APRILIA RS 125 Manual
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APRILIA RS 125 Manual

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SI QUIERE CONSEGUIR MAS INFORMACIÓN DE MOTOS Y MANUALES
HAGA CLICK AQUI www.infomoto.es
RS 125
FOREWORD
GENERAL INFORMATION
ROUTINE MAINTENANCE
LUBRICATION
FUEL SYSTEM
COOLING SYSTEM
ENGINE
CHASSIS
ELECTRICAL SYSTEM
TROUBLESHOOTING INFORMATION
FOREWORD
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2
3
4
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  • Page 1 SI QUIERE CONSEGUIR MAS INFORMACIÓN DE MOTOS Y MANUALES HAGA CLICK AQUI www.infomoto.es FOREWORD RS 125 FOREWORD GENERAL INFORMATION ROUTINE MAINTENANCE LUBRICATION FUEL SYSTEM COOLING SYSTEM ENGINE CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING INFORMATION 0 - 1...
  • Page 2 FOREWORD RS 125 SUMMARY 0.1. FOREWORD ............................ 3 0.1.1. FOREWORD ........................... 3 0.1.2. REFERENCE MANUALS ......................4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..............5 0 - 2...
  • Page 3 manual.
  • Page 4 FOREWORD RS 125 OWNER’S MANUALS 0.1.2. REFERENCE MANUALS aprilia part# (description) ENGINE WORKSHOP MANUALS Model years 1993 aprilia part# (description) 8140133 (926) 8102260 Model years 1994 8140134 (943) 8102260 PARTS CATALOGUES 8102319 aprilia part# (description) Model years 1995 340X ………...
  • Page 5 FOREWORD RS 125 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = is less than > = is more than < = is less than or equal to > = is more than or equal to = approximately ∞ = infinite °C degrees Celsius (centigrade) °F...
  • Page 6 FOREWORD RS 125 T.E. =hexagonal head TEST = diagnostic check T.P. =flat head screw = Twin Spark Ignition UPSIDE- DOWN = inverted fork =volt =watt Ø = Diameter 0 - 6...
  • Page 7 GENERAL INFORMATION RS 125 GENERAL INFORMATION 1 - 1...

  • Page 8: Table Of Contents

    GENERAL INFORMATION RS 125 SUMMARY 1.1. MANUAL LAYOUT ........................... 3 1.1.1. CONVENTIONS USED IN THE MANUAL ................3 1.1.2. SAFETY INFORMATION......................4 1.2. GENERAL RULES ........................... 5 1.2.1. BASIC SAFETY RULES ......................5 1.3. DANGEROUS ELEMENTS......................8 1.3.1. WARNINGS CONCERNING FUEL, LUBRICANTS, COOLAND AND OTHER COMPONENT PARTS......................

  • Page 9: Manual Layout

    GENERAL INFORMATION RS 125 1.1. MANUAL LAYOUT 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. For quick reference, see the sections index. • Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure.

  • Page 10: Safety Information

    GENERAL INFORMATION RS 125 1.1.2. SAFETY INFORMATION The following conventions are used to identify safety information throughout the manual: This symbol identifies safety-related information. Whenever you see this symbol in the manual or attached to the motorcycle, use utmost care to avoid the risk of injury. Disregarding the instructions...

  • Page 11: General Rules

    GENERAL INFORMATION RS 125 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a well- aerated room. Avoid starting the engine in closed or badly-ventilated rooms.
  • Page 12 GENERAL INFORMATION RS 125 DANGER Be careful not to spill the coolant on the red-hot parts of the engine and the exhaust system: it may catch fire and send out invisible flames. In case any maintenance operation should be required, it is advisable to use latex gloves.
  • Page 13 Never clean a bearing with compressed air. NOTE All bearings must rotate freely with no hardness or noise. Replace any bearings that do not meet these requirements. Use ORIGINAL aprilia SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly.

  • Page 14: Dangerous Elements

    GENERAL INFORMATION RS 125 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS CONCERNING FUEL, LUBRICANTS, COOLAND AND OTHER COMPONENT PARTS FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refuelling or in the proximity of sources of fuel vapours.
  • Page 15 GENERAL INFORMATION RS 125 DANGER In case of wet ground the braking distance will be doubled, since both brakes and tyres drives on the road surface are extremely reduced by the water present on the road surface. Any water on brakes, after washing the vehicle or driving on a wet road surface or crossing puddles or gips, can wet brakes so as to greatly reduce their efficiency.
  • Page 16 GENERAL INFORMATION RS 125 Check coolant level before each ride and every 1500 km (932 mi), see 2.10.1. Change coolant every two years, 5.2.1. Coolant mixture is a 50% solution of water and anti-freeze. This is the ideal solution for most operating temperatures and provides good corrosion protection.

  • Page 17: Running-In

    GENERAL INFORMATION RS 125 1.4. RUNNING-IN 1.4.1. RUNNING-IN RECOMMENDATIONS The running-in of the engine is essential to ensure its duration and correct functioning. If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes undergo a more effective running-in.

  • Page 18: Vehicle Identification Data

    GENERAL INFORMATION RS 125 1.5. VEHICLE IDENTIFICATION DATA 1.5.1. SERIAL NUMBERS LOCATION The vehicle serial numbers are used for its homologation. NOTE Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. In...

  • Page 19: Using Tools And Spare Parts

    Should some parts be replaced, use aprilia Original Spare Parts only. aprilia high-quality Original Spare Parts have been expressly designed and manufactured for aprilia vehicles. WARNING The use of aprilia non original spare parts can impair the vehicle performance or cause serious damage to the vehicle itself. 1 - 13...

  • Page 20: Use Of Products

    GENERAL INFORMATION RS 125 1.6.2. USE OF PRODUCTS For all maintenance operations, use the product listed below only. The listed materials have been tested for many years and are suitable for all the applications specified by the manufacturer. NOTE Consumer goods, article number, are available upon request (see table) .

  • Page 21: Special Tools

    GENERAL INFORMATION RS 125 1.6.3. SPECIAL TOOLS Special and suitable tools are required to carry out the disassembly and reassembly operations as well as for a correct setting up. The use of special tools avoids any possible damage arising from the use of non-suitable tools and/or the implementation of improvised procedures.

  • Page 22: General Tightening Torque Settings

    GENERAL INFORMATION RS 125 1.6.4. GENERAL TIGHTENING TORQUE SETTINGS The table shows the standard tightening torque settings for ISO thread screws and bolts. Screw or bolt Wrench Tightening torque thread M 10 M 12 M 14 M 16 13.0 For special couplings on this vehicle, refer to 2.3.4.

  • Page 23: Technical Data

    GENERAL INFORMATION RS 125 1.6.5. TECHNICAL DATA DIMENSIONS Max. length 1950 mm Max. length (with the optional rear mudguard extension). 2005 mm Max. width 720 mm Max. heigth (front part of the fairing included) 1135 mm Seat height 805 mm...
  • Page 24 GENERAL INFORMATION RS 125 FUEL SUPPLY SYSTEM Type Carburettor FUEL SUPPLY Fuel Premium-grade petrol according to DIN 51 600 (4 Stars - UK-), min. O.N. 98 (N.O.R.M.) and 88 (N.O.M.M.) Fuel ( AUS) Premium-grade unleaded petrol according to DIN 51 607, min.

  • Page 25: Stands

    GENERAL INFORMATION RS 125 1.7. STANDS 1.7.1. POSITIONING THE VEHICLE ON THE FRONT SERVICE STAND (OPT) • Position the vehicle on the appropriate rear service stand (OPT), see 1.7.2. • Insert the two ends of the stand (1) in the two holes positioned on the lower ends of the front fork.

  • Page 26: Positioning The Vehicle On The Rear Service Stand (Opt)

    GENERAL INFORMATION RS 125 1.7.2. POSITIONING THE VEHICLE ON THE REAR SERVICE STAND (OPT) • Screw and tighten the pin (1) into its proper location on the rear swingarm. NOTE Have someone help you keep the vehicle in vertical position with the two wheels on the ground.

  • Page 27: Products

    GENERAL INFORMATION RS 125 1.8. PRODUCTS 1.8.1. LUBRICANT CHART LUBRICANT PRODUCT Gear oil RECOMMENDED: F.C., SAE 75W - 90 or GEAR SYNTH, SAE 75W – 90. As an alternative to the recommended oils, it is possible to use select oils having properties in compliance with or even above A.P.I. GL-4 specifications.

  • Page 28: Decals Instructions

    GENER AL INFORMATION RS 125 1.8.2. DECALS INSTRUCTIONS Should some frame parts be removed: NOTE Plastic and painted parts shall be handled with care. Do not score or damage them. Operate with care. Do not damage keys and/or keyways. When sticking decals, carefully follow the instructions listed herebelow.
  • Page 29 GENERAL INFORMATION RS 125 NOTE If present, remove the application tape (5) 20 to 30 minutes after applying the decal. • Remove the application tape (5) from the decal surface. • To ensure a good adhesion, use the spatule again by taking special care to the corners and edges.
  • Page 30 GENERAL INFORMATION RS 125 1 - 24...
  • Page 31 ROUTINE MAINTENANCE RS 125 ROUTINE MAINTENANCE 2 - 1...
  • Page 32 ROUTINE MAINTENANCE RS 125 SUMMARY 2.1. ROUTINE MAINTENANCE ......................4 2.1.1. INTRODUCTION ........................4 2.1.2. REGULAR SERVICE INTERVALS CHART ................5 2.2. POINTS TO BE LUBRICATED ......................6 2.2.1. POINTS TO BE LUBRICATED....................6 2.3. MULTIFUNCTION COMPUTER ...................... 7 2.3.1.

  • Page 33: Routine Maintenance

    ROUTINE MAINTENANCE RS 125 2.21.3. ADJUSTING THE DRIVE CHAIN ..................54 2.21.4. CHECKING CHAIN AND SPROCKETS FOR WEAR ............55 2.21.5. CLEANING AND LUBRICATION..................56 2.21.6. CHAIN SLIDER INSPECTION...................57 2 - 3...

  • Page 34: Introduction

    2.1. ROUTINE MAINTENANCE 2.1.1. INTRODUCTION To keep your vehicle in top performance conditions, aprilia strongly recommends to respect the routine maintenance schedule for the different parts of the vehicle. This section describes the routine maintenance operations for vehicle main components.

  • Page 35: Regular Service Intervals Chart

    ROUTINE MAINTENANCE RS 125 2.1.2. REGULAR SERVICE INTERVALS CHART Parts After running-in Every 4000 km Every 8000 km [1000 km (2485 mi) or (4970 mi) or (621 mi)] 12 months 24 months Rear shock absorber Battery – Terminals tightening – Electrolyte level...

  • Page 36: Points To Be Lubricated

    ROUTINE MAINTENANCE RS 125 LUBRICATING CHART 2.2. POINTS TO BE LUBRICATED Steering bearing Clutch lever pin 2.2.1. POINTS TO BE LUBRICATED Rider right footpeg pin Rider left footpeg pin A good lubrication ensures vehicle smooth operation and Passenger left footpeg pin durability.

  • Page 37: Multifunction Computer

    ROUTINE MAINTENANCE RS 125 2.3. MULTIFUNCTION COMPUTER 2.3.1. MULTIFUNCTION COMPUTER 13. LAP push button 14. MODE push button( ) 15. LOCK push button ( ) 16. START push button ( ) 17. Upper display 18. Lower display FUNCTIONS DESCRIPTION •...
  • Page 38 ROUTINE MAINTENANCE RS 125 VBAT (battery voltage) • If the push button is pressed once more, the battery voltage expressed in volt (1) appears on the display. • The recharge circuit functions correctly if at 4000 rpm the battery voltage with low beam on is included between 13 and 15 V.
  • Page 39 ROUTINE MAINTENANCE RS 125 Recalling the lap times (LAP MEMORY). • To recall lap times, press key • The “Ld” wording will appear on the display. • To scroll the stored lap times, press the “LAP” (2) push button. •...

