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RS 125
1300 6
00/2006-03
workshopmanual

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   Also See for APRILIA RS 125

   Summary of Contents for APRILIA RS 125

  • Page 1

    RS 125 1300 6 00/2006-03 workshopmanual...

  • Page 2

    INTRODUCTION RS125 INTRODUCTION 0 - 1...

  • Page 3

    INTRODUCTION RS125 SUMMARY 0.1. INTRODUCTION ............................. 3 0.1.1. FOREWORD............................3 0.1.2. REFERENCE MANUALS........................4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..................5 0 - 2...

  • Page 4: Introduction

    This manual provides the information required for normal servicing. This publication is intended for use by aprilia Dealers and their qualified mechanics; many concepts have been omitted on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been included in this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair procedures.

  • Page 5: Reference Manuals

    INTRODUCTION RS125 0.1.2. REFERENCE MANUALS SPARE PARTS CATALOGUE OWNER’S MANUALS aprilia part# (description) aprilia part# (description) 3406 Model Year 1993 8102260 Model Year 1994 MANUALI ATTREZZI SPECIALI 8102260 8102319 aprilia part# (description) Model Year 1995 8202278 8102476 8102530 CHASSIS WORKSHOP MANUAL...

  • Page 6: Abbreviations/symbols/conventions

    INTRODUCTION RS125 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = less than > = greater than ≤ = less than or equal to ≥ = more than or equal to = approximately ∞ = infinity °C = degrees Celsius (centigrade) °F = degrees Fahrenheit ±...

  • Page 7

    INTRODUCTION RS125 RIGHT SIDE = right side = Society of Automotive Engineers TEST = diagnostic check T.B.E.I. = crown-head Allen screw T.C.E.I. = cheese-head Allen screw T.E. = hexagonal head T.P. = flat head screw = Twin Spark Ignition UPSIDE- DOWN = inverted fork = volt...

  • Page 8: General Information

    GENERAL INFORMATION RS125 GENERAL INFORMATION 1 - 1...

  • Page 9: Table Of Contents

    GENERAL INFORMATION RS125 SUMMARY 1.1. GENERAL INFORMATION..........................3 1.1.1. CONVENTIONS USED IN THE MANUAL ..................... 3 1.1.2. SAFETY WARNINGS..........................4 1.2. GENERAL RULES............................5 1.2.1. BASIC SAFETY RULES......................... 5 1.3. DANGEROUS ELEMENTS ..........................8 1.3.1. WARNINGS ............................8 1.4. RUNNING-IN ..............................12 1.4.1.

  • Page 10: General Information

    GENERAL INFORMATION RS125 1.1. GENERAL INFORMATION 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. Refer to the index of sections when consulting the manual. •...

  • Page 11: Safety Warnings

    GENERAL INFORMATION RS125 1.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard. Non-compliance with the indications given in the messages preceded by this symbol may result in grave risks for your and other people’s safety and for the vehicle! DANGER Indicates a potential hazard which may result in serious injury or even death.

  • Page 12: General Rules

    GENERAL INFORMATION RS125 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 indoors. In case you are working indoors, use a gas exhaust system.

  • Page 13

    GENERAL INFORMATION RS125 DANGER Take care not to spill coolant onto hot engine parts and exhaust system. It may ignite and produce invisible flames. Wear latex gloves when servicing. Although toxic, it has a sweet taste that might attract animals. Never leave coolant in open container or in a position easily reachable by animals.

  • Page 14

    CAUTION All bearings must rotate freely with no hard spots 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 15: Dangerous Elements

    GENERAL INFORMATION RS125 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS 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, avoid open flames, sparks and any element that could ignite fuel or provoke explosions.

  • Page 16

    GENERAL INFORMATION RS125 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems. DANGER Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working.

  • Page 17

    GENERAL INFORMATION RS125 COOLANT DANGER Coolant is toxic when ingested, contact with eyes or skin may cause irritation. In the event of contact with your skin or eyes, rinse repeatedly with abundant water and seek medical advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice immediately.

  • Page 18

    GENERAL INFORMATION RS125 TYRES WARNING If tyres are excessively inflated, the vehicle will be harder, more difficult and uncomfortable to ride. In addition, the roadworthiness, mainly on wet surfaces and during cornering, will be impaired. Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle. In this case too, both vehicle roadworthiness, manoeuvrability and brake efficiency will be impaired.

  • Page 19: Running-in

    After the first 1000 km (621 mi), have the checking operations indicated in the column "After running- in" carried out by an aprilia Authorised Dealer, see REGULAR SERVICE INTERVALS CHART, in order to avoid hurting yourself or other people and/or damaging the vehicle.

  • Page 20: Vehicle Identification

    GENERAL INFORMATION RS125 1.5. VEHICLE IDENTIFICATION 1.5.1. POSITION OF THE SERIAL NUMBERS These numbers are necessary for vehicle registration. NOTE Altering the vehicle identification numbers is a legal offence. Altering the frame number invalidates the warranty. FRAME NUMBER The frame number is stamped on the right side of the steering column.

  • Page 21

    TECHNICAL INFORMATION RS125 TECHNICAL INFORMATION 2 - 1...

  • Page 22

    TECHNICAL INFORMATION RS125 SUMMARY 2.1. TECHNICAL INFORMATION .......................... 3 2.1.1. TECHNICAL DATA ..........................3 2.1.2. SCHEDULED MAINTENANCE CHART....................5 2.1.3. LUBRICANT CHART..........................6 2.1.4. TIGHTENING TORQUE SETTINGS ...................... 7 2.1.5. SPECIAL TOOLS ..........................11 2.1.6. LOCATION OF KEY COMPONENTS ....................12 2.1.7.

  • Page 23: Technical Information

    TECHNICAL INFORMATION RS125 2.1. TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA DIMENSIONS Max. length 1955 mm (76.97 in.) Max. width 720 mm (28.34 ) in. Max. height (at headlight fairing) 1100 mm (43.31 in.) Seat height 805 mm (31.69 in.) Wheelbase 1345 mm (52.95 in.) Minimum ground clearance 163 mm (6.42 in.) Weight in running order (including fluids and fuel)

  • Page 24

    TECHNICAL INFORMATION RS125 FRAME Type Twin-spar frame with cast and stamped frame sections Steering head angle 25° 30’ Trail 102 mm (4.01 in.) SUSPENSIONS Front hydraulically operated telescopic fork Travel 120 mm (4.72 in.) Rear Adjustable hydraulic mono-shock absorber Wheel stroke 44.5 mm (1.75 in.) BRAKES Front...

  • Page 25: Scheduled Maintenance Chart

    TECHNICAL INFORMATION RS125 2.1.2. SCHEDULED MAINTENANCE CHART After running- Every 4000 km Every 8000 km Component (2485 mi) or (4970 mi) or [1000 km 12 months 24 months (621 mi)] Rear shock absorber Battery - Clamp tightening Spark plug Carburettor Transmission and control cables RAVE control unit Wheel truing...

