APRILIA RS4 125 Manuals

Manuals and User Guides for APRILIA RS4 125. We have 2 APRILIA RS4 125 manuals available for free PDF download: Service Station Manual, Service Manual

APRILIA RS4 125 Service Station Manual (299 pages)

Brand: APRILIA | Category: Motorcycle | Size: 45.24 MB

Index of Topics
4
Characteristics
5
Safety Rules
6
Carbon Monoxide
6
Hot Components
6
Coolant
6
Maintenance Rules
7
Used Engine Oil and Transmission Oil
7
Brake and Clutch Fluid
7
Battery Electrolyte and Hydrogen Gas
7
Before Disassembling Components
8
Components Removal
8
Reassembling Components
8
Electrical Connectors
8
Running-In
9
Vehicle Identification
9
Tightening Torques
9
Engine
10
Dimensions and Mass
10
Chassis Number
10
Transmission
11
Capacities
11
Gear Ratios
11
Electrical System
11
Spark Plug
11
Warning Lights
12
Frame and Suspensions
12
Wheels and Tyres
12
Tightening Torques
13
Central Part
21
Special Tools
44
Maintenance
49
Maintenance Chart
50
Scheduled Maintenance Table
50
Spark Plug
51
Engine Oil Check
52
Engine Oil Replacement
53
Engine Oil Filter
54
Recommended Products
54
Gearbox Oil
55
Air Filter
55
Cooling System
56
Air Filter Cleaning
56
Level Check
57
Top-Up
57
Braking System Level Check
58
Brake Fluid Check
59
Front Brake Fluid Top-Up
61
Rear Brake Fluid Top-Up
61
Clutch System
62
Adjusting the Lever
62
Electrical System
63
Components Arrangement
64
Electrical System Installation
65
Scope and Applicability
65
Small Parts and Mountings
66
Special Checks for the Correct Connection and Laying of Cables
66
Front Side
67
Wiring Diagram
67
Running of Headlight Cables
68
Headlight Cable Running
68
Speed Sensor
69
Left and Right Positioning of Cables
70
Lights Detail
72
Key Switch
72
Instrument Panel
73
Regulator Positioning
73
Flywheel Positioning
74
Pre-Fitting Chassis
75
Fuel Reserve Probe Pre-Fitting
76
Battery Area Components
81
Running Rear Brake Sensor
82
Lambda Probe and Engine Oil Sensor Cable Run
83
Starter Motor Cable Run
84
Neutral Cable Detail
84
Fuel Tank Cable Harness
85
Back Side
87
Quick Shift Preparation
87
Rear Light Pre-Fitting
87
Rear Light Unit
88
Diagnostics Cable Detail
89
Tail Fairing Cable Harness Clamp
90
General Wiring Diagram
92
Checks and Inspections
94
Dashboard
95
Diagnosis
95
Low Fuel
95
Water Temperature
96
Ignition Circuit
97
Battery Recharge Circuit
98
Recharging System
98
Measurement of Resistance (with Engine Off)
99
Empty Voltage
100
Short Circuit Current
101
Voltage Regulator Check
102
Cold Short Circuit Current
102
Start-Up System Check
103
Starter Motor - Check
103
Start-Up Relay Check
104
Starter Command
104
Electrical Errors
104
Horn Control
105
Level Indicators
105
Lights List
106
Rear Light
107
Front Headlamp
107
Fuses
108
Control Unit
108
Battery
108
Auxiliary Fuses
108
Battery Preparation
110
Electrolyte Preparation
110
Procedure for Filling the Battery with Acid
110
Recharging the New Battery
111
Speed Sensor
113
Engine Rpm Sensor
114
Engine Temperature Sensor
115
Lambda Sensor
117
Injector
119
Fuel Pump
119
Coil
120
Neutral Sensor
122
Side Stand Sensor
122
Electric Fan Circuit
122
Connectors
123
Ecu
124
Engine from Vehicle
126
Vehicle Preparation
127
Removing the Engine from the Vehicle
127
Installing the Engine to the Vehicle
133
Gearbox
140
Gearbox Shafts
140
Disassembling the Gearbox
140
Checking the Primary Shaft
140
Checking the Desmodromic Drum
141
Assembling the Gearbox
141
Starter Motor
142
Removing the Starter Motor
143
Installing the Starter Motor
143
Generator Side
143
Removing the Flywheel Cover
144
Magneto Flywheel Removal
145
Freewheel Removal
147
Installing the Flywheel
147
Clutch Side
148
Removing the Clutch Cover
149
Disassembling the Clutch
151
Checking the Clutch Plates
153
Checking the Clutch Housing
153
Checking the Clutch Hub
154
Checking the Springs
155
Assembling the Clutch
155
Crankcase
157
Balancing Countershaft Removal
158
Balancing Countershaft Fitting
159
Crankcase Opening
160
Bearing Removal
163
Crankcase Check
164
Crankshaft Check
165
Balancing Countershaft Check
166
Bushing Selection
166
Bearing Fitting
166
Crankcase Closing
167
Left Crankcase
167
Head and Timing
171
Removing the Head Cover
172
Removing the Timing Control
174
Cylinder Head
175
Removing the Overhead Camshaft
175
Removing the Valves
177
Checking the Overhead Camshaft
178
Valve Check
178
Inspecting the Valve Sealings
181
Inspecting the Valve Housings
182
Valve Sealing Surface
182
Inspecting the Springs and Half-Cones
183
Checking the Cylinder Head
183
Installing the Valves
183
Checking the Chain Tensioner
184
Checking the Chain
184
Cylinder-Piston Assembly
184
Removing the Cylinder
185
Disassembling the Piston
186
Checking the Piston
187
Inspecting the Wrist Pin
188
Inspecting the Piston Rings
188
Checking the Connecting Rod Small End
189
Fitting the Piston
189
Installing the Cylinder
190
Selecting the Base Gasket
191
Installing the Cylinder Head
191
Base Gasket Selection
191
Lubrication
194
Conceptual Diagrams
195
Power Supply
198
Fuel Tank Inspection
200
Fuel Tank Diagram
201
Removing the Throttle Body
202
Suspensions
204
Front
205
Removing the Front Wheel
207
Checking the Front Wheel
207
Installing the Front Wheel
209
Handlebar
210
Front Fork
210
Removing the Fork Legs
210
Disassembling the Fork
211
Checking the Components
216
Reassembling the Fork
218
Installing the Fork Legs
221
Removing the Rear Wheel
225
Checking the Rear Wheel
227
Flexible Coupling
227
Sprocket
227
Installing the Rear Wheel
228
Shock Absorbers
228
Shock Absorbers Removing
229
Chassis
230
Swinging Arm
232
Installing
234
Pinion
234
Swingarm Pin
234
Drive Chain
238
Chain Tensioner
241
Side Stand
243
Stand Rod Removal
243
Remove Stand Together with the Plate
243
Exhaust
244
Removing the Tail Pipe
244
Removing the Exhaust Manifold
246
Braking System
247
Front Brake Pump
248
Front Caliper
248
Rear Braking System
249
Rear Brake Calliper
249
Front Brake Calliper
251
Rear Brake Disc
252
Disc Inspection
252
Front Brake Disc
253
Front Brake Pads
254
Rear Brake Pads
256
Bleeding the Braking System
257
Changing the Brake Fluid
259
Rear Brake Pump
260
Rimozione
261
Radiator
263
Circuit Diagram
264
Water Pump
264
Electric Fan
265
Coolant Replacement
265
Water Pump
266
Removing the Expansion Tank
271
Bodywork
273
Tank
274
Driving Mirrors
275
Instrument Panel
275
Instrument Panel Support Removal
276
Headlight Assy.
276
Headlight Fairing
277
Front Wheelhouse
279
Taillight Assy.
280
Footrest
281
Side Fairings
281
License Plate Holder
282
Air Box
283
Rear Mudguard
284
Lower Cowl
285
Fuel Tank
286
Rear Wheelhouse
287
Radiator Cover
288
Tail Guard
289
Pre-Delivery
290
Aesthetic Inspection
291
Tightening Torques Inspection
291
Levels Check
292
Road Test
293
Static Test
293
Functional Inspection
293
Specific Operations for the Vehicle
294
Index
296