  • Page 40: Instruments And Indicators Table

    ROUTINE MAINTENANCE RS 125 2.3.2. INSTRUMENTS AND INDICATORS TABLE Description Function Direction indicator warning light Blinks when the direction indicators are on. High beam warning light ( Comes on when the front high beam bulb is on or when the passing is operated.

  • Page 41: Nut, Bolt, Screw Tightening

    ROUTINE MAINTENANCE RS 125 2.3.3. NUT, BOLT, SCREW TIGHTENING Check after the first 1000 km (621 mi) and then every 4000 km (2485 mi) or 12 months. Check all fastening parts with accuracy. Mainly check all safety-related components and, in particular: Handlebar-to-upper plate fastener;...

  • Page 42: Fastening Elements

    ROUTINE MAINTENANCE RS 125 2.3.4. FASTENING ELEMENTS Check and, if necessary, tighten after the first 1000 km (621 mi) and after every 4000 km (2485 mi) or 12 months. WARNING The fastening elements specified in the table must be tightened to the specified torque value using a ®...
  • Page 43 ROUTINE MAINTENANCE RS 125 ENGINE Q.ty Screw/Nut Notes Description Tcei screw frame head connector Tcei M8x20 Upper front engine mount Tcei M10x120 Lower front engine mount Tepf M10x205 Rear engine mount Tcei M8x85 Gearbox transmission conrod mounting Te fi M6x20...
  • Page 44 ROUTINE MAINTENANCE RS 125 ELECTRICAL PARTS Q.ty Screw/Nut Notes Description Battery box mount plate mounting Te fi M5x25 Te fi M6x16 Horn mounting Te fi M8x16 Frame / battery box fixing Tcei M8x30 Oil tank and tail guard mounting Te fi M6x20...

  • Page 45: Battery

    ROUTINE MAINTENANCE RS 125 2.4. BATTERY 2.4.1. BATTERY Carefully read 1.2.1. Two different types of battery are available on the market: battery needing to be maintained with plugs; maintenance-free battery without plugs needing electrolyte level check and topping up. After the first 1000 km (621 mi) and then every 4000 km (2485 mi) or 12 months, check the electrolyte level and the terminals correct tightening.

  • Page 46: Checking And Cleaning The Terminals

    ROUTINE MAINTENANCE RS 125 2.4.2. CHECKING AND CLEANING THE TERMINALS Carefully read 2.4.1. • Make sure that the ignition switch is in position " ". • Raise the fuel tank, see 2.9.1. • Make sure that the cable terminals (1) and the battery...

  • Page 47: Checking The Battery Electrolyte Level

    ROUTINE MAINTENANCE RS 125 2.4.3. CHECKING THE BATTERY ELECTROLYTE LEVEL Carefully read 2.4.1. • Lift the fuel tank, see 2.9.1. • Keep the vehicle in vertical position, with the two wheels resting on the ground. • Make sure that the fluid level is included between the “MIN”...

  • Page 48: Recharging The Battery

    ROUTINE MAINTENANCE RS 125 2.4.4. RECHARGING THE BATTERY Carefully read 2.4.1. NOTE If the battery is almost fully flat, when the starting button " " is pressed, the starting relay will issue a vibrating noise. Do not remove the battery plugs: without plugs the battery may be damaged.

  • Page 49: Long Inactivity Of The Battery

    ROUTINE MAINTENANCE RS 125 2.4.5. LONG INACTIVITY OF THE BATTERY Carefully read 2.4.1. WARNING If the vehicle remains unused for more than twenty days, disconnect the 20A fuses, in order to avoid the deterioration of the battery caused by the current consumption due to the multifunction computer.

  • Page 50: Electrical Parts

    ROUTINE MAINTENANCE RS 125 2.5. ELECTRICAL PARTS 2.5.1. ELECTRICAL PARTS Carefully read 1.2.1. Check after the first 1000 km (621 mi) and then every 4000 km (2485 mi) or 12 months. • Position the vehicle on the stand. • Make sure that all lighting devices are working properly.

  • Page 51: Spark Plugs

    ROUTINE MAINTENANCE RS 125 2.6. SPARK PLUGS 2.6.1. SPARK PLUGS TIGHTENING TORQUE SETTINGS Spark plug tightening torque: 20 Nm (2.0 kgm). Check the spark plug after the first 1000 km (621 mi) and then after 4000 km (2485 mi), change it every 8000 km (4970 mi).
  • Page 52 ROUTINE MAINTENANCE RS 125 WARNING The spark plug must be well tightened, otherwise the engine may overheat and be seriously damaged. Use the recommended type of spark plugs only, in order not to compromise the life and performance of the engine.

  • Page 53: Air Cleaner

    ROUTINE MAINTENANCE RS 125 2.7. AIR CLEANER 2.7.1. AIR CLEANER • Check the air cleaner every 4000 km (2485 mi) or 12 months, change it every 8000 km (4970 mi) or more frequently if the vehicle is used on dusty or wet roads.

  • Page 54: Tubes

    ROUTINE MAINTENANCE RS 125 2.8. TUBES 2.8.1. TUBES FUEL Check fuel lines every 4000 km (2485 mi) or 12 months. Change them every four years. WARNING In case of wear, cracking or other damage, change the fuel lines. For further information, see section 4 (FUEL SYSTEM).

  • Page 55: Fuel Tank

    ROUTINE MAINTENANCE RS 125 2.9. FUEL TANK 2.9.1. LIFTING THE FUEL TANK Carefully read 1.2.1 TIGHTENING TORQUE SETTINGS Tank front screw (1) 7 Nm (0.7 kgm). • Turn the fuel cock to the “OFF” position. • Remove the seat, see 7.1.1.

  • Page 56: Coolant

    ROUTINE MAINTENANCE RS 125 2.10. COOLANT 2.10.1. CHECKING AND TOPPING UP THE COOLANT LEVEL Carefully read 1.2.1 1.3.1 • Check the coolant level before starting and change it every two years. WARNING Check the coolant level and top up the expansion reservoir with cold engine.

  • Page 57: Clutch

    ROUTINE MAINTENANCE RS 125 2.11. CLUTCH 2.11.1. ADJUSTING THE CLUTCH Clutch shall be adjusted when the engine is coming to a stop or when the vehicle tends to move with the clutch lever pulled and a gear is engaged or, if the clutch is “slipping”, the deceleration will be delayed if compared to the engine rpm.
  • Page 58 ROUTINE MAINTENANCE RS 125 • Use the special wrench (5) to loosen the inner nut (6). • Fit a flat screwdriver into the special wrench (5) and fully screw the adjuster (7). • Loosen the adjuster (7) by half of a turn, namely 3 to 4 mm of the lever travel (8).

  • Page 59: Brake Fluid

    ROUTINE MAINTENANCE RS 125 2.12. BRAKE FLUID 2.12.1. CHECKING AND TOPPING UP THE FRONT BRAKE FLUID LEVEL Carefully read 1.2.1 1.3.1. Check the brake fluid after the first 1000 km (621 mi) and then every 4000 km (2485 mi) or 12 months, change it every year.
  • Page 60 ROUTINE MAINTENANCE RS 125 • Remove the gasket (2). NOTE In order not to spill the brake fluid while topping up, do not shake the vehicle. • Top up tank (3) with brake fluid, see 1.8.1 until reaching the correct level between the "MIN"...

  • Page 61: Changing The Brake Fluid

    ROUTINE MAINTENANCE RS 125 2.12.2. CHANGING THE BRAKE FLUID Carefully read 1.2.1. and 1.3.1. • Brake fluid must be changed every year. NOTE These operations apply to both front and rear brakes. WARNING When using the fluid, take care not to spill it on the plastic and painted parts, since it damages them.

  • Page 62: Checking The Brake Pad Wear

    ROUTINE MAINTENANCE RS 125 2.12.3. CHECKING THE BRAKE PAD WEAR Carefully read 1.2.1, 1.3.1.and 2.1.2. NOTE The following information refer to a single braking system, but are valid for both. Check the brake pad wear after the first 1000 km (621 mi) and successively every 2000 km (1242 mi).

  • Page 63: Checking And Topping Up The Rear Brake Fluid

    ROUTINE MAINTENANCE RS 125 2.12.4. CHECKING AND TOPPING UP THE REAR BRAKE FLUID Carefully read 1.2.1 and see 1.3.1. Check the brake fluid after the first 1000 km (621 mi) and then every 4000 km (2485 mi) or 12 months, change it every year.
  • Page 64 ROUTINE MAINTENANCE RS 125 NOTE In order not to spill the brake fluid while topping up, keep the fluid in the reservoir parallel to the tank rim (in horizontal position). • Remove the gasket (3). • Using a syringe, top up fluid inside the brake tank (1), 1.8.1, until reaching the correct level...

  • Page 65: Bleeding The Braking Systems

    ROUTINE MAINTENANCE RS 125 2.12.5. BLEEDING THE BRAKING SYSTEMS Carefully read 1.2.1 1.3.1. For maintenance operations, see 2.1.2. The air, if any, present inside the hydraulic circuit will serve as “pad” by absorbing most of the pressure coming from the brake master cylinder and thus reducing the calipers efficiency during braking.
  • Page 66 ROUTINE MAINTENANCE RS 125 REAR BRAKE TIGHTENING TORQUE VALUES Screws (3-4) 3 Nm (0.3 kgm) Screws (7) 22 Nm (2.2 kgm) • Top up brake fluid inside tank, see 2.12.4. • Undo and remove the two screws (3-4). Keep the two cable guides (5-6) with washers.

  • Page 67: Adjusting The Rear Brake Control Lever

    ROUTINE MAINTENANCE RS 125 2.13. ADJUSTING THE REAR BRAKE CONTROL LEVER 2.13.1. ADJUSTING THE REAR BRAKE CONTROL LEVER The brake pedal is placed in an ergonomic position during vehicle assembly. If necessary, the brake pedal height can be adjusted to fit your riding position: •...

  • Page 68: Adjusting The Gearbox Lever

    ROUTINE MAINTENANCE RS 125 2.14. ADJUSTING THE GEARBOX LEVER 2.14.1. ADJUSTING THE GEARBOX LEVER The gearbox lever can be adjusted using the transmission rod (1). Proceed as follows: • Loosen the nuts (2, 3). • Rotate the transmission rod and adjust the gearbox lever height.

  • Page 69: Throttle

    ROUTINE MAINTENANCE RS 125 2.15. THROTTLE 2.15.1. THROTTLE Inspect after the first 1000 km (621 mi) and every 4000 km (2485 mi) or 12 months afterwards. CHECKING FOR THROTTLE PROPER OPERATION CAUTION Throttle operation may be impaired when the throttle cables are damaged, bent in...
  • Page 70 ROUTINE MAINTENANCE RS 125 mixer oil pump adjuster (3); cable end-caps; throttle control. • Check throttle cable play adjustment, see 2.15.1. THROTTLE CABLE PLAY ADJUSTMENT There should be 2–3 mm free play in the throttle twistgrip cable (measured at twistgrip edge).

  • Page 71: Idling Adjustment

    ROUTINE MAINTENANCE RS 125 2.15.2. IDLING ADJUSTMENT Adjust as follows whenever idling speed seems erratic. • Ride a few kilometres until warming engine up to regular operating temperature. • Place the gearbox in neutral. • Look at engine idle speed (rpm) on the rev counter.

  • Page 72: Cold-Start Cable Play Adjustment

    ROUTINE MAINTENANCE RS 125 2.15.3. COLD-START CABLE PLAY ADJUSTMENT There should be 2-3 mm free play in the cold-start cable. Play is adjusted as follows: • Place the motorcycle on the stand. • Lift the fuel tank; see 2.9.1. •...

  • Page 73: Front End

    ROUTINE MAINTENANCE RS 125 2.16. FRONT END 2.16.1. STEERING Inspect after the first 1000 km (621 mi) and every 4000 km (2485 mi) or 12 months afterwards. The steering is fitted with rolling bearings to ensure smooth handling. Proper steering adjustment is vital to smooth steering movement and safe riding.