  • Page 26: Lubricant Chart

    TECHNICAL INFORMATION RS125 2.1.3. LUBRICANT CHART LUBRICANT PRODUCT Gearbox fluid RECOMMENDED: F.C., SAE 75W - 90. As an alternative to recommended oils, top brand oils meeting or exceeding A.P.I. GL-4 specifications can be used. Mixer oil RECOMMENDED: MAX 2T COMPETITION. As an alternative to recommended oil, top brand oils meeting or exceeding ISO-L-ETC ++,A.P.I.

  • Page 27: Tightening Torque Settings

    TECHNICAL INFORMATION RS125 2.1.4. TIGHTENING TORQUE SETTINGS Check and tighten as required after the first 1000 km (621 mi) and every 4000 km (2485 mi) or 12 months afterwards. WARNING The fasteners listed in the chart must be tightened to the specified torque using a torque wrench and ®...

  • Page 28

    TECHNICAL INFORMATION RS125 DESCRIPTION Q.ty Screw / nut Nm Kgm Note ENGINE Head to frame screw Socket-head screw M8x20 Upper front engine mount Socket-head screw M10x120 Lower front engine mount Hex flange screw M10x205 Rear engine mount Socket-head screw M8x85 Gearbox connecting rod Hex flange screw M6x20 Lower rear fastener...

  • Page 29

    TECHNICAL INFORMATION RS125 DESCRIPTION Q.ty Screw / nut Note ELECTRICAL COMPONENTS Battery box mount Hex flange screw M5x25 bracket Expansion tanks to battery Hex flange screw M6x16 Horn fastener Hex flange screw M8x16 Battery box mount to frame Socket-head screw M8x30 Undertail and oil tank fastener Hex flange screw M5x16 Fuse box to frame...

  • Page 30

    TECHNICAL INFORMATION RS125 DESCRIPTION Q.ty Screw / nut Nm Kgm Note CENTRE BODYWORK Upper RH-LH fairing to frame Allen crowned-head screw M5x16 Upper RH-LH fairing to front piece S/TAP crowned cheese-hd screw 4.2X16 RH-LH fairing to upper side fairing Allen crowned-head screw M5x16 2 RH-LH fairing to lwr fastening plate Allen crowned-head screw M5x16 2 PLSTC S/TAP crowned chesse-hd screw...

  • Page 31: Special Tools

    TECHNICAL INFORMATION RS125 2.1.5. SPECIAL TOOLS In order to perform assembly, reassembly and settings correctly, special tools suitable for the task must be used. The use of special tools avoids the potential risk of damage as a result of inappropriate tools and/or improvised methods.

  • Page 32: Location Of Key Components

    TECHNICAL INFORMATION RS125 2.1.6. LOCATION OF KEY COMPONENTS Key: Instrument panel Left rear-view mirror Ignition switch/steering lock Battery Fuse carrier Seat lock Mixer oil tank Mixer oil tank plug Glove / tool kit compartment 10. Passenger left footrest (snapping, closed/open) 11.

  • Page 33

    TECHNICAL INFORMATION RS125 Key: Passenger right footrest (snapping, closed/open) Passenger grab strap Rider seat Air filter Rear brake fluid reservoir Fuel tank filler plug Expansion tank Coolant expansion tank plug Right rear-view mirror 10. Front brake fluid reservoir 11. Rear brake master cylinder 12.

  • Page 34: Location Of Instruments / Controls

    TECHNICAL INFORMATION RS125 2.1.7. LOCATION OF INSTRUMENTS / CONTROLS Key: Ignition switch / steering lock ( Choke lever ( ) Turn indicator switch ( Horn button ( MODE button Light dimmer switch ( High beam flasher button ( Clutch lever Instruments and indicators 10.

  • Page 35

    TECHNICAL INFORMATION RS125 Rev counter Green turn indicator warning light ( Blue high beam light ( Multifunction digital display: coolant temperature, clock, battery voltage, lap timer, diagnostics, mixer oil level ( Amber low fuel light ( ) Green neutral light (N) Red general warning light ( 2 - 15...

  • Page 36: Instrument Panel Operation

    TECHNICAL INFORMATION RS125 2.1.8. INSTRUMENT PANEL OPERATION CONTROLS 1) MODE button: - press briefly to toggle between functions; - press longer (over three seconds) to enter the setup mode. Turn the ignition key to (“ ”) and the following instrument panel lights will come on for two seconds: - all warning lights;...

  • Page 37

    TECHNICAL INFORMATION RS125 Description of functions Press the MODE button repeatedly and zone C of the display will cycle through the following functions: - ODOMETER - TRIP METER - CLOCK - BATTERY VOLTAGE - LAP TIMER ODOMETER (ODO) The display shows the total distance covered by the vehicle. The odometer cannot be reset.

  • Page 38

    TECHNICAL INFORMATION RS125 LAP TIMER When the Clock readout is displayed, press the MODE button briefly to switch to the Lap Timer. Press and hold the MODE button while the motorcycle is moving to enter acquisition mode, or - at standstill - to view stored lap times.

  • Page 39

    Afterwards: every 4000 Km (1.7 mi) The icon will be turned off during the service procedure at an aprilia Dealer or Authorised Service Centre. HOW TO SELECT KM OR MILES Upon power-on with the key set to “ ”, hold down the MODE button for more than ten seconds to change the unit of measurement from kilometres (Km) to miles (Mi);...

  • Page 40: Gearbox Fluid

    TECHNICAL INFORMATION RS125 2.1.9. GEARBOX FLUID INSPECTION • Check gearbox fluid level every 4000 km (2500 mi); change gearbox fluid after the first 1000 km (625 mi) and every 12000 km (7500 mi) afterwards, see (CHANGING GEARBOX FLUID). CHECK CAUTION Place the vehicle on a firm and flat surface. •...

  • Page 41: Changing Gearbox Fluid

    TECHNICAL INFORMATION RS125 2.1.10. CHANGING GEARBOX FLUID Check gearbox fluid level every 4000 km (2500 mi); change fluid after the first 1000 km (625 mi) and every 12000 km (7500 mi) afterwards. CHANGE • Start the engine and let it idle for several minutes so the oil will drain off more easily later.

  • Page 42: Clutch Adjustment

    TECHNICAL INFORMATION RS125 2.1.11. CLUTCH ADJUSTMENT Warning signs that the clutch needs adjusting are the engine stalling, or the vehicle moving forward with the clutch lever pulled and a gear engaged, or clutch slippage, leading to sluggish acceleration compared to engine rpm. Minor adjustments may be performed using the adjuster (1): •...

  • Page 43: Scheduled Maintenance

    TECHNICAL INFORMATION RS125 2.2. SCHEDULED MAINTENANCE 2.2.1. BRAKE FLUID NOTE Check brake fluid after the first 1000 km (621 mi) and every 4000 km (2485 mi) or 12 months afterwards; change fluid every year. WARNING In case of excessive stroke of the brake lever, excessive elasticity or air bubbles, bleed the air out of the circuit.