APRILIA RS4 125 Service Manual (155 pages)

Brand: APRILIA | Category: Motorcycle | Size: 1.53 MB

English

5
- Table of Contents
  5
- General Rules
  9
- Foreword
  10
- Carbon Monoxide
  10
- Fuel
  11
- Hot Components
  13
- Coolant
  13
- Used Engine Oil and Gearbox Oil
  14
- Brake and Clutch Fluid
  15
- Battery Hydrogen Gas and Electrolyte
  16
- Stand
  17
- Reporting of Defects that Affect Safety
  18
- Vehicle
  21
- Arrangement of the Main Components
  22
- Dashboard
  24
- Analog Instrument Panel
  26
- Light Unit
  26
- Setting the Total and Trip Odometers
  27
- Control Buttons
  29
- Advanced Functions
  31
- Ignition Switch
  31
- Locking the Steering Wheel
  32
- Horn Button
  33
- Switch Direction Indicators
  33
- Gear Pedal
  34
- High/Low Beam Selector
  34
- Passing Button
  35
- Start-Up Button
  35
- Accessing the Fuel Tank
  35
- Fairings
  38
- The Saddle
  41
- Opening the Saddle
  41
- Glove/Tool Kit Compartment
  43
- Identification
  44
- Use
  47
- Checks
  48
- Refuelling
  51
- Front Fork Adjustment
  52
- Clutch Lever Adjustment
  53
- Running in
  54
- Starting up the Engine
  55
- Moving off / Riding
  60
- Stopping the Engine
  69
- Parking
  70
- Catalytic Silencer
  72
- Stand
  74
- Suggestion to Prevent Theft
  75
- Maintenance
  79
- Engine Oil Level Check
  80
- Engine Oil Top-Up
  82
- Engine Oil Change
  83
- Engine Oil Filter Replacement
  83
- Tyres
  84
- Spark Plug Dismantlement
  87
- Removing the Air Filter
  90
- Air Filter Cleaning
  91
- Cooling Fluid Level
  92
- Coolant Check
  94
- Coolant Top-Up
  95
- Checking the Brake Oil Level
  97
- Braking System Fluid Top up
  98
- Battery
  99
- Use of a New Battery
  100
- Charging the Battery
  102
- Long Periods of Inactivity
  102
- Fuses
  103
- Fuse Distribution
  105
- Lamps
  106
- Headlight Adjustment
  109
- Front Direction Indicators
  111
- Rear Optical Unit
  112
- Rear Turn Indicators
  112
- Front and Rear Disc Brake
  113
- Periods of Inactivity
  115
- Cleaning the Vehicle
  117
- Transport
  121
- Transmission Chain
  124
- Chain Backlash Check
  125
- Chain Backlash Adjustment
  127
- Checking Wear of Chain, Front and Rear Sprockets
  127
- Chain Lubrication and Cleaning
  129
- Technical Data
  131
- Kit Equipment
  138
- Programmed Maintenance
  141
- Scheduled Maintenance Table
  142
- Table of Recommended Products
  147
Dutch