  • Page 74: Front Suspension

    ROUTINE MAINTENANCE RS 125 2.16.2. FRONT SUSPENSION The front suspension is managed by a hydraulic fork, which is held to the steering stem by two yokes. NOTE Vehicle set-up may not be modified. Change front fork oil every 12,000 km (7456 mi).

  • Page 75: Tail Section

    ROUTINE MAINTENANCE RS 125 2.17. TAIL SECTION 2.17.1. REAR SWINGING ARM INSPECTION Periodically check that the nut-and-spindle assembly and the needle roller bearings of the swinging arm are properly tightened. Inspection procedure: • Place the motorcycle on the front service stand (OPT);...

  • Page 76: Rear Suspension

    ROUTINE MAINTENANCE RS 125 2.17.2. REAR SUSPENSION Read 1.2.1 carefully. The rear suspension is managed by a spring/damper unit that is connected to the frame and to the rear swinging arm through silent-blocks and a linkage system, respectively. To modify vehicle response, the rear shock absorber is fitted with an adjuster nut (1) which controls spring preload (2).

  • Page 77: Rear Swinging Arm Adjustment

    ROUTINE MAINTENANCE RS 125 2.17.3. REAR SWINGING ARM ADJUSTMENT Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Spindle (1) 100 Nm (10.0 kgm). Lockring (2) 35 Nm (3.5 kgm). Lockring adjusting bush (3) 12 Nm (1.2 kgm). • Put the motorcycle on the front wheel stand (OPT), 1.7.1.

  • Page 78: Inspecting The Rear Suspension Linkage System

    ROUTINE MAINTENANCE RS 125 2.17.4. INSPECTING THE REAR SUSPENSION LINKAGE SYSTEM Read 1.2.1 carefully. Check bearings every 4000 km (2485 mi). NOTE An assistant will be required to keep the vehicle upright during the procedure. • Hold the tail of the motorcycle firmly with your hands.

  • Page 79: Wheels

    ROUTINE MAINTENANCE RS 125 2.18. WHEELS 2.18.1. WHEELS Read 1.2.1 carefully. FRONT WHEEL Check every 4000 km (2485 mi). • Place the vehicle on the front wheel stand; see 1.7.1. • Rotate the wheel manually in both directions. • The wheel should be spinning smoothly, with no hardness or unusual noise.

  • Page 80: Tyres

    Using tyres other than the specified sizes may change vehicle behaviour, impair handling and make the vehicle unsafe to ride. Use only the first-equipment tyre types selected by aprilia; see 1.7.1. MINIMUM RECOMMENDED TREAD DEPTH (A): Front and rear tyre 2 mm (2 mm).

  • Page 81: Exhaust System

    ROUTINE MAINTENANCE RS 125 2.20. EXHAUST SYSTEM 2.20.1. EXHAUST MANIFOLD NUTS Tighten the exhaust manifold nuts after the first 1000 km (621 mi) and every 4000 km (2485 mi) or 12 months afterwards. DANGER Allow the engine to cool down to ambient temperature.

  • Page 82: Drive Chain

    ROUTINE MAINTENANCE RS 125 2.21. DRIVE CHAIN 2.21.1. DRIVE CHAIN Read 1.2.1 carefully. Inspect and lubricate as required every 500 km (310 mi). This motorcycle is equipped with a master link chain. When dismantling and refitting the chain, be sure to install the master link clip (1) with the open end pointing away from the direction of chain movement (see figure).

  • Page 83: Chain Slack Inspection

    ROUTINE MAINTENANCE RS 125 2.21.2. CHAIN SLACK INSPECTION To check chain slack: • Stop the engine. • Place the vehicle on the stand. • Put the gearbox in neutral. • Check chain slack in the lower straight portion of chain.

  • Page 84: Adjusting The Drive Chain

    ROUTINE MAINTENANCE RS 125 2.21.3. ADJUSTING THE DRIVE CHAIN TORQUE WRENCH SETTINGS Rear wheel spindle nut 100 Nm (10.0 kgm). If inspection proved the need for adjustment, set drive chain as follows: • Position the vehicle on the rear wheel stand (OPT), 1.7.2.

  • Page 85: Checking Chain And Sprockets For Wear

    ROUTINE MAINTENANCE RS 125 2.21.4. CHECKING CHAIN AND SPROCKETS FOR WEAR Visually inspect chain, front and rear sprockets looking for: • Damaged chain rollers. • Loose chain link pins. • Dry, rusty, warped or seized links. • Exceeding wear. •...

  • Page 86: Cleaning And Lubrication

    TINE MAINTENANCE RS 125 2.21.5. CLEANING AND LUBRICATION WARNING utmost care when adjusting, lubricating, washing or replacing the chain. Lubricate the chain every 500 km (310 mi) and whenever it seems appropriate. Lubricate with aerosol lubricant for chains or SAE 80W-90 oil.

  • Page 87: Chain Slider Inspection

    ROUTINE MAINTENANCE RS 125 2.21.6. CHAIN SLIDER INSPECTION • Place the vehicle on the stand. • Check the chain slider (1) for damage or wear. Replace as required; see 7.1.15. 2 - 57...
  • Page 88 ROUTINE MAINTENANCE RS 125 2 - 58...
  • Page 89 LUBRICATION RS 125 LUBRICATION 3 - 1...
  • Page 90 LUBRICATION RS 125 SUMMARY REMOVING THE ENGINE OIL TANK ..................... 3 3.1.1 REMOVING THE ENGINE OIL TANK..................3 3 - 2...
  • Page 91 LUBRICATION RS 125 REMOVING THE ENGINE OIL TANK 3.1.1 REMOVING THE ENGINE OIL TANK Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Screw (4) 5 Nm (0.5 kgm) Screws (5) 3 Nm (0.3 kgm) • Remove the seat; see 7.1.1. • Disconnect the two connectors (1).
  • Page 92 LUBRICATION RS 125 THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK 3 - 4...
  • Page 93 FUEL SYSTEM RS 125 FUEL SYSTEM 4 - 1...
  • Page 94 FUEL SYSTEM RS 125 SUMMARY 4.1. FUEL TANK............................3 4.1.1. FUEL TANK REMOVAL ......................3 4.1.2. DRAINING THE FUEL TANK ....................4 4.1.3. COMPLETE REMOVAL OF THE FUEL COCK ..............5 4.2. AIR CLEANER..........................6 4.2.1. AIRBOX REMOVAL......................... 6 4.2.2.

  • Page 95: Fuel Tank

    FUEL SYSTEM RS 125 4.1. FUEL TANK 4.1.1. FUEL TANK REMOVAL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Fuel tank rear mounting bolt (3) 7 Nm (0.7 Kgm). NOTE It is not necessary to drain the fuel. • Lift the fuel tank; see 2.9.1.

  • Page 96: Draining The Fuel Tank

    FUEL SYSTEM RS 125 4.1.2. DRAINING THE FUEL TANK Read 1.3.1 carefully. DANGER Fire hazard! Allow the engine and exhaust silencers to cool down completely. Fuel vapours are harmful to human health. Ensure that the room is well ventilated before proceeding.

  • Page 97: Complete Removal Of The Fuel Cock

    FUEL SYSTEM RS 125 4.1.3. COMPLETE REMOVAL OF THE FUEL COCK TORQUE WRENCH SETTINGS Fuel cock retaining screws 3 Nm (0.3 kgm) Read 1.2.1 1.3.1 carefully. • Drain the fuel tank; see 4.1.2. • Remove the fuel tank; see 4.1.1.

  • Page 98: Air Cleaner

    FUEL SYSTEM RS 125 4.2. AIR CLEANER 4.2.1. AIRBOX REMOVAL TORQUE WRENCH SETTINGS Screws (1) 5 Nm (0.5 Kgm). Screws (2) 5 Nm (0.5 Kgm). • Remove the fuel tank; see 4.1.1. • Release and remove the two screws (1).

  • Page 99: Air Cleaner Removal

    FUEL SYSTEM RS 125 4.2.2. AIR CLEANER REMOVAL TORQUE WRENCH SETTINGS Screws (1) 5 Nm (0.5 Kgm). Screws (2) 5 Nm (0.5 Kgm). • Lift the fuel tank; see 2.9.1. • Release and remove the two screws (1). • Release and remove the two screws (2) and collect the nuts from beneath the screws.

  • Page 100: Carburetor

    FUEL SYSTEM RS 125 4.3. CARBURETOR 4.3.1. CARBURETOR REMOVAL Read 1.2.1 1.3.1 carefully. • Remove the airbox. • Slacken the clip (1). • Ease the carburetor (2) off the intake manifold. • Block off the intake manifold with a cloth to prevent the ingress of debris into the engine.

  • Page 101: Removing The Fuel Feed Filter

    FUEL SYSTEM RS 125 4.3.2. REMOVING THE FUEL FEED FILTER Read 1.2.1 1.3.1 carefully. • Close the fuel cock. • Lift the fuel tank; see 2.9.1. • Release and remove the screw (1). • Remove the cap (2). • Remove the fuel filter (3).

  • Page 102: Carburetor Specifications 1999-2002

    FUEL SYSTEM RS 125 4.3.3. CARBURETOR SPECIFICATIONS 1999-2002 Description Dimensions Countries Model Carburetor phbh 28 bd B-D-E-F-I-SF 11kW-MP AUS-B-D- DK-E-GR- phbh 28-bd f.p. J-NL-P-SGP phbH 28-Rd f.p.-MP phbh 28 bd 11 kW -SF phbH 28-Bd 80km phbH 28-Bd 11 kW -MP...
  • Page 103 COOLING SYSTEM RS 125 COOLING SYSTEM 5 - 1...
  • Page 104 COOLING SYSTEM RS 125 SUMMARY 5.1. COOLING SYSTEM DIAGRAM ....................... 3 5.1.1. COOLING SYSTEM DIAGRAM ....................3 5.2. COOLANT ............................4 5.2.1. COOLANT CHANGE ....................... 4 5.3. RADIATOR ............................5 5.3.1. RADIATOR ..........................5 5.4. THERMISTOR..........................6 5.4.1. COOLANT THERMISTOR....................... 6 5.5.
  • Page 105 COOLING SYSTEM RS 125 5.1. COOLING SYSTEM DIAGRAM 5.1.1. COOLING SYSTEM DIAGRAM An engine-driven centrifugal pump accommodated in the engine circulates coolant through the system. The pump takes in the coolant from the bottom section of the radiator and directs it through the ducts into the cylinders and cylinder heads to cool down engine internals.

  • Page 106: Cooling System Diagram

    COOLING SYSTEM RS 125 5.2. COOLANT 5.2.1. COOLANT CHANGE Read 1.2.1 1.3.1 carefully. Change coolant every two years. • Remove left-hand side fairing; 7.1.2. • Lift the fuel tank; see 2.9.1. • Place a container with capacity greater than 1 litre under the drain plug (1) to collect coolant.

  • Page 107: Radiator

    COOLING SYSTEM RS 125 5.3. RADIATOR 5.3.1. RADIATOR Read 1.2.1 1.3.1 carefully. TORQUE WRENCH SETTINGS Radiator to frame mounting screw (3): 10 Nm (1.0 kgm). REMOVAL • Drain all coolant from the cooling circuit; see 5.2.1. • Remove the right-hand side fairing; see 7.1.2.

  • Page 108: Thermistor

    COOLING SYSTEM RS 125 5.4. THERMISTOR 5.4.1. COOLANT THERMISTOR Read 1.2.1 1.3.1 carefully. REMOVAL • Lift the fuel tank; see 4.1.1. • Remove the rubber cover (1). • Disconnect the electrical connector (2). • Unscrew and remove the thermistor (3).