  • Page 44

    TECHNICAL INFORMATION RS125 • Check the brake pads for wear, see (BRAKE PADS). • If the pads and/or the disc do not need replacing, provide for topping up. TOPPING UP THE FRONT BRAKING SYSTEM WARNING Danger: brake fluid could leak out. Do not operate the front brake lever when the brake fluid reservoir plug has been loosened or removed.

  • Page 45

    TECHNICAL INFORMATION RS125 CHECKING AND TOPPING UP REAR BRAKE FLUID LEVEL • The brake fluid reservoir is on the right side of the vehicle. • The procedure is the same as for the front brake. BLEEDING THE FRONT AND REAR BRAKES •...

  • Page 46

    TECHNICAL INFORMATION RS125 FRONT BRAKE • Top up the brake fluid reservoir. • Remove the rubber cap (4) of the bleed valve (5). • Insert one end of a transparent plastic tubing inside the calliper bleed valve (5) and the other end in a container for collection.

  • Page 47

    TECHNICAL INFORMATION RS125 • Tighten the bleed valve (7) and remove the tubing. • Top up brake fluid inside the reservoir up to correct level. • Refit the rubber cap (6). 2 - 27...

  • Page 48: Brake Pads

    TECHNICAL INFORMATION RS125 2.2.2. BRAKE PADS NOTE The information provided below applies to both braking systems. • Check the brake pads for wear after the first 1000 km (621 mi) and every 2000 km (1242 mi) afterwards. • The wear of the disc brake pads depends on the use, on the riding style and on the road.

  • Page 49: Lifting The Fuel Tank

    TECHNICAL INFORMATION RS125 2.2.3. LIFTING THE FUEL TANK DANGER Allow for the engine and exhaust silencers to cool down completely before proceeding. Fuel vapours are harmful to human health. Ensure that the room is adequately ventilated before proceeding. Do not inhale fuel vapours. Do not smoke or use naked flames.

  • Page 50: Cleaning The Air Filter

    TECHNICAL INFORMATION RS125 2.2.4. CLEANING THE AIR FILTER • Check the air filter every 4000 km (2485 mi) or 12 months; change it every 8000 km (4970 mi) or more frequently if the vehicle has been used on dusty or wet roads.

  • Page 51: Coolant

    TECHNICAL INFORMATION RS125 2.2.5. COOLANT Check • Check coolant level before each ride; change coolant every two years. WARNING Check the coolant level and top up the expansion tank with cold engine. • Stop the engine and wait until it has cooled down. CAUTION Place the vehicle on a firm and flat surface.

  • Page 52: Removing The Battery

    TECHNICAL INFORMATION RS125 2.2.6. REMOVING THE BATTERY NOTE Removing the battery will reset the digital clock. To set time, see (INSTRUMENT PANEL OPERATION). • Lift the fuel tank, see (LIFTING THE FUEL TANK). • Disconnect the negative lead (–) first and then the positive lead (+).

  • Page 53: Idling Speed Adjustment

    TECHNICAL INFORMATION RS125 2.2.7. IDLING SPEED ADJUSTMENT • Adjust idling speed in the event of erratic idling. • Proceed as follows: • Ride until covering several kilometres to warm up engine operating temperature ( ), (INSTRUMENT PANEL OPERATION). • Place the gearbox in neutral (green neutral light "N" on).

  • Page 54: Choke Adjustment

    TECHNICAL INFORMATION RS125 2.2.8. CHOKE ADJUSTMENT Choke control play should be about 2 ÷ 3 mm (0.078 ÷ 0.118 in). To adjust play: • Position the vehicle on the stand. • Lift the fuel tank, see (LIFTING THE FUEL TANK). •...

  • Page 55: Drive Chain Adjustment

    TECHNICAL INFORMATION RS125 2.2.9. DRIVE CHAIN ADJUSTMENT If the chain needs adjusting after the inspection, proceed as follows: • Place the vehicle on the rear support stand (OPT). • Loosen the nut (1) completely. WARNING Fixed references (2-3) for wheel centring are provided on the inside of the tensioner seats on the arms of the swinging arm, before the wheel shaft.

  • Page 56

    TECHNICAL INFORMATION RS125 WARNING Too much slack will result in noise or cause the chain to rattle, leading to slider and chain guide plate wear. Improper maintenance may lead to early wear of the chain and/or sprocket damage. Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas or under severe conditions.

  • Page 57: Inspecting The Drive Chain Slider

    TECHNICAL INFORMATION RS125 2.2.10. INSPECTING THE DRIVE CHAIN SLIDER • Position the vehicle on the stand. • Check the chain slider (1) for wear or damage, and replace it if necessary, see (REMOVING THE DRIVE CHAIN SLIDER). 2 - 37...

  • Page 58

    FUEL SYSTEM RS125 FUEL SYSTEM 3 - 1...

  • Page 59

    FUEL SYSTEM RS125 SUMMARY 3.1. FUEL SYSTEM..............................3 3.1.1. FUEL SUPPLY SYSTEM DIAGRAM...................... 3 3.1.2. REMOVING THE FUEL TANK....................... 4 3.1.3. REMOVING THE OIL TANK ........................5 3.2. AIR FILTER ..............................7 3.2.1. REMOVING THE AIR FILTER ....................... 7 3 - 2...

  • Page 60: Fuel System

    FUEL SYSTEM RS125 3.1. FUEL SYSTEM 3.1.1. FUEL SUPPLY SYSTEM DIAGRAM Key: Fuel tank Fuel sensor Fuel cock Fuel tank cover Oil reservoir Oil level indicator Oil tank plug Rubber block 3 - 3...

  • Page 61: Removing The Fuel Tank

    FUEL SYSTEM RS125 3.1.2. REMOVING THE FUEL TANK • Remove the seat, see (REMOVING THE SEAT). • Lift the fuel tank, see (LIFTING THE FUEL TANK). • Disconnect the fuel sensor connector. • Release the two fuel vapour hoses from the clamps. •...

  • Page 62: Removing The Oil Tank

    FUEL SYSTEM RS125 3.1.3. REMOVING THE OIL TANK • Remove the seat, see (REMOVING THE SEAT). • Remove the small flap in a downward motion. • Disconnect the oil level sensor connectors. • Place a container of adequate capacity under the oil mixer hose.

  • Page 63

    FUEL SYSTEM RS125 • Remove the oil mixer tank in a downward motion. 3 - 6...

  • Page 64: Air Filter

    FUEL SYSTEM RS125 3.2. AIR FILTER 3.2.1. REMOVING THE AIR FILTER • Lift the fuel tank, see (LIFTING THE FUEL TANK). • Unscrew and remove the two screws (1). • Loosen and remove the two screws (2) and collect the nuts from underneath.

  • Page 65

    ENGINE RS125 ENGINE 4 - 1...