9
- Algemene Normen
  9
- Voorwaarde
  10
- Koolmonoxide
  10
- Brandstof
  11
- Warme Onderdelen
  13
- Koelvloeistof
  13
- Gebruikte Olie Van Motor en Versnellingsbak
  14
- Rem- en Koppelingsvloeistof
  15
- Elektrolyt en Waterstofgas Van de Accu
  16
- Standaard
  17
- Algemene Waarschuwingen Voorzorgsmaatregelen
  18
- Voertuig
  21
- Plaats Van de Hoofdzakelijke Onderdelen
  22
- Analogisch Instrumentenbord
  26
- Groep Controlelampen
  26
- Instelling Van de Totale en de Partiële Kilometerteller
  27
- Commandotoetsen
  29
- Gevorderde Functies
  31
- Startschakelaar
  31
- Activering Van Het Stuurslot
  32
- Drukknop Voor de Claxon
  33
- Knipperlichtenschakelaar
  33
- Schakelpedaal
  34
- Schakelaar Van de Lichten
  34
- Knop Knippering Groot Licht
  35
- Startknop
  35
- Toegang Tot de Benzinetank
  35
- Bekledingen
  38
- Het Zadel
  41
- Opening Van Het Zadel
  41
- Documentenruimte / Gereedschapskit
  43
- De Identificatie
  44
- Het Gebruik
  47
- Controles
  48
- Tanken
  51
- Regeling Van de Voorvork
  52
- Regeling Van de Hendel Van de Koppeling
  53
- Het Inrijden
  54
- Start Van de Motor
  55
- Het Vertrek en Het Rijden
  60
- Het Stilleggen Van de Motor
  69
- Parkeren
  70
- Katalytische Uitlaat
  72
- Standaard
  74
- Voorstellen Tegen Diefstal
  75
- Het Onderhoud
  79
- Controle Van Het Peil Van de Motorolie
  80
- Het Bijvullen Van Olie in de Motor
  82
- Vervanging Van de Motorolie
  83
- Vervanging Van de Filter Van de Motorolie
  83
- Banden
  84
- Demontage Van de Bougie
  87
- Demontage Van de Luchtfilter
  90
- Reiniging Van de Luchtfilter
  91
- Koelvloeistofpeil
  92
- Controle Van de Koelvloeistof
  94
- Het Bijvullen Van de Koelvloeistof
  95
- Controle Van Het Peil Van de Remvloeistof
  97
- Bijvulling Van de Vloeistof Van Het Remsysteem
  98
- Accu
  99
- Ingebruikname Van Een Nieuwe Accu
  100
- Oplading Van de Accu
  102
- Lange Ernstige Stilstand
  102
- Zekeringen
  103
- Plaats Van de Zekeringen
  105
- Lampen
  106
- Regeling Van de Koplamp
  109
- Voorste Richtingaanwijzers
  111
- Achterste Optische Groep
  112
- Achterste Richtingaanwijzers
  112
- Voorste en Achterste Schijfrem
  113
- Periodes Van Inactiviteit
  115
- Reiniging Van Het Voertuig
  117
- Vervoer
  121
- Transmissieketting
  124
- Controle Van de Speling Van de Ketting
  125
- Regeling Van Speling Van de Ketting
  127
- Controle Van de Slijtage Van de Ketting, Het Rondsel en de Kroon
  127
- Smeren en Reinigen Van de Ketting
  129
- Technische Gegevens
  131
- Bijgevoegd Gereedschap
  138
- Geprogrammeerd Onderhoud
  141
- Tabel Van Het Geprogrammeerd Onderhoud
  142
- Tabel Met Aanbevolen Producten
  147

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