  • Page 109: Thermostat

    COOLING SYSTEM RS 125 5.5. THERMOSTAT 5.5.1. 70° THERMOSTAT Read 1.2.1 1.3.1 carefully. TORQUE WRENCH SETTINGS Cylinder head cover screws (5): 10 Nm (1.0 kgm) Thermostat bridge retaining screws (6): 6 Nm (0.6 kgm) REMOVAL • Drain all coolant from the cooling circuit; see 5.2.1.

  • Page 110: Expansion Reservoir

    COOLING SYSTEM RS 125 5.6. EXPANSION RESERVOIR 5.6.1. EXPANSION RESERVOIR TORQUE WRENCH SETTINGS Expansion reservoir retaining screw (1) 3 Nm (0.3 kgm). REMOVAL • Drain the cooling circuit; see 5.2.1. • Release and remove the screw (1). • Remove the clip (2).
  • Page 111 ENGINE RS 125 ENGINE 6 - 1...
  • Page 112 ENGINE RS 125 SUMMARY 6.1. EXHAUST SYSTEM......................... 3 6.1.1. EXHAUST PIPE REMOVAL ....................3 6.2. ENGINE............................4 6.2.1. GENERAL INFORMATION ..................... 4 6.2.2. ENGINE COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE INSTALLED IN THE FRAME ............................. 5 6.2.3. ENGINE REMOVAL ........................ 6 6.2.4.

  • Page 113: Exhaust System

    ENGINE RS 125 6.1. EXHAUST SYSTEM 6.1.1. EXHAUST PIPE REMOVAL TORQUE WRENCH SETTINGS Screws (1-2) 22 Nm (2.2 Kgm) Screw (3) 20 Nm (2.0 Kgm) • Remove both side fairings; see 7.1.2. • Remove the fairing air dam; see 7.1.3.

  • Page 114: Engine

    ENGINE RS 125 6.2. ENGINE 6.2.1. GENERAL INFORMATION Type 2-stroke single-cylinder engine with intake reed valve. Separate lubrication with variable-rate automatic mixer (1.0 – 3.0%). Cylinders Total displacement 124.82 cu cm Bore/stroke 54 mm / 54.5 mm Compression ratio 12.5 ± 0.5 : 1...

  • Page 115: Engine Components That Can Be Removed With The Engine Installed In The Frame

    ENGINE RS 125 6.2.2. ENGINE COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE INSTALLED IN THE FRAME The parts listed below can be removed leaving the engine in the frame. LEFT SIDE OF ENGINE • Clutch cover • Mixing pump •...

  • Page 116: Engine Removal

    ENGINE RS 125 6.2.3. ENGINE REMOVAL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Bolt (1) 10 Nm (1.0 kgm) Sprocket cover screws (3) 5 Nm (0.5 kgm) Engine rear mounting bolt (11) 22 Nm (2.2 kgm) Engine front mounting nut (12) 50 Nm (5.0 kgm) Front upper nut (13) 50 Nm (5.0 kgm).
  • Page 117 ENGINE RS 125 • Release the tie (2). NOTE Place some paper under the fitting to collect any oil spillage. • Disconnect the oil tubes and block them off. • Disconnect the throttle cable at the mixture oil pump end; see 7.3.2.
  • Page 118 ENGINE RS 125 Generator (5) Pick-up (6). ECU ground (7). Neutral light switch (8). 6 - 8...
  • Page 119 ENGINE RS 125 Release and remove the screw (9) and disconnect the grounding connectors of the system. • Partially remove the swinging arm spindle; see 7.11.1. NOTE You need not remove the swinging arm completely. When you are removing the engine of a full-power (f.p.) vehicle: •...
  • Page 120 ENGINE RS 125 • Undo and remove the nut (12) working from the right side of the motorcycle and collect the washer. • Remove the bolt from the opposite side. WARNING The engine is heavy and you will need an assistant to help during the next steps of the procedure.

  • Page 121: Installing The Engine Into The Frame

    ENGINE RS 125 6.2.4. INSTALLING THE ENGINE INTO THE FRAME Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Top engine nut (1) 50 Nm (5.0 kgm) Front engine nut (2) 50 Nm (5.0 kgm) Rear engine bolt (3) 22 Nm (2.2 kgm) Sprocket cover screws (10) 5 Nm (0.5 kgm)
  • Page 122 ENGINE RS 125 NOTE The next two operations are only required on full- power (f.p.) engines: • Secure the RAVE valve by the two screws (14). • Connect the RAVE valve connector. • Refit the swinging arm spindle; see 7.11.5.
  • Page 123 ENGINE RS 125 ECU ground (6). Pick-up (7). Generator (8). Starter motor (9). 6 - 13...
  • Page 124 ENGINE RS 125 • Fit the front chain sprocket to the shaft together with the drive chain. • Fit the circlip. • Position the sprocket cover and secure it with the two screws (10). • Connect the throttle cable to the mixer oil pump; see 7.3.2.
  • Page 125 ENGINE RS 125 • Position the gearbox link rod and tighten the screw (13). • Install the exhaust system; see 6.1.1 Install the carburetor; see 4.3.1. • Install the radiator; see 5.3.1. When finished with engine installation, go on to the next operations.

  • Page 126: Rave

    ENGINE RS 125 6.3. RAVE 6.3.1. RAVE VALVE SPECIFICATIONS The RAVE exhaust valve is operated by a solenoid via a Bowden cable. The engine control unit operates the solenoid within a predetermined range of engine rpm. The ECU uses primary circuit frequency to calculate engine rpm.

  • Page 127: Special Tools

    ENGINE RS 125 6.3.2. SPECIAL TOOLS Exhaust valve extractor : ROTAX part no. 277 445 6 - 17...

  • Page 128: Rave) Exhaust Valve Removal

    ENGINE RS 125 6.3.3. (RAVE) EXHAUST VALVE REMOVAL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS RAVE valve screws (2) 10 Nm (1.0 kgm) • Remove the fuel tank; see 4.1.1. • Remove the battery and battery box mount; see 7.2.1. PARTIAL REMOVAL •...
  • Page 129 ENGINE RS 125 • Disconnect the control unit connector at the wiring harness end. • Release and remove both screws (8) from the battery bracket. • Remove the complete RAVE valve. 6 - 19...

  • Page 130: Component Inspection

    ENGINE RS 125 6.3.4. COMPONENT INSPECTION SEALS • Check the valve stem seal (1) and the O-ring (2) (located inside the valve housing) for wear or damage. EXHAUST VALVE • Remove any combustion residue from the exhaust valve (3) and the valve duct in the cylinder.

  • Page 131: Rave) Exhaust Valve Installation

    ENGINE RS 125 6.3.5. (RAVE) EXHAUST VALVE INSTALLATION Read 1.2.1 carefully. TORQUE WRENCH SETTINGS RAVE valve screws (1) 10 Nm (1.0 kgm) • Remove the fuel tank; see 4.1.1. • Remove the battery together with the battery box mount; see 7.2.1.
  • Page 132 ENGINE RS 125 INSTALLATION AFTER PARTIAL REMOVAL • Connect the Bowden cable (3) to the valve stem housing (4). • Rotate the valve stem housing (4) through 180°. NOTE The cable anchor point must be pointing downwards. • Refit the dust cover.
  • Page 133 CHASSIS RS 125 CHASSIS 7 - 1...
  • Page 134 CHASSIS RS 125 SUMMARY 7.1. CHASSIS ............................4 7.1.1. CHASSIS............................4 7.1.2. RIDER SEAT REMOVAL ......................6 7.1.3. REMOVING THE SIDE FAIRINGS ....................7 7.1.4. AIR DAM REMOVAL ........................9 7.1.5. FRONT FAIRING REMOVAL..................... 10 7.1.6. WINDSCREEN REMOVAL ......................11 7.1.7.
  • Page 135 CHASSIS RS 125 7.6.2. REMOVING THE COMPLETE REAR WHEEL................69 7.6.3. REAR WHEEL DISASSEMBLY ....................71 7.6.4. FINAL DRIVE REMOVAL ......................72 7.6.5. INSPECTING THE REAR WHEEL COMPONENTS ..............73 7.6.6. REFITTING THE COMPLETE REAR WHEEL ................74 7.7. FRONT BRAKE ..........................76 7.7.1.

  • Page 136: Chassis

    CHASSIS RS 125 7.1. CHASSIS 7.1.1. CHASSIS Headlight Left rearview mirror Clutch control Ignition switch / steering lock / parking lights Fuse carrier Fuel tank Seat lock Left-hand seat subframe cover Passenger seat 10. Tail section 11. Tail light 12. Left-hand passenger footpeg (spring-loaded, snaps open/closed) 13.

  • Page 137: Chassis

    CHASSIS RS 125 24. Engine Control Unit 25. Rear brake master cylinder 26. Rider seat 27. Air cleaner 28. Right-hand seat subframe cover 29. Coolant expansion reservoir 30. Battery 31. Front brake fluid reservoir 32. Right rearview mirror 33. Front fairing 34.

  • Page 138: Rider Seat Removal

    CHASSIS RS 125 7.1.2. RIDER SEAT REMOVAL • Insert the key (1) into the lock (2) and turn counter clockwise. • Lift and remove the seat. • Remove the lid (3). INSTALLATION • Locate the tabs (4) at the seat rear end into the suitable recesses.

  • Page 139: Removing The Side Fairings

    CHASSIS RS 125 7.1.3. REMOVING THE SIDE FAIRINGS TORQUE WRENCH SETTINGS Screws (1-3-7-9) 3 Nm (0.3 Kgm) Screws (12) 2 Nm (0.2 Kgm) RIGHT-HAND SIDE FAIRING • Release and remove the six screws (1). • Withdraw the pin (2). •...
  • Page 140 CHASSIS RS 125 LEFT-HAND SIDE FAIRING • Put the motorcycle on the rear wheel stand (OPT), see 1.7.2. • Lower the side stand. • Disconnect the speedometer cable (6). • Release and remove the six screws (7). • Withdraw the pin (8).

  • Page 141: Air Dam Removal

    CHASSIS RS 125 7.1.4. AIR DAM REMOVAL TORQUE WRENCH SETTINGS Screws (1-2-3) 3 Nm (0.3 Kgm) • Release and remove the two side screws (1) on either side. • Release and remove the two screws (2). • Release and remove the two screws (3).

  • Page 142: Front Fairing Removal

    CHASSIS RS 125 7.1.5. FRONT FAIRING REMOVAL TORQUE WRENCH SETTINGS Screws (1-3) 3 Nm (0.3 Kgm) Repeat these three steps on either side: • Release and remove the two screws (1). • Remove the rearview mirror (2). • Release and remove the three screws on the side fairing (3).

  • Page 143: Windscreen Removal

    CHASSIS RS 125 7.1.6. WINDSCREEN REMOVAL • Working from inside the front fairing, remove the seven washers (1) and collect the seals (2). • Remove the seven retaining pins (3). • Remove the windscreen. NOTE Fit new washers (1) on assembly.

  • Page 144: Fuel Tank Filler Cap Removal

    CHASSIS RS 125 7.1.7. FUEL TANK FILLER CAP REMOVAL TORQUE WRENCH SETTINGS Screws (1) 5 Nm (0.5 kgm) Screws (3) 3 Nm (0.3 kgm) • Put the motorcycle on the stand. • Release and remove the three screws (1). NOTE The other three screws are there for aesthetic purposes only and can be left in place.

  • Page 145: Fuel Tank Fairing Removal

    CHASSIS RS 125 7.1.8. FUEL TANK FAIRING REMOVAL TORQUE WRENCH SETTINGS Fuel tank fairing screws (1) 3 Nm (0.3 Kgm). • Remove the fuel tank and place it on a work bench; 4.1.2. • Release and remove the two screws (1). Collect the washers and the rubber spacer (2).

  • Page 146: Seat Subframe Cover Removal

    CHASSIS RS 125 7.1.9. SEAT SUBFRAME COVER REMOVAL TORQUE WRENCH SETTINGS Front screws (1) 3 Nm (0.3 Kgm). Rear screws (2) 2 Nm (0.2 Kgm). Inner screw (3) 3 Nm (0.3 Kgm). Nut (4) 5 Nm (0.5 Kgm). • Remove the seat; see 7.1.1.