  • Page 66

    ENGINE RS125 SUMMARY 4.1. EXHAUST................................ 3 4.1.1. DIAGRAM .............................. 3 4.1.2. REMOVING THE EXHAUST SYSTEM ....................4 4.2. SECONDARY AIR SYSTEM ........................... 6 4.2.1. SECONDARY AIR SYSTEM........................6 4.3. REMOVING AND INSTALLING THE ENGINE ....................7 4.3.1. REMOVING THE ENGINE FROM THE FRAME..................7 4.3.2.

  • Page 67: Exhaust

    ENGINE RS125 4.1. EXHAUST 4.1.1. DIAGRAM Key: Muffler Spring Flanged self-locking nut Spacer Silent block Washer Shear bolt Fairing retaining plate Muffler central bracket Short self-locking nut Flanged self-locking nut Silencer gasket Silencer Curved spring washer Socket-head screw Silencer clamp Washer Socket-head screw 4 - 3...

  • Page 68: Removing The Exhaust System

    ENGINE RS125 4.1.2. REMOVING THE EXHAUST SYSTEM • Remove the lower fairing, see (REMOVING THE LOWER FAIRING). • Remove the side fairings, see (REMOVING THE SIDE FAIRINGS). • Remove the lower cowl, see (REMOVING THE LOWER COWL). • Remove the clamp. •...

  • Page 69

    ENGINE RS125 • Loosen and remove the screw on the left passenger footrest bracket and collect the spacers. • Loosen and remove the screw and collect nut and washer. • Remove the complete exhaust from the left side. WARNING On refitting, replace the exhaust gasket and ensure that mounting...

  • Page 70: Secondary Air System

    ENGINE RS125 4.2. SECONDARY AIR SYSTEM 4.2.1. SECONDARY AIR SYSTEM The Secondary Air System (SAS) has been developed to reduce carbon oxide and unburnt hydrocarbon emissions in vehicles that are not equipped with a lambda sensor. Natural air (which is rich in oxygen) is channelled into the exhaust stream to trigger a post-combustion process.

  • Page 71: Removing And Installing The Engine

    ENGINE RS125 4.3. REMOVING AND INSTALLING THE ENGINE 4.3.1. REMOVING THE ENGINE FROM THE FRAME WARNING Before beginning the next procedure, prepare position necessary equipment considering that you will need to lower the engine into the frame in order to remove it. NOTE Prepare a hoist and lifting slings.

  • Page 72

    ENGINE RS125 • Release the clamp (1). NOTE Place some paper under the union to collect any oil drops. • Disconnect the oil hoses and block off the open ends. • Loosen and remove the three screws and remove the oil pump cover •...

  • Page 73

    ENGINE RS125 • Disconnect the spark plug cap. • Disconnect the thermistor electric connector. • Remove the clamp and slide out the hose from the cylinder head cover. • Loosen the lock washer (2) completely. • Tighten the adjuster (3) completely. •...

  • Page 74

    ENGINE RS125 • Loosen and remove the gearbox fluid filler plug. • Lever the clutch cable out of its housing using a small flat screwdriver and remove the cable. • Slide out the clutch cable. WARNING On refitting, check clutch lever free play, see (CLUTCH ADJUSTMENT).

  • Page 75

    ENGINE RS125 • Remove the circlip. NOTE Slacken the drive chain moderately to facilitate removal of the drive sprocket. • Slide drive sprocket and chain off the shaft. • Disconnect the following connectors in the order: Starter motor, by releasing the wiring from the ties and removing the screw.

  • Page 76

    ENGINE RS125 Control unit ground. • Release the clamps. • Disconnect the neutral sensor. 4 - 12...

  • Page 77

    ENGINE RS125 • Loosen the clamp. • Loosen and remove the four screws and remove the air box cover. • Remove the clamp and disconnect the secondary air hose. 4 - 13...

  • Page 78

    ENGINE RS125 • Slide the intake manifold off the carburettor pushing the air box rearwards. • Loosen and remove the two screws and remove the throttle cable. • Loosen and remove the screw and disconnect the choke cable. • Loosen and remove the screw to disconnect the system ground connectors.

  • Page 79

    ENGINE RS125 • Loosen and remove the screw and disconnect the speed sensor. • Working from the right side with the box wrench for swinging arm pivot adjustment (part no. 8101945), loosen the ring nut (5) completely. • Loosen the ring nut adjusting bush (6). •...

  • Page 80

    ENGINE RS125 • Working from the right side of the vehicle, loosen and remove the nut and collect the washer. • Slide out the screw, on the opposite side. WARNING The engine is heavy. Have someone assist you with the next operations. Plan the whole procedure before proceeding.

  • Page 81: Installing The Engine Into The Frame

    ENGINE RS125 4.3.2. INSTALLING THE ENGINE INTO THE FRAME • Shift the engine in small motions until matching the mounting holes perfectly. • Insert the upper screw with its washer and tighten the nut (1). • Insert the upper screw with its washer and tighten the nut.

  • Page 82

    ENGINE RS125 • To achieve correct swinging arm pivot play, tighten the ring nut adjusting bush (2) fully home and then tighten one more ¼ of a turn. NOTE Make sure to have the suitable box wrench for swinging arm pivot adjustment (part no. 8101945) ready at hand.

  • Page 83

    ENGINE RS125 • Fit the intake manifold to the carburettor pushing the air box forward. • Fit the throttle cable and tighten the two screws. • Fit a new clamp and connect the secondary air hose. • Fit the air box cover and tighten the four screws. 4 - 19...

  • Page 84

    ENGINE RS125 • Tighten the clamp. • Connect the following connectors in the order: system ground, by tightening the screw. Connect the neutral sensor. 4 - 20...

  • Page 85

    ENGINE RS125 • Change the clamps. Control unit ground. Pick-up. 4 - 21...

  • Page 86

    ENGINE RS125 Generator. Starter motor, by releasing the wiring and tightening the screw. • Fit the drive sprocket with the chain to the shaft. • Fit the circlip. • Fit the sprocket cover and tighten the two screws to secure it in place. 4 - 22...

  • Page 87

    ENGINE RS125 • Install the battery, see (REMOVING THE BATTERY). • Fit a new clamp and connect the expansion tank hose. • Refit the clutch cable into its housing. • Tighten the gearbox fluid filler plug. • Fit the clutch cable (4) to the clutch lever. •...

  • Page 88

    ENGINE RS125 • Fit a new clamp and fit the hose onto the cylinder head cover. • Connect the thermistor electric connector. • Fit the spark plug cap. • Fit the throttle cable to the oil pump. 4 - 24...

  • Page 89

    ENGINE RS125 • Adjust throttle cable tension by turning the nut on the oil pump until the two reference marks are aligned. • Fit the oil pump cover and tighten the three screws. • Connect the oil hoses and secure them with a new clamp.

