NGINE FAIRING pos. Description Type Quantity Torque Notes Engine fairing fastening screw M5x16 3 Nm (2.21 lb ft)
  • Page 331 RS 125 - Tuono 125 - Euro 4 Bodywork pos. Description Type Quantity Torque Notes Front mudguard fixing screw M6x25 4.4 Nm (3.25 lb ft) Flanged self-tapping nut 6 Nm (4.43 lb ft) Screw fastening the lower fairing to M5x12 3 Nm (2.21 lb ft) the cradle Front mudguard mounting fixing...
  • Page 332 RS 125 - Tuono 125 - Euro 4 Bodywork RONT LIGHTS pos. Description Type Quantity Torque Notes Headlamp fastener screw M5x14 1.5 Nm (1.11 lb ft) Headlamp fastener screw 1.5 Nm (1.11 lb ft) Turn indicator fastener screw M5x12 3 Nm (2.21 lb ft) Turn indicator cover fastener screw 0.3 Nm (0.22 lb ft) BODYW - 332...
  • Page 333 RS 125 - Tuono 125 - Euro 4 Bodywork RONT LIGHTS pos. Description Type Quantity Torque Notes Headlamp fastener screw M5x14 1.5 Nm (1.11 lb ft) Turn indicator fastener screw M5x12 3 Nm (2.21 lb ft) Turn indicator cover fastener screw Self tapping 0.3 Nm (0.22 lb ft) ASHBOARD...
  • Page 334 RS 125 - Tuono 125 - Euro 4 Bodywork ASHBOARD pos. Description Type Quantity Torque Notes Instrument panel mounting fixing 8 Nm (5.90 lb ft) screw Instrument panel mounting fixing Self tapping 2 Nm (1.48 lb ft) screw screw, Ø 5 Instrument panel fixing screws Self tapping 2.5 Nm (1.84 lb ft)
  • Page 335 RS 125 - Tuono 125 - Euro 4 Bodywork OOTRESTS pos. Description Type Quantity Torque Notes Screw fastening the rider footrest M8x25 25 Nm (18.44 lb ft) Loctite 243 mounting Footrest protection fastening screw M5x12 5 Nm (3.69 lb ft) Passenger footrest bracket fastening M8x40 20 Nm (14.75 lb ft)
  • Page 336 RS 125 - Tuono 125 - Euro 4 Bodywork ILTER BOX Pos. Description Type Quantity Torque Notes Air filter box fastening screw 3.5 Nm (2.58 lb ft) Driving mirrors (RS 125) • Unscrew and remove the two nuts in- side the top fairing, two for each mirror. •...

  • Page 337: Instrument Panel

    RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the protective rubber (1) • Using a suitable wrench unscrew the threaded pin (2) • Remove the right rear view mirror (3) • Repeat the entire procedure to remove the left rear-view mirror Instrument panel (RS 125)
  • Page 338 RS 125 - Tuono 125 - Euro 4 Bodywork • Unscrew and remove the six perimeter screws and remove the two cases. REMOVING INSTRUMENT CLUSTER MOUNT- • Unscrew and remove the two through- passing screws and retrieve the wash- er form the left side and the nut from the right side.
  • Page 339 RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the clamp (6) • Retrieve the four bushings (7) • Turn the instrument panel mounting 180° • Unscrew and remove the screw (8) • Unscrew and remove the screw (9) and retrieve the washer (10) •...
  • Page 340 RS 125 - Tuono 125 - Euro 4 Bodywork • Unscrew and remove the two screws (13) and retrieve the two washers (14) • Disconnect the connector (15) • Remove the instrument panel (16) • Remove the left instrument panel mounting (17) Headlight assy.