  • Page 147: Tail Removal

    CHASSIS RS 125 7.1.10. TAIL REMOVAL TORQUE WRENCH SETTINGS Inner nuts (1) 5 Nm (0.5 Kgm). Screws (2) 2 Nm (0.2 Kgm). Screws (3) 2 Nm (0.2 Kgm). • Remove both seat subframe covers; see 7.1.8. • Undo and remove the two inner nuts (1) and collect the screws.

  • Page 148: Removing The Front Mudguard

    CHASSIS RS 125 7.1.11. REMOVING THE FRONT MUDGUARD TORQUE WRENCH SETTINGS Screws (1) 2 Nm (0.2 Kgm). • Release and remove the two screws (1) on both sides. • Remove the front mudguard. 7 - 16...

  • Page 149: Removing The Rear Mudguard

    CHASSIS RS 125 7.1.12. REMOVING THE REAR MUDGUARD • Release and remove the screw (1) on both sides. • Remove the rear mudguard. 7 - 17...

  • Page 150: Removing The Seat End Cover

    CHASSIS RS 125 7.1.13. REMOVING THE SEAT END COVER TORQUE WRENCH SETTINGS Screws (1) 2 Nm (0.2 Kgm). Screws (2) 3 Nm (0.3 Kgm). Screws (4) 3 Nm (0.3 Kgm). • Remove the seat; see 7.1.1. • Release and remove the two screws (1) on both sides.
  • Page 151 CHASSIS RS 125 • Remove the number plate bracket; see 7.1.13. • Unscrew the two screws (4) and collect the nut. • Remove the ECU. • Pull the seat end cover in a rearward motion to remove. 7 - 19...

  • Page 152: Removing The Number Plate Bracket

    CHASSIS RS 125 7.1.14. REMOVING THE NUMBER PLATE BRACKET Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Screws (1) 3 Nm (0.3 kgm) Nut (2) 3 Nm (0.3 kgm) • Release and remove the two screws (1). • Undo and remove the nut (2).

  • Page 153: Chain Guard Removal

    CHASSIS RS 125 7.1.15. CHAIN GUARD REMOVAL TORQUE WRENCH SETTINGS Screws (1) 2 Nm (0.2 kgm) • Release and remove the two screws (1). • Remove the chain guard (2). 7 - 21...

  • Page 154: Upper Chain Slider Removal

    CHASSIS RS 125 7.1.16. UPPER CHAIN SLIDER REMOVAL TORQUE WRENCH SETTINGS Screw (1) 2 Nm (0.2 kgm) Screw (3) 2 Nm (0.2 kgm) NOTE The chain slider is best accessed after splitting the drive chain; see 7.13.1. • Release and remove the screw (1) and collect the nut (2).

  • Page 155: Lower Chain Slider Removal

    CHASSIS RS 125 7.1.17. LOWER CHAIN SLIDER REMOVAL TORQUE WRENCH SETTINGS Screws (1) 2 Nm (0.2 kgm) NOTE The chain slider is best accessed after splitting the drive chain; see 7.13.1. • Release and remove the two screws (1). •...

  • Page 156: Air Scoop Removal

    CHASSIS RS 125 7.1.18. AIR SCOOP REMOVAL • Remove the front fairing; see 7.1.4. • Remove the air scoop (1). 7 - 24...

  • Page 157: Electric Components

    CHASSIS RS 125 7.2. ELECTRIC COMPONENTS 7.2.1. BATTERY REMOVAL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Screw (2) 3 Nm (0.3 kgm) NOTE When the battery is removed, the digital clock will be reset to zero. See clock setting instructions at paragraph 2.3.1.

  • Page 158: Removing The Engine Control Unit

    CHASSIS RS 125 7.2.2. REMOVING THE ENGINE CONTROL UNIT TORQUE WRENCH SETTINGS Screw (2) 3 Nm (0.3 kgm) • Remove the tail section; see 7.1.9. • Disconnect the connector (1). • Release and remove the two screws (2) and collect the nuts underneath.

  • Page 159: Voltage Rectifier Removal

    CHASSIS RS 125 7.2.3. VOLTAGE RECTIFIER REMOVAL TORQUE WRENCH SETTINGS Screw (1-2) 10 Nm (1.0 Kgm) • Remove the tail section; see 7.1.9. • Release the wiring from the clip. • Release and remove the screw (1) and collect the washer.

  • Page 160: Removing The Right-Hand Light Dip Switch

    CHASSIS RS 125 7.2.4. REMOVING THE RIGHT-HAND LIGHT DIP SWITCH Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Screws (2) 3 Nm (0.3 kgm) • Lift the fuel tank; see 2.9.1. • Disconnect the two connectors (1) of the right-hand light dip switch.

  • Page 161: Removing The Left-Hand Light Dip Switch

    CHASSIS RS 125 7.2.5. REMOVING THE LEFT-HAND LIGHT DIP SWITCH Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Screws (2) 3 Nm (0.3 kgm) • Lift the fuel tank; see 2.9.1. • Disconnect the connector (1) of the left-hand light dip switch.

  • Page 162: Removing The Ignition Switch/Steering Lock

    CHASSIS RS 125 7.2.6. REMOVING THE IGNITION SWITCH/STEERING LOCK Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Screw (5-6) 25 Nm (2.5 kgm) • Remove the top yoke; see 2.16.1. • Lift the fuel tank; see 2.9.1. • Disconnect the connector (1) of the ignition switch assembly at the main wiring harness.

  • Page 163: Removing The Instrument Panel

    CHASSIS RS 125 7.2.7. REMOVING THE INSTRUMENT PANEL Read 1.2.1 carefully. • Remove the front fairing; see 7.1.4. • Disconnect the speedometer cable (1) and remove it from the left fairing. • Undo and remove the three nuts (2) and collect the washers.
  • Page 164 CHASSIS RS 125 • Release and remove the three screws (5) and collect the bushes. • Lift the sponge. • Release and remove the two screws (6). • Remove the multi-function computer. SPEEDOMETER – REV COUNTER • Undo and remove the two nuts (7) and collect the washers.

  • Page 165: Headlight Removal

    CHASSIS RS 125 7.2.8. HEADLIGHT REMOVAL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Screws (1) 2 Nm (0.2 kgm) • Remove the front fairing; see 7.1.4. • Release and remove the three screws (1). • Remove the headlight. NOTE See 8.15.1.

  • Page 166: Removing The Front Direction Indicators

    CHASSIS RS 125 7.2.9. REMOVING THE FRONT DIRECTION INDICATORS Read 1.2.1 carefully. • Disconnect the connector (1). NOTE It is not necessary to remove the fairing. • Release and remove the screw (2). • Remove the direction indicator. 7 - 34...

  • Page 167: Removing The Rear Direction Indicators

    CHASSIS RS 125 7.2.10. REMOVING THE REAR DIRECTION INDICATORS Read 1.2.1 carefully. • Remove the number plate bracket but leave it attached to the wiring; see 7.1.13. • Disconnect the pair of connectors (1) of the direction indicator you wish to remove. Look at the colour to...

  • Page 168: Warning Horn Removal

    CHASSIS RS 125 7.2.11. WARNING HORN REMOVAL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Screw (2) 22 Nm (2.2 kgm) • Remove the air dam; see 7.1.3. • Disconnect the two connectors (1). • Release and remove the screw (2). •...

  • Page 169: Removing The Tail Light

    CHASSIS RS 125 7.2.12. REMOVING THE TAIL LIGHT Read 1.2.1 carefully. • Remove the number plate bracket but leave it attached to the wiring; see 7.1.13.. • Disconnect the three tail light connectors (1). WARNING Make sure to refit the connectors (1) to the matching connectors on assembly.

  • Page 170: Controls

    CHASSIS RS 125 7.3. CONTROLS 7.3.1. REMOVING THE THROTTLE CONTROL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Screws (1) 3 Nm (0.3 kgm) Screws (3) 10 Nm (1.0 kgm) • Release and remove the two screws (1) securing the two shells from the bottom.

  • Page 171: Removing The Throttle Cable From Intermediate Pulley To Oil Pump

    CHASSIS RS 125 7.3.2. REMOVING THE THROTTLE CABLE FROM IN- TERMEDIATE PULLEY TO OIL PUMP TORQUE WRENCH SETTINGS Screw (2) 5 Nm (0.5 Kgm) • Lift the fuel tank, see 2.9.1. • Remove the left fairing, see 7.1.2. • Loosen and remove the three screws (1) and remove oil pump cover.

  • Page 172: Removing The Front Brake Control

    CHASSIS RS 125 7.3.3. REMOVING THE FRONT BRAKE CONTROL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Reservoir retaining screw (1) 7 Nm (0.7 kgm) PARTIAL REMOVAL • Release and remove the reservoir retaining screw (1). • Release and remove the two screws (2) securing the front brake control.
  • Page 173 CHASSIS RS 125 7.3.4. REMOVING THE FRONT BRAKE CONTROL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Reservoir retaining screw (1) 7 Nm (0.7 kgm) PARTIAL REMOVAL • Release and remove the reservoir retaining screw (1). • Release and remove the two screws (2) securing the front brake control.

  • Page 174: Removing The Clutch Cable

    CHASSIS RS 125 7.3.5. REMOVING THE CLUTCH CABLE • Slacken the lockring (1) fully. • Tighten the adjuster (2) fully. • Detach the clutch cable (3) from the lever. • Remove the left fairing; see 7.1.2. • Undo and remove the gearbox oil filler cap (4).

  • Page 175: Complete Removal Of The Gear Shift Lever

    CHASSIS RS 125 7.3.6. COMPLETE REMOVAL OF THE GEAR SHIFT LEVER TORQUE WRENCH SETTINGS Nut (1) 5 Nm (0.5 Kgm) Screw (4) 10 Nm (1.0 Kgm) PARTIAL REMOVAL: • Undo and release the nut (1). • Slide the actuating rod off the lever.

  • Page 176: Removing The Rear Brake Lever

    CHASSIS RS 125 7.3.7. REMOVING THE REAR BRAKE LEVER TORQUE WRENCH SETTINGS Lever adjuster screw 10 Nm (1.0 Kgm) • Unhook the spring (1). • Release and remove the pivot bolt (2) and collect the washer. • Remove the rear brake lever.

  • Page 177: Chassis

    CHASSIS RS 125 7.4. CHASSIS 7.4.1. REMOVING THE HANDLEBARS Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Screw (1) 10 Nm (1.0 kgm) LEFT HANDLEBAR • Slacken the screw (1) and remove the counterweight (2). • Fit the nozzle of an air gun between twistgrip (3) and handlebar.

  • Page 178: Removing The Instrument Panel Subframe

    CHASSIS RS 125 7.4.2. REMOVING THE INSTRUMENT PANEL SUB- FRAME Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Nuts (1) 10Nm (1.0 kgm) • Remove the instrument panel; see 7.2.7. • Release the tie securing the wiring to the instrument panel subframe.

  • Page 179: Removing The Seat Latch

    CHASSIS RS 125 7.4.3. REMOVING THE SEAT LATCH TORQUE WRENCH SETTINGS Screws (1) 10 Nm (1.0 kgm) • Remove the seat; see 7.1.1. • Remove the left cover of the seat subframe; see 7.1.8. • Release and remove the two bolts (1) and collect the two nuts.

  • Page 180: Removing The Right-Hand Rider Footpeg Bracket

    CHASSIS RS 125 7.4.4. REMOVING THE RIGHT-HAND RIDER FOOTPEG BRACKET TORQUE WRENCH SETTINGS Screw (1) 3 Nm (0.3 Kgm) Screws (2) 10 Nm (1.0 Kgm) Screws (3) 22 Nm (2.2 Kgm) Screw (5) 2 Nm (0.2 Kgm) • Release and remove the screw (1).