  • Page 90

    ENGINE RS125 • Position the gearbox connecting rod and tighten the screw. • Install radiator, (REMOVING RADIATOR). • Install the complete exhaust, see (REMOVING THE EXHAUST SYSTEM). • Install the lower cowl, see (REMOVING THE LOWER COWL). • Install the lower fairings, see (REMOVING THE LOWER FAIRINGS).

  • Page 91: Rave Valve

    ENGINE RS125 4.4. RAVE VALVE 4.4.1. RAVE VALVE GENERAL INFORMATION The exhaust valve is solenoid-actuated via a Bowden cable. The ECU determines engine rpm based on primary circuit frequency input and operates the solenoid within a preset rpm range. NOTE Using the exhaust valve on type-approved 11kW vehicles makes such vehicles illegal to ride on public roads.

  • Page 92: Rave Valve Circuit

    ENGINE RS125 4.4.2. RAVE VALVE CIRCUIT The solenoid controlled by the Rave control unit opens the exhaust valve at 8100 rpm. TROUBLESHOOTING • Check the condition of the 15-A fuse • Connect a 12 V battery to the solenoid and check it for proper operation.

  • Page 93

    ENGINE RS125 CONTROL UNIT • Remove the fuel tank, see (REMOVING THE FUEL TANK). • Remove the battery along with its box mount, see (REMOVING THE BATTERY). • Disconnect the connector. • Start the engine and turn on the low beam. •...

  • Page 94: Removing The Exhaust Valve

    ENGINE RS125 4.4.3. REMOVING THE EXHAUST VALVE • Remove the fuel tank, see (REMOVING THE FUEL TANK). • Remove the battery along with its box mount, see (REMOVING THE BATTERY). PARTIAL REMOVAL • Move the protection element (1) out of the way. •...

  • Page 95

    ENGINE RS125 • Disconnect the control unit connector from the system. • Loosen and remove both screws (8) of the battery mount frame. • Remove the complete RAVE valve. 4 - 31...

  • Page 96: Checking The Components

    ENGINE RS125 4.4.4. CHECKING THE COMPONENTS SEALS • Check the valve stem seal (1) and the O-ring (2) located inside the valve housing for wear or damage. EXHAUST VALVE • Clean off any combustion residue from exhaust valve (3) and valve port in the cylinder. •...

  • Page 97: Rave Valve Installation

    ENGINE RS125 4.4.5. RAVE VALVE INSTALLATION • Remove the fuel tank, see (REMOVING THE FUEL TANK). • Remove the battery along with its box mount, see (REMOVING THE BATTERY). • On derated vehicles, remove the fixed slide valve by unscrewing the two screws (1) and collect the washers before installing the RAVE valve.

  • Page 98

    ENGINE RS125 PARTIAL INSTALLATION • Connect the Bowden cable (3) to the valve stem housing (4). • Rotate the valve stem housing (4) through 180°. NOTE The cable connection should be pointing downwards. • Refit the protection element. • Insert the exhaust valve assembly complete with gasket (5) into the cylinder.

  • Page 99

    CHASSIS RS125 CHASSIS 5 - 1...

  • Page 100

    CHASSIS RS125 SUMMARY 5.1. REMOVING THE OUTER STRUCTURES ...................... 3 5.1.1. REMOVING THE SEAT ......................... 3 5.1.2. REMOVING THE PASSENGER SEAT ....................4 5.1.3. REMOVING THE SIDE FAIRINGS ......................5 5.1.4. REMOVING THE LOWER COWL......................6 5.1.5. REMOVING THE LOWER FAIRINGS....................7 5.1.6.

  • Page 101: Removing The Outer Structures

    CHASSIS RS125 5.1. REMOVING THE OUTER STRUCTURES 5.1.1. REMOVING THE SEAT • Insert the key in the seat latch and turn it anticlockwise. • Remove the seat and take out the key. 5 - 3...

  • Page 102: Removing The Passenger Seat

    CHASSIS RS125 5.1.2. REMOVING THE PASSENGER SEAT • Remove the seat, see (REMOVING THE SEAT). • Remove the small flap in a downward motion. • Release and remove the two screws. • Remove the passenger seat by withdrawing it from the front.

  • Page 103: Removing The Side Fairings

    CHASSIS RS125 5.1.3. REMOVING THE SIDE FAIRINGS WARNING Allow for the engine and exhaust silencer to cool down completely before working on the side fairings. NOTE The following information applies to both side fairings. • Release and remove the two screws. •...

  • Page 104: Removing The Lower Cowl

    CHASSIS RS125 5.1.4. REMOVING THE LOWER COWL • If you have not removed the side and lower fairings yet, loosen and remove the two screws working on both sides. • Working on either side, loosen and remove the screw. • Remove the lower cowl.

  • Page 105: Removing The Lower Fairings

    CHASSIS RS125 5.1.5. REMOVING THE LOWER FAIRINGS • Working on either side, loosen and remove the four screws. • Remove the lower fairings in a downward motion. 5 - 7...

  • Page 106: Removing The Headlight Fairing

    CHASSIS RS125 5.1.6. REMOVING THE HEADLIGHT FAIRING • Working on either side, loosen and remove the screw. • Working on either side, release the side deflector. • Working on either side, loosen and remove the two screws. • Fold in the rear view mirrors and loosen and remove the four retaining screws.

  • Page 107

    CHASSIS RS125 • Push the headlight fairing forward. • Disconnect the parking light connector. • Disconnect the high / low beam light connector. • Remove the headlight fairing in a forward motion. 5 - 9...

  • Page 108: Removing The Tank Fairing

    CHASSIS RS125 5.1.7. REMOVING THE TANK FAIRING • Remove the fuel tank, see (REMOVING THE FUEL TANK) and place it on a bench. • Remove the two rubber elements (3) and the spacer (2). • Loosen and remove the two screws and collect the washers.

  • Page 109: Removing The Tail Guard

    CHASSIS RS125 5.1.8. REMOVING THE TAIL GUARD • Remove the passenger seat, see (REMOVING THE PASSENGER SEAT). • Release and remove the four screws. • Working on either side, loosen and remove the three lower screws. • Disconnect the tail light connector. •...

  • Page 110: Removing The Tail Light

    CHASSIS RS125 5.1.9. REMOVING THE TAIL LIGHT • Remove the passenger seat, see (REMOVING THE PASSENGER SEAT). • Disconnect the tail light connector. • Release and remove the two screws. • Remove the tail light pulling rearwards. 5 - 12...

  • Page 111: Removing The Lower Cover

    CHASSIS RS125 5.1.10. REMOVING THE LOWER COVER • Remove the passenger seat, see (REMOVING THE PASSENGER SEAT). • Working on either side, loosen and remove the three screws. • Working on either side, loosen and remove the screw. • Pull the connector out of its seat. •...

  • Page 112

    CHASSIS RS125 • Working on either side, loosen and remove the two screws. • Remove the lower cover. 5 - 14...