  • Page 341: Headlight Fairing

    RS 125 - Tuono 125 - Euro 4 Bodywork • Unscrew and remove the four top fair- ing fastening screws • Remove the light assembly. (TUONO 125) • Remove the top fairing • Unscrew and remove the two screws • Disconnect the two connectors (2) •...
  • Page 342 RS 125 - Tuono 125 - Euro 4 Bodywork • First remove the fairing and the rear- view mirrors. • Unscrew and remove the turn indicator screw. • Remove the glass and disconnect the two bulb wires. • Remove the two screws inside the top fairing from both sides of the motorcy- cle.
  • Page 343 RS 125 - Tuono 125 - Euro 4 Bodywork • Disconnect the instrument panel con- nector. • Remove the top fairing. (TUONO 125) • Remove the side fairings • Unscrew and remove the two screws • Unscrew and remove the two screws •...
  • Page 344 RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the right lamp side panel (5) • Remove the instrument panel dash- board (6) • Undo and remove the screw (7) • Unscrew and remove the screw (8) BODYW - 344...
  • Page 345 RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the rivet (9). • Undo and remove the screw (10) • Retrieve the washer (11) and the spacer (12) • Undo and remove the screw (13) • Retrieve the washer (14) and the bush- ing (15) •...
  • Page 346 RS 125 - Tuono 125 - Euro 4 Bodywork • Disconnect the connector (17) • Disconnect the connector (18) • Remove the front fairing (19) • Unscrew and remove the two screws (20) BODYW - 346...
  • Page 347 RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the top fairing (21) 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 348: Passenger Footrest

    RS 125 - Tuono 125 - Euro 4 Bodywork Taillight assy. • First remove the tail fairing and the passenger seat. • Remove the two side screws (1). • Remove the two top screws (2). • Disconnect the connector. • Take off the rear light unit, by removing it from the hooks.

  • Page 349: Side Body Panels

    RS 125 - Tuono 125 - Euro 4 Bodywork Tail guard Side body panels The following procedure is only shown from one side of the vehicle, but it is valid for both side fair- ings • Remove the saddle • Undo and remove the screw (1) •...
  • Page 350 RS 125 - Tuono 125 - Euro 4 Bodywork The following describe the procedure for removing one fairing but are applicable for both. • Rest the vehicle on its stand. • Remove the side fairing. • Unscrew and remove the two screws (1) and retrieve the washers.
  • Page 351 RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the rivet (3) • Undo and remove the screw (4) • Remove the right side engine fairing • Remove the rivets (6) BODYW - 351...
  • Page 352 RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the rivets (7) • Remove the rivet (8) • Undo and remove the screw (9) • Remove the left side engine fairing (10) BODYW - 352...
  • Page 353 RS 125 - Tuono 125 - Euro 4 Bodywork • Undo and remove the screw (11) • Remove the front right turn indicator from its seat (12) • Undo and remove the screw (13) • Remove the washer (14) • Remove the spacer (15) BODYW - 353...
  • Page 354 RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the inside right side fairing (16) • Remove the clamp (17) • Remove the clamp (18) • Undo and remove the screw (19) BODYW - 354...
  • Page 355 RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the front left turn indicator from its seat (20) • keeping the two screws locked (21) un- screw and remove the two fastening nuts (23) • Retrieve the two washers (22) •...
  • Page 356 RS 125 - Tuono 125 - Euro 4 Bodywork • Undo and remove the screw (27) • Retrieve the washer (28) • Retrieve the washer (29) • Remove the inside left side fairing (30) License plate holder • First remove the passenger saddle. •...
  • Page 357 RS 125 - Tuono 125 - Euro 4 Bodywork • Unscrew and remove the lower central screw. • Unscrew and remove the two lower screws. • Remove the three clamps. • Disconnect the connector. • Remove the licence plate support. BODYW - 357...
  • Page 358 RS 125 - Tuono 125 - Euro 4 Bodywork Air box • Remove the passenger footrest, the saddle, the tank, the fairing and the splash guard. • Unscrew and remove the four screws (1). • Loosen the clamp and remove the in- take tube.