  • Page 181: Removing The Left-Hand Rider Footpeg Bracket

    CHASSIS RS 125 7.4.5. REMOVING THE LEFT-HAND RIDER FOOTPEG BRACKET TORQUE WRENCH SETTINGS Nut (1) 5 Nm (0.5 Kgm) Screws (2) 22 Nm (2.2 Kgm) Screws (3) 3 Nm (0.3 Kgm) • Undo and remove the nut (1). • Release and remove the two screws (2).

  • Page 182: Removing The Rider Footpeg

    CHASSIS RS 125 7.4.6. REMOVING THE RIDER FOOTPEG Read 1.2.1 carefully. • Remove the retaining ring (1). • Withdraw the spindle (2). • Collect footpeg (3) and spring (4). NOTE Repeat the process to remove the other rider footpeg if needed.

  • Page 183: Removing The Passenger Footpeg Brackets

    CHASSIS RS 125 7.4.7. REMOVING THE PASSENGER FOOTPEG BRACKETS TORQUE WRENCH SETTINGS Screws (1) 13 Nm (1.3 Kgm) NOTE The following procedure applies to both footpeg brackets. • Remove the side body panel; see 7.1.8. • Release and remove the two screws (1) and collect the nuts.

  • Page 184: Passenger Footpeg Removal

    CHASSIS RS 125 7.4.8. PASSENGER FOOTPEG REMOVAL • Remove the retaining ring (1). • Withdraw the spindle (2). WARNING The ball (3) sits on a spring (4) and might be thrown out due to spring action on disassembly. Proceed carefully and make sure to collect the ball.

  • Page 185: Side Stand Removal

    CHASSIS RS 125 7.4.9. SIDE STAND REMOVAL TORQUE WRENCH SETTINGS Screws (1) 2 Nm (0.2 Kgm) Screw (2) 3 Nm (0.3 Kgm) Stand bracket bolts (3) 22 Nm (2.2 Kgm) Stand switch screw 10 Nm (1.0 Kgm) Stand pivot bolt 10 Nm (1.0 Kgm)

  • Page 186: Seat Subframe Removal

    CHASSIS RS 125 7.4.10. SEAT SUBFRAME REMOVAL TORQUE WRENCH SETTINGS Screw (1) 7 Nm (0.7 Kgm) Screws (2) 22 Nm (2.2 Kgm) • Remove the voltage regulator; see 7.2.3. • Remove the seat subframe lower moulded cover; see 7.1.12. •...

  • Page 187: Frame Removal

    CHASSIS RS 125 7.4.11. FRAME REMOVAL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Shock absorber to frame (1) 50 Nm (5.0 kgm) Linkages to frame (2) 50 Nm (5.0 kgm) Footpeg bracket screws (3) 22 Nm (2.2 Kgm) Upper screws (5) 22 Nm (2.2 Kgm)
  • Page 188 CHASSIS RS 125 • Release and remove the two screws (3). • Remove the left-hand rider footpeg bracket. • Disconnect the connector of the starter relay. • Disconnect the connector of the left light dip switch. • Disconnect the two connectors of the right light dip switch.
  • Page 189 CHASSIS RS 125 • Disconnect coil connector and grounding cable. • Remove the seat subframe complete with carburetor, oil tank and airbox, see 7.4.10 • Working on both sides of the motorcycle, release and remove the two screws (4) at the front end.

  • Page 190: Frame Installation

    CHASSIS RS 125 7.4.12. FRAME INSTALLATION Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Upper screws (1) 22 Nm (2.2 Kgm) Footpeg bracket screws (3) 22 Nm (2.2 Kgm) Shock absorber to frame (4) 50 Nm (5.0 kgm) Linkages to frame (5) 50 Nm (5.0 kgm)
  • Page 191 CHASSIS RS 125 • Position the rear swinging arm complete with shock absorber. • Insert the swinging arm spindle. • Insert the shock absorber top bolt (4) from the left side and tighten the nut. • Locate the linkages to the frame.
  • Page 192 CHASSIS RS 125 starter relay; left light dip switch; both connectors of the right light dip switch. After re-installing the frame, check the following: Ensure that all components are fastened securely. Check that wiring and cables are properly routed and fastened.

  • Page 193: Front Wheel

    CHASSIS RS 125 7.5. FRONT WHEEL 7.5.1. FRONT WHEEL DIAGRAM Wheel spindle Speedometer drive Seal Drive ring Front wheel bearing Bearing spacer Front wheel right-hand outer spacer Washer Wheel spindle special bolt NOTE Grease the wheel spindle (1). 7 - 61...

  • Page 194: Removing The Complete Front Wheel

    CHASSIS RS 125 7.5.2. REMOVING THE COMPLETE FRONT WHEEL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Brake caliper mounting bolts (1) 22 Nm (2.2 kgm). Wheel spindle bolt (2) 80 Nm (8 kgm). Wheel spindle clamp screws (3) 12 Nm (1.2 kgm)
  • Page 195 CHASSIS RS 125 • Remove the wheel pulling from the front and collect the spacer (4). • Disengage the speedometer drive (5). 7 - 63...

  • Page 196: Front Wheel Disassembly

    CHASSIS RS 125 7.5.3. FRONT WHEEL DISASSEMBLY Read 1.2.1 carefully. • Remove the front wheel; see 7.5.2. • Clean both ends of the wheel hub with a cloth. • Remove the seals (1). • Remove the drive ring (2). •...

  • Page 197: Front Wheel Component Inspection

    CHASSIS RS 125 7.5.4. FRONT WHEEL COMPONENT INSPECTION WARNING Check that all components are in perfect condition. Inspect the following components with special care. BEARINGS Rotate the inner ring (1) manually. The ring should turn smoothly, with no hardness or noise.

  • Page 198: Refitting The Complete Front Wheel

    CHASSIS RS 125 7.5.5. REFITTING THE COMPLETE FRONT WHEEL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Caliper mounting bolts (7) 22 Nm (2.2 kgm). Wheel spindle bolt (6) 80 Nm (8 kgm). Wheel spindle clamp screws (8) 12 Nm (1.2 kgm) •...
  • Page 199 CHASSIS RS 125 • Start the two caliper mounting bolts (7) in their holes and tighten. • Hold in the front brake lever and press down on the handlebars repeatedly to pump the front fork up and down. This will allow the fork legs to seat themselves properly.

  • Page 200: Rear Wheel

    CHASSIS RS 125 7.6. REAR WHEEL 7.6.1. REAR WHEEL DIAGRAM 10. Rear wheel spindle 11. Left chain slider 12. Left outer spacer 13. Rear wheel oil seal 14. Rear wheel bearing 15. Rear wheel inner spacer 16. Wheel right outer spacer 17.

  • Page 201: Removing The Complete Rear Wheel

    CHASSIS RS 125 7.6.2. REMOVING THE COMPLETE REAR WHEEL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Wheel spindle nut (1): 100 Nm (10.0 kgm) WARNING To avoid the risk of burns, allow the engine and silencer to cool down completely before proceeding.
  • Page 202 CHASSIS RS 125 NOTE Note the positions of the spacers (5) and (6) so as to refit them in the original position on assembly. • Collect the left-hand spacer (5). • Collect the right-hand spacer (6). 7 - 70...

  • Page 203: Rear Wheel Disassembly

    CHASSIS RS 125 7.6.3. REAR WHEEL DISASSEMBLY Read 1.2.1 carefully. • Remove the rear wheel; see 7.6.2. • Clean the wheel hub at both ends with a cloth. Remove the oil seals (1-2). • Remove the right-hand bearing (3) and then the left- hand bearing (4) using a bearing extractor.

  • Page 204: Final Drive Removal

    CHASSIS RS 125 7.6.4. FINAL DRIVE REMOVAL Read 1.2.1 carefully. DISASSEMBLY • Remove the wheel; see 7.6.2. NOTE If you only need to remove the rear chain sprocket, simply perform the following five steps. • Clean the wheel hub at both ends with a cloth.

  • Page 205: Inspecting The Rear Wheel Components

    CHASSIS RS 125 7.6.5. INSPECTING THE REAR WHEEL COMPONENTS WARNING Check the condition of all components. Pay particular attention to those listed below. BEARINGS, SEALS, WHEEL SPINDLE and WHEEL RIM; 7.5.4. CUSH-DRIVE RUBBER • Inspect the cush-drive rubber for damage or wear.

  • Page 206: Refitting The Complete Rear Wheel

    CHASSIS RS 125 7.6.6. REFITTING THE COMPLETE REAR WHEEL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Wheel spindle nut (7): 100 Nm (10.0 kgm). WARNING To avoid the risk of burns, allow the engine and silencer to cool down completely before proceeding.
  • Page 207 CHASSIS RS 125 NOTE Ensure that the right-hand (4) and left -hand (5) tensioners do not get mixed up. Refit each tensioner in its original position. • Locate the right-hand chain tensioner (4) and the left- hand chain tensioner (5) to the swinging arm at the correct positions.

  • Page 208: Front Brake

    CHASSIS RS 125 7.7. FRONT BRAKE 7.7.1. FRONT BRAKE DIAGRAM Key: 19. Brake disc 20. Brake caliper mounting bolt 21. Brake caliper 22. Bleed nipple 23. Brake fluid hose 24. Brake pad retainer 25. Brake pads 26. Brake pad cover For detailed information: 1.3.1;...

  • Page 209: Replacing The Front Brake Pads

    CHASSIS RS 125 7.7.2. REPLACING THE FRONT BRAKE PADS Read 1.2.1 2.12.3 carefully. • Place the motorcycle on the side stand. • Remove the brake caliper cover (1). • Release the retaining ring (2). • Withdraw the pin (3) and collect the clip.

  • Page 210: Front Brake Disc Inspection

    CHASSIS RS 125 7.7.3. FRONT BRAKE DISC INSPECTION NOTE The operations described below are to be performed with the brake disc installed to the wheel. • Check for wear measuring disc thickness with a mi- crometer gauge at different positions along the disc.

  • Page 211: Front Brake Disc Removal

    CHASSIS RS 125 7.7.4. FRONT BRAKE DISC REMOVAL Read 1.2.1 carefully. TORQUE WRENCH SETTING Screws (1) 22 Nm (2.2 kgm). • Remove the front wheel; see 7.5.2. ® NOTE The screws (1) are retained with LOCTITE 243. Use of an air gun is recommended to release the screws.

  • Page 212: Rear Brake

    CHASSIS RS 125 7.8. REAR BRAKE 7.8.1. REAR BRAKE DIAGRAM Key: For detailed information: 27. Brake fluid reservoir 1.3.1; 28. Rubber hose - reservoir to pump 2.12.4; 29. Brake disc 2.12.5; 30. Brake caliper carrier 2.13.1; 31. Brake caliper 2.12.3.

  • Page 213: Replacing The Rear Brake Pads

    CHASSIS RS 125 7.8.2. REPLACING THE REAR BRAKE PADS Read 1.2.1 2.12.3 carefully. • Place the motorcycle on the stand. • Remove the brake caliper cover (1). • Release the retaining ring (2). • Withdraw the pin (3) and collect the clip (4).

  • Page 214: Rear Brake Disc Inspection

    CHASSIS RS 125 7.8.3. REAR BRAKE DISC INSPECTION NOTE The operations described below are to be performed with the brake disc installed to the wheel. • Check for wear measuring disc thickness with a micrometer gauge at different positions along the disc.

  • Page 215: Rear Brake Disc Removal

    CHASSIS RS 125 7.8.4. REAR BRAKE DISC REMOVAL Read 1.2.1 carefully. TORQUE WRENCH SETTING Screws (1) 10 Nm (1.0 kgm). • Remove the rear wheel; see 7.6.2. ® NOTE The screws (1) are retained with LOCTITE 243. Use of an air gun is recommended to release the screws.