  • Page 113: Removing The Number Plate Holder

    CHASSIS RS125 5.1.11. REMOVING THE NUMBER PLATE HOLDER • Remove the tail guard, see (REMOVING THE TAIL GUARD). • Disconnect the number plate light connector. • Disconnect the four turn indicator connectors and pull them out in a rearward motion. •...

  • Page 114

    CHASSIS RS125 • Unscrew and remove the screw. • Remove the number plate holder pulling in a downward motion. 5 - 16...

  • Page 115: Removing The Side Body Panels

    CHASSIS RS125 5.1.12. REMOVING THE SIDE BODY PANELS NOTE The following information applies to both components. • Lift the fuel tank, see (LIFTING THE FUEL TANK). • Remove the tail guard, see (REMOVING THE TAIL GUARD). • Unscrew and remove the screw. •...

  • Page 116: Controls

    CHASSIS RS125 5.2. CONTROLS 5.2.1. REMOVING THE THROTTLE CONTROL • Lift the fuel tank, see (LIFTING THE FUEL TANK). • Remove the left side fairing, see (REMOVING THE SIDE FAIRINGS). • Loosen and remove the three screws and remove the oil pump cover.

  • Page 117

    CHASSIS RS125 • Loosen and remove the screw located on the inside of the frame on the left side of the vehicle. • Remove the throttle cable splitter cover. • Remove the throttle cable from the oil pump. WARNING On refitting, adjust throttle cable tension using the adjuster nut.

  • Page 118: Front Fork

    CHASSIS RS125 5.3. FRONT FORK 5.3.1. FRONT FORK DIAGRAM Key: Slider cap O-ring Half ring Ring for spring Spacer Sliding bush Guide bush retainer Seal Snap ring Dust seal with spring Sleeve Slider + stanchion tube 5 - 20...

  • Page 119: Removing The Fork Legs

    CHASSIS RS125 5.3.2. REMOVING THE FORK LEGS NOTE Position the tall front stand (OPT). NOTE The following information applies to both fork legs. • Loosen and remove the two screws and remove the bottom yoke cover. • Position the tall front stand. •...

  • Page 120

    CHASSIS RS125 • Working on either side, loosen and remove the two screws. • Remove the front mudguard. • Remove the front wheel, see (REMOVING THE FRONT WHEEL). • Loosen the screw on the top yoke. • Loosen the screw on the bottom yoke. •...

  • Page 121: Removing The Fork Legs

    CHASSIS RS125 5.3.3. REMOVING THE FORK LEGS NOTE The procedures described below apply to both stanchion-and-slider assemblies. • Remove stanchion-and-slider assembly, (REMOVING THE FORK LEGS). • Clean whole stanchion-and-slider assembly thoroughly. NOTE Before proceeding with the following operations, take a container having a capacity greater than 440 ± 2,5 cm³ (26.85 ±...

  • Page 122

    CHASSIS RS125 • Hold the slider and pull firmly until separating it from the stanchion tube. NOTE Proceed carefully when removing the different components, or you might damage the inner seating surface of the slider. • Remove the dust seal (4) using a flat screwdriver. •...

  • Page 123: Changing Fluid

    CHASSIS RS125 5.3.4. CHANGING FLUID Fluid quantity: 440 ± 2,5 cm³ (26.85 ± 0.15 cuin) Fluid type, see (LUBRICANT CHART). NOTE The procedures described below apply to both stanchion-and-slider assemblies. DRAINING THE FRONT FORK NOTE The procedures described below apply to both stanchion-and-slider assemblies.

  • Page 124

    CHASSIS RS125 FILLING THE FORK • Place the slider in a vertical position in a vice with soft jaws. • Pour fork fluid into the slider. • Fit the spring ring (3). • Insert the two half rings (2). • Make sure that the O-ring is in place and tighten the top cap (1).

  • Page 125: Refitting The Fork Legs

    CHASSIS RS125 5.3.5. REFITTING THE FORK LEGS • Check fork components, see (CHECKING FORK COMPONENTS). WARNING Make sure no dirt or foreign objects fall into the slider or the stanchion. Never reuse have drained previously. CAUTION Apply a light film of fork oil to the seals and bushes before assembly.

  • Page 126: Checking Fork Components

    CHASSIS RS125 5.3.6. CHECKING FORK COMPONENTS STANCHION TUBE • Inspect sliding surface scoring and/or scratching. Eliminate minor scoring with wet sand paper (grain size 1). • Replace the stanchion if badly scored. • Check for stanchion buckling using a dial gauge. •...

  • Page 127: Installing The Fork Legs

    CHASSIS RS125 5.3.7. INSTALLING THE FORK LEGS • Slide the complete slider-and-stanchion assembly through the bottom and top yokes. • Insert the wheel shaft into the both fork legs to keep the holes aligned. • Tighten the screw that retains the slider to the bottom yoke.

  • Page 128

    CHASSIS RS125 • Working on either side, tighten the two screws. • Position the front brake calliper and tighten the two retaining screws. • Lower the hoist arm. WARNING Before detaching the slings, make sure the rear stand (OPT) is positioned correctly. •...

  • Page 129: Steering Bearings

    CHASSIS RS125 5.4. STEERING BEARINGS 5.4.1. DIAGRAM Steering tube cap Front fork top yoke Front fork lower ring nut Seal Steering washer Ball bearing Roller bearing Bottom dust seal Base and steering tube 5 - 31...

  • Page 130: Checking Bearing Play

    CHASSIS RS125 5.4.2. CHECKING BEARING PLAY • Position the vehicle on the front stand. • Shake the fork in the direction of travel. • Adjust if you feel any play. 5 - 32...

  • Page 131: Adjusting Bearing Play

    CHASSIS RS125 5.4.3. ADJUSTING BEARING PLAY • Partially loosen the two screws that retain the top yoke. • Loosen and remove the top bush. • Tap lightly at the bottom end to knock out the top yoke complete with handlebar and ignition switch/steering lock.

  • Page 132

    CHASSIS RS125 • Refit the top yoke and position it fully home. • Lubricate the thread and contact face of the bush with oil. • Tighten the top bush. • Loosen the bush and retighten it to the specified torque, see (TIGHTENING TORQUES). •...

  • Page 133: Rear Shock Absorber

    CHASSIS RS125 5.5. REAR SHOCK ABSORBER 5.5.1. REMOVING THE SHOCK ABSORBER • Place the vehicle on the front support stand (OPT). • Place the vehicle on the rear support stand (OPT). • Place a support between swinging arm and seat frame to keep the shock absorber in an unloaded state.

  • Page 134

    CHASSIS RS125 • Remove the shock absorber pulling it downward. 5 - 36...

  • Page 135: Fitting The Shock Absorber

    CHASSIS RS125 5.5.2. FITTING THE SHOCK ABSORBER • Insert the shock absorber from the bottom up. • Insert the upper shock absorber screw with its washer from the left side. • Tighten the nut (1) on the opposite side. • Fit the connecting rods to the shock absorber.