  • Page 359: Rear Mudguard

    RS 125 - Tuono 125 - Euro 4 Bodywork Rear mudguard • Unscrew and remove the screw. • Slide off the pipe grommet. • Operating from the right side, unscrew and remove the central screw. • Working on the left side, unscrew and remove the two screws.
  • Page 360 RS 125 - Tuono 125 - Euro 4 Bodywork • - Remove the side fairings. • Put the vehicle on the optional rear stand, with the side stand open. • Remove the side rivet. • Carry out the following operations on one side of the vehicle and then on the other side.
  • Page 361 RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the lower rivet. • From the right side take out the right half-fairing. • Remove the left engine fairing from the left side, accompanying it along the profile of the stand. (TUONO 125) •...
  • Page 362 RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the pipes (8) from the point shown in the figure • Remove the engine fairing complete with lower fairings • Unscrew and remove the five fixing screws (9) • Remove the lower left fairing (10) •...
  • Page 363 RS 125 - Tuono 125 - Euro 4 Bodywork Fuel tank • Remove the rider saddle. • Working on both sides of the vehicle, undo and remove the lateral screw. • After removing the passenger saddle, lift the saddle and support its weight adequately.

  • Page 364: Radiator Cover

    RS 125 - Tuono 125 - Euro 4 Bodywork • 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 365 RS 125 - Tuono 125 - Euro 4 Bodywork • Unscrew and remove the two lower screws. • Slide off the radiator cover. • Working from both sides of the vehicle, release the two rivets and slide off the front lug. Tail guard (RS 125) •...
  • Page 366 RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the saddle • Remove the side fairings • Unscrew and remove the screw (1) • Unscrew and remove the screw (2) • Unscrew and remove the seven screws (3) •...
  • Page 367 RS 125 - Tuono 125 - Euro 4 Bodywork • Remove the top handle (6) • Unscrew and remove the six screws • Remove the top handle (8) • Unscrew and remove the two screws BODYW - 367...
  • Page 368 RS 125 - Tuono 125 - Euro 4 Bodywork • Undo and remove the screw (10) • Remove the right tail fairing (11). • Unscrew and remove the screws (12) • Undo and remove the screw (13) BODYW - 368...
  • Page 369 RS 125 - Tuono 125 - Euro 4 Bodywork • Disengage the saddle opening cable (14) • Remove the left tail fairing (15). BODYW - 369...
  • Page 370 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 371 RS 125 - Tuono 125 - Euro 4 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...
  • Page 372 RS 125 - Tuono 125 - Euro 4 Pre-delivery - Through the diagnostic tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about avail- able upgrades and details regarding the operation.

  • Page 373: Static Test

    RS 125 - Tuono 125 - Euro 4 Pre-delivery Road test - Cold start - Instrument panel operation - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive:...

  • Page 374: Shift Sensor

    RS 125 - Tuono 125 - Euro 4 Pre-delivery Specific operations for the vehicle (RS 125) To fit the Quick Shift, follow the fitting instructions. • Remove the gear tie-rod by unscrew- ing and removing the two fixing screws. • Place the screw (1) with its compo- nents in the spherical joint of the Quick Shift sensor.
  • Page 375 RS 125 - Tuono 125 - Euro 4 Pre-delivery • Access the Quick Shift connector by lifting the tank, the connector is placed, as shown in the figure, internally on the left side of the chassis. • Connect the two cables. PRE DE - 375...
  • Page 376 ABS: 276, 288 Air filter: 70 Battery: 112, 124 Brake: 294, 295, 297, 299, 300, 303, 304, 306 Brake calliper: 294, 295 Brake disc: 295, 297 Brake fluid: 303 Brake pads: 299, 300 Brake pump: 304, 306 Bulbs: CAN line: 150 Chain: 210, 211, 254, 259 Chain tensioner: 210, 259 Clutch: 73, 139, 180–185...
  • Page 377 Handlebar: Head cover: 200 Headlight: 340, 341 Horn: 119 Identification: 11 Instrument panel: 337 License plate holder: 356 Maintenance: 8, 64 Mirrors: 336 Mudguard: 359 Oil filter: 70 Oil pressure sensor: 137 Primary shaft: 169 Radiator: 312, 316, 364 Rear wheel: 243, 245, 246 Recommended products: 66 Run/Stop switch: 142 Scheduled maintenance: 64...
  • Page 378 Voltage regulator: 116 Warning lights: Water pump: 313 Wiring diagram: 105...

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Tuono 125 euro 4

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