  • Page 216: Removing The Brake Master Cylinder

    CHASSIS RS 125 7.8.5. REMOVING THE BRAKE MASTER CYLINDER TORQUE WRENCH SETTINGS Screws (5) 10 Nm (1.0 kgm). • Disconnect the brake light switch connector (1). • Drain the rear brake circuit; see 2.12.2. • When all fluid has drained out, unscrew and remove the connector (1).

  • Page 217: Steering

    CHASSIS RS 125 7.9. STEERING 7.9.1. STEERING DIAGRAM Key: 40. Top yoke 41. Steering tube cap 42. Bottom lockring 43. Seal 44. Headstock washer 45. Ball bearing 46. Roller bearing 47. Bottom dust seal 48. Bottom yoke and steering stem Always grease the bottom yoke and steering stem on refitting;...

  • Page 218: Headstock Removal

    CHASSIS RS 125 7.9.2. HEADSTOCK REMOVAL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Brake caliper mounting bolts (1) 22 Nm (2.2 kgm) • Place the motorcycle on the rear wheel stand (OPT); 1.7.2. • Remove the air scoop; see 7.1.17. •...

  • Page 219: Component Inspection

    CHASSIS RS 125 7.9.3. COMPONENT INSPECTION WARNING Check that all components are in perfect condition. Pay special attention to the components listed below. BEARINGS Rotate the inner ring manually. The ring should turn smoothly, with no hardness or noise. There should be no end float.

  • Page 220: Headstock Re-Assembly

    CHASSIS RS 125 7.9.4. HEADSTOCK RE-ASSEMBLY Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Brake caliper mounting bolts 22 Nm (2.2 kgm) NOTE Make sure to have a drift with the same diameter as the bearing outer ring available. • Fit the bearing (1) to the top end of the steering tube using the drift.

  • Page 221: Front Fork

    CHASSIS RS 125 7.10. FRONT FORK 7.10.1. FRONT FORK DIAGRAM Key: 49. Top cap 50. O-ring 51. Half ring 52. Spring cup 53. Spacer 54. Slide bush 55. Guide bush cup 56. Oil seal 57. Retaining ring 58. Dust seal with clip 59.

  • Page 222: Removing The Stanchion Tubes - Sliders

    CHASSIS RS 125 7.10.2. REMOVING THE STANCHION TUBES – SLIDERS Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Top yoke bolt (1) 25 Nm (2.5 kgm) Bottom yoke bolts (2) 25 Nm (2.5 kgm) NOTE The operations described below apply to both fork legs.

  • Page 223: Disassembling The Stanchion Tubes - Sliders

    CHASSIS RS 125 7.10.3. DISASSEMBLING THE STANCHION TUBES – SLIDERS Read 1.2.1 carefully. NOTE The operations described below apply to both fork legs. • Remove the stanchion tubes-sliders; see 7.10.2 • Clean the stanchion tubes-sliders thoroughly. NOTE Make sure to have a container having a capacity greater than 430 cu.
  • Page 224 CHASSIS RS 125 • Grasp the slider and pull firmly to separate slider and stanchion. NOTE Take care not to damage the slider inner seating surface during removal of the different components. • Lever with a flat-blade screwdriver to remove the dust seal (4).

  • Page 225: Changing Front Fork Oil

    CHASSIS RS 125 7.10.4. CHANGING FRONT FORK OIL Read 1.2.1 carefully. Oil quantity: 430±2.5 cu cm; see 1.7.1. Oil specifications; see 1.8.1. NOTE The operations described below apply to both fork legs. DRAINING OIL • Perform the first six steps of the procedure described at paragraph 7.10.3.

  • Page 226: Component Inspection

    CHASSIS RS 125 7.10.5. COMPONENT INSPECTION Read 1.2.1 carefully. STANCHION TUBE • Inspect sliding surface scoring and/or scratching. Eliminate minor scoring with wet sand paper (grain size 1). • Replace the stanchion (1) if badly scored. • Check for stanchion (1) buckling using a dial gauge.

  • Page 227: Stanchion Tube - Slider Assembly

    CHASSIS RS 125 7.10.6. STANCHION TUBE – SLIDER ASSEMBLY Read 1.2.1 carefully. • Inspect the components; see 7.10.5. WARNING Take care to prevent the ingress of dirt into slider and stanchion. Never reuse the oil you have drained from the fork.

  • Page 228: Installing Stanchions And Sliders

    CHASSIS RS 125 7.10.7. INSTALLING STANCHIONS AND SLIDERS Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Top yoke bolt (5) 25 Nm (2.5 kgm) Bottom yoke bolts (4) 25 Nm (2.5 kgm) Slide the slider-and-stanchion assembly through the bottom (1) and top yokes (2).
  • Page 229 CHASSIS RS 125 • Tighten the bolt (5) securing the top yoke (2) to the slider. • Remove the wheel spindle (3). • Refit the wheel; see 7.5.2. • Lower the hoist arm. WARNING Make sure the rear wheel stand (OPT) is...

  • Page 230: Rear Swinging Arm

    CHASSIS RS 125 7.11. REAR SWINGING ARM 7.11.1. REMOVING THE REAR SWINGING ARM Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Linkages to swinging arm (1) 80 Nm (8.0 kgm) Brake hose clips (2-3) 3 Nm (0.3 kgm) Rear screw (4) 22 Nm (2.2 kgm) Lockring (5) 35 Nm (3.5 kgm)
  • Page 231 CHASSIS RS 125 • Slacken the engine-to-frame mounting bolt (4) to facilitate swinging arm removal. NOTE Make sure to have the special tool no. 8101945 (socket for swinging arm spindle adjustment) ready at hand. • Working from the right-hand side, slacken the lockring (5) fully using the special socket.

  • Page 232: Dismantling The Swinging Arm

    CHASSIS RS 125 7.11.2. DISMANTLING THE SWINGING ARM Read 1.2.1 carefully. • Remove the swinging arm; see 7.11.2. • Place the swinging arm on a work bench. • Clean both sides of the bearing housings with a cloth. • Remove the outer plastic washers (1).

  • Page 233: Component Inspection

    CHASSIS RS 125 7.11.3. COMPONENT INSPECTION NOTE Check all components for distortion, damage, cracking and denting. Replace any damaged components. NEEDLE ROLLER BEARINGS Rotate the roller cages manually. They must rotate smoothly, with no hardness or noise. There should be no end float.

  • Page 234: Reassembling The Swinging Arm

    CHASSIS RS 125 7.11.4. REASSEMBLING THE SWINGING ARM Read 1.2.1 carefully. NOTE Change both needle roller bearings. • Clean all components of the swinging arm articulated connection and apply lithium grease. • Install two new needle roller bearings (1) using a drift with adequate diameter.

  • Page 235: Installing The Swinging Arm

    CHASSIS RS 125 7.11.5. INSTALLING THE SWINGING ARM Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Swinging arm spindle (1) 100 Nm (10.0 kgm). Adjusting bush (2) 12 Nm (1.2 kgm) Lockring (3) 35 Nm (3.5 kgm) Rear screw (4) 22 Nm (2.2 kgm) Linkages to swinging arm (5) 80 Nm (8.0 kgm)
  • Page 236 CHASSIS RS 125 • Position the linkages to the swinging arm. • Insert the screw from the right-hand side. • Position the washer and tighten the nut (5). • Route the brake hose along the swinging arm. • Secure the brake hose inner clip with the screw (6).

  • Page 237: Rear Suspension

    CHASSIS RS 125 7.12. REAR SUSPENSION 7.12.1. REAR SHOCK ABSORBER REMOVAL Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Shock absorber to frame (1) 50 Nm (5.0 kgm) Linkages to frame (2) 50 Nm (5.0 kgm) Shock absorber to linkages (3) 25 Nm (2.5 kgm) •...
  • Page 238 CHASSIS RS 125 • Pull the shock absorber in a downward motion to remove. 7 - 106...

  • Page 239: Rear Shock Absorber Installation

    CHASSIS RS 125 7.12.2. REAR SHOCK ABSORBER INSTALLATION Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Shock absorber to frame (1) 50 Nm (5.0 kgm) Shock absorber to linkages (2) 25 Nm (2.5 kgm) Linkages to frame (3) 50 Nm (5.0 kgm) •...

  • Page 240: Removing The Rear Suspension Linkages

    CHASSIS RS 125 7.12.3. REMOVING THE REAR SUSPENSION LINKAGES Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Linkages to frame (1) 50 Nm (5.0 kgm) Shock absorber to linkages (2) 25 Nm (2.5 kgm) Linkages to swinging arm (3) 80 Nm (8.0 kgm) •...

  • Page 241: Dismantling The Rear Suspension Linkage System

    CHASSIS RS 125 7.12.4. DISMANTLING THE REAR SUSPENSION LINKAGE SYSTEM Read 1.2.1 carefully. TORQUE WRENCH SETTINGS Single to double connecting link (1) 50 Nm (5.0 kgm) • Remove the complete linkage assembly; see 7.12.3. • Undo and remove the nut (1).

  • Page 242: Component Inspection

    CHASSIS RS 125 7.12.5. COMPONENT INSPECTION NOTE Visually inspect all components for distortion, damage, cracking and denting. Replace any damaged components. ROLLER BEARINGS Rotate the roller cages manually. They must rotate smoothly, with no hardness or noise. There should be no end float.

  • Page 243: Drive Chain

    CHASSIS RS 125 7.13. DRIVE CHAIN 7.13.1. REMOVING THE DRIVE CHAIN Read 1.2.1 carefully. • Slacken the chain; see 2.21.3. • Rotate the rear wheel until locating the master link. • Slip off the clip (1). • Remove the link plate underneath.

  • Page 244: Refitting The Drive Chain

    CHASSIS RS 125 7.13.2. REFITTING THE DRIVE CHAIN Read 1.2.1 carefully. • Check that the chain is correctly positioned on the front and rear sprockets. • The chain open ends should be in the lowermost portion of the chain midway between the sprockets.
  • Page 245 ELECTRICAL SYSTEM RS 125 ELECTRICAL SYSTEM 8 - 1...
  • Page 246 ELECTRICAL SYSTEM RS 125 SUMMARY 8.1. LAYOUT OF COMPONENTS ......................3 8.1.1. LAYOUT OF ELECTRICAL COMPONENTS ................3 8.2. FOREWORD ............................ 4 8.2.1. FOREWORD..........................4 8.3. BATTERY ............................5 8.3.1. BATTERY ..........................5 8.4. IGNITION SYSTEM.......................... 7 8.4.1. IGNITION SYSTEM ......................... 7 8.5.

  • Page 247: Layout Of Components

    ELECTRICAL SYSTEM RS 125 8.1. LAYOUT OF COMPONENTS 8.1.1. LAYOUT OF ELECTRICAL COMPONENTS Key: CDI unit Headlight Coolant thermistor Battery Diode Spark plug RAVE control unit (fp) Fuses Front brake light switch Coil Instrument panel Flasher Front right indicator Voltage regulator...

  • Page 248: Foreword

    IMPIANTO ELETTRICO RS 125 8.2. FOREWORD 8.2.1. FOREWORD Please read the following information before reading this section. NOTE For ease of reference, the same numbering is used in the specific wiring diagrams and in the general schematics. WIRING COLOUR CODES...

  • Page 249: Battery

    ELECTRICAL SYSTEM RS 125 8.3. BATTERY 8.3.1. BATTERY Battery rating: 12V - 9 Ah FIRST-TIME INSTALLATION AND MAINTENANCE Remove the battery from the motorcycle; see 7.2.1. • Remove plugs and breather cap. • Fill cells with fluid having a specific weight of 1.3.
  • Page 250 ELECTRICAL SYSTEM RS 125 SAFETY RULES WARNING Battery electrolyte fluid contains sulphuric acid. Keep away from the skin and clothes. Keep the battery well away from any sources of ignition, such as flames, sparks, or any heat sources because hydrogen output might ignite.