  • Page 136: Removing The Rear Suspension Connecting Rods

    CHASSIS RS125 5.5.3. REMOVING THE REAR SUSPENSION CONNECTING RODS • Working on the right side, loosen and remove the nut (1). • Slide out the screw on the opposite side and collect the washer. • Working on the left side, loosen and remove the nut (2).

  • Page 137: Disassembling The Connecting Rods

    CHASSIS RS125 5.5.4. DISASSEMBLING THE CONNECTING RODS • Remove the complete connecting rods assembly of the suspension, (REMOVING REAR SUSPENSION CONNECTING ROD). • Unscrew and remove the nut (1). • Slide out the screw on the opposite side and collect the washer.

  • Page 138: Checking The Components

    CHASSIS RS125 5.5.5. CHECKING THE COMPONENTS NOTE Check all components for distortion, breakage, cracks and/or denting. Replace any damaged components. ROLLER CAGE Manually turn the roller cages, they should turn smoothly with no noise and/or hard spots. No axial play should be noticed. Faulty roller cages should be changed.

  • Page 139: Adjusting The Rear Shock Absorber

    CHASSIS RS125 5.5.6. ADJUSTING THE REAR SHOCK ABSORBER Factory setting is designed for any riding condition, low or high speed, with reduced or full load. However, the suspension can be adjusted to suit usage conditions. DANGER Allow for engine and silencer to cool down completely before proceeding.

  • Page 140: Swinging Arm

    CHASSIS RS125 5.6. SWINGING ARM 5.6.1. REMOVAL NOTE Support the front end of the vehicle using the front stand (OPT); support the rear end using slings and a hoist (OPT). • Connect the slings to the frame at the engine top mount.

  • Page 141

    CHASSIS RS125 • Loosen and remove the screw and remove the speed sensor. • Loosen the screw retaining the engine (4) to the frame to facilitate swinging arm removal. NOTE Make sure to have the suitable special tool part no. 8101945 (box wrench for swinging arm pivot adjustment) ready at hand.

  • Page 142: Removal And Reassembly

    CHASSIS RS125 5.6.2. REMOVAL AND REASSEMBLY REMOVAL • Remove the swinging arm, see (REMOVAL). • Place the swinging arm on a bench. • Clean the two sides of the bearing housings with a cloth. • Remove the plastic washers (1) on the outside. •...

  • Page 143: Checking The Rear Swinging Arm Components

    CHASSIS RS125 5.6.3. CHECKING THE REAR SWINGING ARM COMPONENTS NOTE Check all components for distortion, breakage, cracks and/or denting. Replace any damaged components. NEEDLE ROLLER CAGES Manually turn the needle roller cages, they should turn smoothly with no noise and/or hard spots. No axial play should be noticed.

  • Page 144: Installation

    CHASSIS RS125 5.6.4. INSTALLATION WARNING The tail end is heavy. Have someone assist you with the next operations. • Position the swinging arm on the frame. • Set the swinging arm in position so as to match the holes and insert the pivot (1) fully from the left side. •...

  • Page 145

    CHASSIS RS125 • Tighten the screw retaining the engine (4) to the frame. • Fit the connecting rods to the swinging arm. • Insert the screw from the right side. • Fit the washer and tighten the nut (5). • Route the brake hose along the swinging arm.

  • Page 146

    CHASSIS RS125 • Fit the speed sensor. 5 - 48...

  • Page 147: Front Wheel

    CHASSIS RS125 5.7. FRONT WHEEL 5.7.1. DIAGRAM Key: Front tyre Wheel shaft special screw Washer Flanged screw Front brake disc Front wheel external right spacer Seal Snap ring Bearing Internal spacer Naked front wheel Front wheel shaft Tubeless tyre valve 5 - 49...

  • Page 148: Removing The Front Wheel

    CHASSIS RS125 5.7.2. REMOVING THE FRONT WHEEL WARNING When removing, pay utmost attention not to damage the brake lines, discs and pads. • Place the vehicle on the rear support stand (OPT). NOTE Ensure that vehicle stable. Have an assistant hold the handlebar steady pointing in the direction of travel so that it cannot move.

  • Page 149

    CHASSIS RS125 • Working from the right side, loosen and remove the plug and collect the washer. • Place a support under the tyre so the wheel will stay in place after you release it. • Remove the wheel shaft from the left side. •...

  • Page 150: Checking The Front Wheel Components

    CHASSIS RS125 5.7.3. CHECKING THE FRONT WHEEL COMPONENTS WARNING Ensure that all components are intact and especially the following ones. BEARINGS Manually turn the inner ring (1); it should turn smoothly with no noise and/or hard spots. No axial play should be noticed. Faulty bearings should be changed.

  • Page 151: Installing The Front Wheel

    CHASSIS RS125 5.7.4. INSTALLING THE FRONT WHEEL • Smear some grease all along the wheel shaft. WARNING When refitting, pay utmost attention not to damage the brake lines, discs and pads. NOTE Fit the spacer with the larger diameter facing the right fork leg.

  • Page 152

    CHASSIS RS125 • Tighten the two screws of the wheel shaft clamp. • Fit the front mudguard. • Working on either side, tighten the two screws. • Remove the front stand (OPT). • Remove the rear stand (OPT). WARNING After reassembly, pull the front brake lever repeatedly and check the braking system for correct operation.

  • Page 153: Rear Wheel

    CHASSIS RS125 5.8. REAR WHEEL 5.8.1. DIAGRAM Key: Wheel RH ext. spacer Wheel LH ext. spacer Comp. chain, master link Tubeless valve Rear tyre 150/60" Rear wheel int. spacer Bearing 20x47x14 Seal 28x47x7 Snap ring d47 10. Naked blue rear wheel 11.

  • Page 154: Removing The Rear Wheel

    CHASSIS RS125 5.8.2. REMOVING THE REAR WHEEL WARNING Before carrying out the following operations, let the engine and the silencer cool down until they reach room temperature, in order to avoid burns. When removing, pay utmost attention not to damage the brake line, disc and pads. NOTE Make sure to have the suitable rear support stand (OPT) ready before removing the rear wheel.

  • Page 155

    CHASSIS RS125 NOTE Note the position of the right (3) and left (4) chain tensioners to refit them to their original positions later on. • Take the right (3) and left (4) chain tensioners. NOTE Drop the chain outboard of the rear chain sprocket. •...

  • Page 156: Removing The Final Drive Assembly

    CHASSIS RS125 5.8.3. REMOVING THE FINAL DRIVE ASSEMBLY REMOVAL • Remove the rear wheel, see (REMOVING THE REAR WHEEL). NOTE If you only need to remove the rear chain sprocket, perform only five of the steps described here. • Clean the two sides of the hub with a clean cloth. •...