  • Page 251: Ignition System

    ELECTRICAL SYSTEM RS 125 8.4. IGNITION SYSTEM 8.4.1. IGNITION SYSTEM KILL SWITCH 7,5 A V/AR R/GR R/AR Bi/Vi COUNTER 20 A LIGHT SYSTEM COIL STAND/STARTER LOGIC PICK UP TROUBLESHOOTING • Check that the 7.5A and 20A fuses are in good condition.
  • Page 252 ELECTRICAL SYSTEM RS 125 TEST READINGS Ignition coil test The coils may be checked using a hand-held multimeter. Check for continuity of the primary and secondary windings. The resistance readings found need not match standard values exactly. If the windings are in good working order, resistance readings should approximate the standard values.

  • Page 253: Ignition System

    ELECTRICAL SYSTEM RS 125 8.5. CHARGE SYSTEM 8.5.1. CHARGE SYSTEM LAYOUT AND POWER SUPPLY RAVE CONTROL IGNITION UNIT SYSTEM V/AR V/AR LIGHT SYSTEM G/Bi R/AR G/Bi FUSES G/Bi FLY WHEEL REGULATOR BATTERY CHARGE SYSTEM TEST • Start the engine and rev it up to 6000 rpm.
  • Page 254 ELECTRICAL SYSTEM RS 125 TEST READINGS Flywheel test • Disconnect the alternator wiring connector. • Start the engine and rev it up to 5,000 rpm. • Measure AC voltage across the three yellow wires using a hand-held multimeter. A reading below 53 V indicates a faulty alternator.

  • Page 255: Starter Circuit

    ELECTRICAL SYSTEM RS 125 8.6. STARTER CIRCUIT 8.6.1. STARTER CIRCUIT START BUTTON R/AR STAND/ STARTER LOGIC STARTER RELAY STARTER MOTOR BATTERY TROUBLESHOOTING • Check the condition of the fuses. • Check the starter button. • Check the starter relay. •...
  • Page 256 ELECTRICAL SYSTEM RS 125 Starter motor test • Connect a 12-V 9-AH battery to the starter motor. • Measure current draw during regular operation (after 5 seconds) using a DC ampere meter. Correct reading: 50 - 60 A. 8 - 12...

  • Page 257: Sensors And Rev Counter

    ELECTRICAL SYSTEM RS 125 8.7. SENSORS AND REV COUNTER 8.7.1. SENSORS AND REV COUNTER CIRCUIT OIL WARNING REV COUNTER WATER T. DISPLAY LIGHT (LED) 15 A Bi/Vi Bi/N THERMISTOR LEVEL SENSOR COIL TROUBLESHOOTING • Check the condition of the 15A fuse.
  • Page 258 ELECTRICAL SYSTEM RS 125 Coolant temperature • Disconnect the green-grey terminal wire and connect V/Gr three resistors rated 1,000 Ω, 50 Ω and 15 Ω, respectively as shown. • When the ignition key is turned to ON, the following temperature readings or messages will appear on the display.

  • Page 259: Visual And Acoustic Signals

    ELECTRICAL SYSTEM RS 125 8.8. VISUAL AND ACOUSTIC SIGNALS 8.8.1. VISUAL AND ACOUSTIC SIGNALLING SYSTEM PASSING Key: Left-hand light dip switch Warning horn Fuse (15A) Fuse (20A) Battery Flasher Rear right indicator bulb Rear left indicator bulb 10. Front right indicator bulb 11.
  • Page 260 ELECTRICAL SYSTEM RS 125 Warning horn test To test warning horn operation: • Feed 12 Volts to the two connectors of the warning horn. • Adjust through the adjuster screw if needed. Flasher test When none of the direction indicators is working, there might be a problem with the flasher.

  • Page 261: Brake Lights Circuit

    ELECTRICAL SYSTEM RS 125 8.9. BRAKE LIGHTS CIRCUIT 8.9.1. BRAKE LIGHTS CIRCUIT Key: Front brake light switch Rear brake light switch Fuse (15 A) Fuse (20 A) Battery Tail light Brake lights 8 - 17...
  • Page 262 ELECTRICAL SYSTEM RS 125 TROUBLESHOOTING • Check the condition of the 15A and 20A fuses. • Check the condition of the brake light bulb. Switches Check switches for continuity using a multimeter. Please refer to the relevant diagram. Replace any switch assembly found to deviate from the specified mode of operation.

  • Page 263: Light Circuit

    ELECTRICAL SYSTEM RS 125 8.10. LIGHT CIRCUIT 8.10.1. LIGHT CIRCUIT RH LIGHT LH LIGHT SWITCH PASSING SWITCH BUTTON BATTERY HIGH BEAM W. LIGHT BEAM TROUBLESHOOTING • Check the condition of the 15A and 20A fuses. • Check the right and left light dip switches for proper operation.
  • Page 264 ELECTRICAL SYSTEM RS 125 LIGHT DIP SWITCH TEST RH DIP SWITCH Check for continuity across the contacts using a multimeter set to the ohm range. Please refer to the relevant diagram. START OFF LH DIP SWITCH PASSING RH DIP SWITCH-...

  • Page 265: Rave Valve

    ELECTRICAL SYSTEM RS 125 8.11. RAVE VALVE 8.11.1. RAVE VALVE CIRCUIT G/Bi FLY WHEEL/ REGULATOR RAVE CONTROL RAVE UNIT SOLENOID The RAVE control unit operates the solenoid to open the valve at the exhaust end at 8100 rpm. TROUBLESHOOTING •...
  • Page 266 ELECTRICAL SYSTEM RS 125 CONTROL UNIT • Remove the fuel tank; see 4.1.1. • Remove the battery and battery box mount together; 7.2.1. • Disconnect the connector. • Start the engine and switch on the low beam. • Speed up engine up to 2500 rpm.

  • Page 267: Stand

    ELECTRICAL SYSTEM RS 125 8.12. STAND 8.12.1. STAND LOGIC CIRCUIT IGNITION CONTROL UNIT NEUTRAL STAND W. LIGHT W. LIGHT STARTER RELAY DIODE NEUTRAL STAND SWITCH SWITCH Engine starting and ignition are inhibited when the stand is down and/or a gear is engaged.
  • Page 268 ELECTRICAL SYSTEM RS 125 TEST READINGS Check for continuity across the contacts using a multimeter set to the ohm range. Refer to the diagrams below. Neutral light switch test Wires Pos. SCREW Neutral Stand test Wires Stand position Down DIODE TEST To test diode operation: •...
  • Page 269 ELECTRICAL SYSTEM RS 125 Correct reading (layout A): 0 – 1 Ω. Correct reading (layout B): ∞. If your multimeter does not include a diode-test feature, feed 12 Volts to the diode, fit a 12 V - 2 W bulb to the positive lead and connect the leads to the diode as shown in the diagram.

  • Page 270: Bulb Replacement

    ELECTRICAL SYSTEM RS 125 8.13. BULB REPLACEMENT 8.13.1. BULB REPLACEMENT Read carefully. 1.2.1 WARNING Before proceeding to change a bulb, rotate the ignition switch to “ ” . Wear clean gloves or use a clean, dry cloth to handle bulbs. Do not put your fingerprints on a bulb, as this may cause overheating leading to failure.
  • Page 271 ELECTRICAL SYSTEM RS 125 TAIL LIGHT BULBS NOTE Check the BRAKE light switches for proper operation before changing a bulb; see 8.9.1. • Place the motorcycle on the stand. • Release and remove the two screws (12). • Remove the guard (11).

  • Page 272: Replacing The Fuses

    ELECTRICAL SYSTEM RS 125 8.14. REPLACING THE FUSES 8.14.1. REPLACING THE FUSES WARNING Never attempt to repair a defective fuse. Never use a fuse of a rating other than specified. This could damage the electrical system or cause a short circuit, with the risk of fire.

  • Page 273: Beam Setting

    ELECTRICAL SYSTEM RS 125 8.15. BEAM SETTING 8.15.1. BEAM HEIGHT SETTING 10 m This is a quick beam-setting inspection procedure. Place the motorcycle ten metres away from a vertical wall. It is important that the motorcycle be on level ground.

  • Page 274: Wiring Diagram

    ELECTRICAL SYSTEM RS 125 8.16. WIRING DIAGRAM 8.16.1. WIRING DIAGRAM 8 - 30...
  • Page 275 ELECTRICAL SYSTEM RS 125 Key: WIRE COLOUR CODES Orange Generator Ignition coil Light blue Blue Starter motor Voltage regulator White Fuses Yellow Grey Battery Starter relay Brown Black Front brake light switch Rear brake light switch 10. Coolant thermistor Pink 11.
  • Page 276 ELECTRICAL SYSTEM RS 125 THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK 8 - 32...
  • Page 277 TROUBLESHOOTING INFORMATION RS 125 TROUBLESHOOTING INFORMATION 9 - 1...
  • Page 278 TROUBLESHOOTING INFORMATION RS 125 SUMMARY 9.1. TROUBLESHOOTING INFORMATION ................... 3 9.1.1. ENGINE ........................... 3 9.1.2. CARBURETOR........................5 9.1.3. RADIATOR ..........................5 9.1.4. ELECTRICAL SYSTEM......................6 9.1.5. BATTERY ..........................6 9.1.6. BRAKES ..........................7 9.1.7. CHASSIS ..........................7 9.2. HOSE ROUTING..........................8 9.2.1.

  • Page 279: Troubleshooting Information

    TROUBLESHOOTING INFORMATION RS 125 9.1. TROUBLESHOOTING INFORMATION 9.1.1. ENGINE Trouble Symptom and possible causes Remedy Engine does not start or Low compression is difficult to start Cylinder or piston rings exceedingly worn. Replace. Piston ring sticking in its groove. Repair or replace.
  • Page 280 TROUBLESHOOTING INFORMATION RS 125 Engine is burning oil Oil pump out of adjustment. Adjust. Crankshaft seal damaged or worn. Replace. Loss of engine power Piston rings or cylinder worn. Replace. Incorrect air gap between spark plug electrodes or ignition Adjust or replace.

  • Page 281: Carburetor

    TROUBLESHOOTING INFORMATION RS 125 9.1.2. CARBURETOR Trouble Symptom and possible causes Remedy Difficulties on starting Starter jet obstructed. Clean. Starter duct obstructed. Clean. Air leaking past the gasket between cold-start body and Check and tighten. carburetor. Cold-start shutter is malfunctioning.

  • Page 282: Electrical System

    TROUBLESHOOTING INFORMATION RS 125 9.1.4. ELECTRICAL SYSTEM Trouble Symptom and possible causes Remedy Spark plugs develop Carburetion too rich. Adjust carburetor. exceeding carbon build- Idling speed set too high. Adjust carburetor. up too quickly Fuel does not meet specification. Change fuel.

  • Page 283: Brakes

    TROUBLESHOOTING INFORMATION RS 125 9.1.6. BRAKES Trouble Symptom and possible causes Remedy Loss of braking Brake hydraulic system leaking. Repair or replace. Brake pads worn. Replace. Contact surfaces of brake pads contaminated with oil. Replace. Brake discs worn. Replace. Air in the hydraulic circuit.

  • Page 284: Hose Routing

    TROUBLESHOOTING INFORMATION RS 125 9.2. HOSE ROUTING 9.2.1. ROUTING AND CONNECTIONS OF WIRING, CABLES AND HOSES FRONT BRAKE HOSES REAR BRAKE HOSES 9 - 8...
  • Page 285 TROUBLESHOOTING INFORMATION RS 125 FUEL SYSTEM HOSES OIL TUBES 9 - 9...
  • Page 286 TROUBLESHOOTING INFORMATION RS 125 CLUTCH CABLE COLD-START CABLE 9 - 10...
  • Page 287 TROUBLESHOOTING INFORMATION RS 125 THROTTLE CABLE 9 - 11...
  • Page 288 TROUBLESHOOTING INFORMATION RS 125 COOLING SYSTEM 9 - 12...
  • Page 289 TROUBLESHOOTING INFORMATION RS 125 9 - 13...
  • Page 290 TROUBLESHOOTING INFORMATION RS 125 THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK 9 - 14...

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