  • Page 157: Checking The Rear Wheel Components

    CHASSIS RS125 5.8.4. CHECKING THE REAR WHEEL COMPONENTS WARNING Ensure that all components are intact and especially the following ones. BEARINGS, SEALS, WHEEL SHAFT, WHEEL RIM See (CHECKING THE FRONT WHEEL COMPONENTS). VIBRATION DAMPER Inspect the vibration damper seal for damage and/or excess wear.

  • Page 158

    Use only tyres of the same type as the first- equipment tyres selected by aprilia, see (TECHNICAL DATA). MINIMUM TREAD DEPTH (A): Front and rear 2 mm ( 0.08 in.). 5 - 60...

  • Page 159: Installing The Rear Wheel

    CHASSIS RS125 5.8.5. INSTALLING THE REAR WHEEL WARNING Before carrying out the following operations, let the engine and the silencer cool down until they reach room temperature, in order to avoid burns. When removing, pay utmost attention not to damage the brake line, disc and pads. •...

  • Page 160

    CHASSIS RS125 • Fit the washer and tighten the nut (6) manually. • Check chain tension, (DRIVE CHAIN ADJUSTMENT). • Tighten the nut (6). WARNING After reassembly, pull the rear brake lever repeatedly and check the braking system for correct operation. Check that wheel is centred.

  • Page 161: Drive Chain

    CHASSIS RS125 5.9. DRIVE CHAIN 5.9.1. REMOVING THE DRIVE CHAIN • Slacken chain, (DRIVE CHAIN ADJUSTMENT). • Turn the rear wheel until locating the master link. • Remove the clip (1). • Remove the bottom plate. • Remove the master link from the opposite side. •...

  • Page 162: Checking Chain And Chain Sprockets For Wear

    CHASSIS RS125 5.9.2. CHECKING CHAIN AND CHAIN SPROCKETS FOR WEAR Check the following components and inspect chain and chain sprockets for: damaged rollers; loose pins; dry, rusty, crushed or seized links; excessive wear; sprocket or teeth excessively worn or damaged. WARNING If chain rollers are damaged and/or the pins are loose, change chain and chain sprockets as a...

  • Page 163: Refitting The Drive Chain

    CHASSIS RS125 5.9.3. REFITTING THE DRIVE CHAIN • Check that the chain is correctly positioned on the sprockets. • Bring the two open ends of the chain midway between the sprockets in the lower span. • Join the open ends and insert the master link pins from the inside outward.

  • Page 164: Removing The Drive Chain Slider

    CHASSIS RS125 5.9.4. REMOVING THE DRIVE CHAIN SLIDER NOTE Break the chain to facilitate access to affected components, see (REMOVING THE DRIVE CHAIN). • Loosen and remove the upper screw (2) and collect the nut (6). • Loosen and remove the screw (3) and collect the seal (5).

  • Page 165

    COOLING SYSTEM RS125 COOLING SYSTEM 6 - 1...

  • Page 166

    COOLING SYSTEM RS125 SUMMARY 6.1. COOLING SYSTEM ............................3 6.1.1. DIAGRAM .............................. 3 6.1.2. CHANGING COOLANT.......................... 4 6.1.3. REMOVING THE RADIATOR ........................ 5 6.1.4. REMOVING THE EXPANSION TANK ....................6 6 - 2...

  • Page 167: Cooling System

    COOLING SYSTEM RS125 6.1. COOLING SYSTEM 6.1.1. DIAGRAM Key: Expansion tank Radiator plug Tube - from union to expansion tank Tube - from pump to union Tube - from radiator to tee Rubber block Cooler Upper radiator bracket Tube - from head to union Breather union Tube - from radiator to union 6 - 3...

  • Page 168: Changing Coolant

    COOLING SYSTEM RS125 6.1.2. CHANGING COOLANT WARNING Do not ride when coolant is below the minimum level. Check coolant level every 1500 km (935 mi) and after a long trip; change coolant every 24 months. • Do not ride when coolant is below the minimum level. Check coolant level every 1500 km (935 mi) and after a long trip;...

  • Page 169: Removing The Radiator

    COOLING SYSTEM RS125 6.1.3. REMOVING THE RADIATOR REMOVAL • Drain all coolant from the cooling circuit, see (CHANGING COOLANT). • Remove the right side fairing, see (REMOVING THE SIDE FAIRINGS). • Unhook the hose clamp head (1) and slide out the hose from the radiator.

  • Page 170: Removing The Expansion Tank

    COOLING SYSTEM RS125 6.1.4. REMOVING THE EXPANSION TANK REMOVAL • Drain all coolant from the cooling circuit, see (CHANGING COOLANT). • Unscrew and remove the screw (1). • Remove the clamp (2). • Disconnect the hose (3) from the expansion tank (4). •...

  • Page 171

    ELECTRIC SYSTEM RS125 ELECTRIC SYSTEM 7 - 1...

  • Page 172

    ELECTRIC SYSTEM RS125 SUMMARY 7.1. ELECTRIC SYSTEM ............................3 7.1.1. ELECTRIC PARTS TROUBLESHOOTING CHART ................3 7.1.2. IGNITION SYSTEM..........................15 7.1.3. CHARGING SYSTEM AND MAIN POWER SUPPLY ................16 7.1.4. STARTER CIRCUIT ..........................18 7.1.5. STOPLIGHT CIRCUIT ......................... 19 7.1.6. RAVE VALVE CIRCUIT ........................

  • Page 173: Electric System

    ELECTRIC SYSTEM RS125 7.1. ELECTRIC SYSTEM 7.1.1. ELECTRIC PARTS TROUBLESHOOTING CHART 7 - 3...

  • Page 174

    ELECTRIC SYSTEM RS125 1. HEADLIGHT Low beam light (halogen): 12 V - 55 W H11 High beam light (halogen): 12 V - 55 W H11 Parking light: 12 V - 5 W 2. BATTERY (12 V - B9 – B) In the event of abnormal operation, firstly check that the charging system is operating correctly.

  • Page 175

    ELECTRIC SYSTEM RS125 4. COIL Coil winding resistance Primary 0.11 – 0.21 Ohm Secondary 4.3 – 8.1 kOhm Check You may use a hand-held tester for this test. Check the continuity of primary and secondary windings. Please note that some degree of deviation from the specified Ohm readings is acceptable;...

  • Page 176

    ELECTRIC SYSTEM RS125 7. TAIL LIGHT Rear parking light / number plate light / stoplight: 12 V – 5 / 21 W 8. REAR RIGHT TURN INDICATOR Turn indicator light: Mini lamps (cannot be replaced) 9. SPEED SENSOR Operating voltage: VDC= 5÷24 V Peak voltage capacity: 26 V Maximum inverse voltage: -16 V Maximum consumption current: 10 mA...

  • Page 177

    ELECTRIC SYSTEM RS125 10. INSTRUMENT PANEL Service Service +Key +Battery RH indicator input LH indicator input Speed sensor High beam input power RPM input Speed sensor input Speed sensor ground General ground K line / Lap timer input Neutral input Oil level sensor Functions ground Fuel level sensor...

  • Page 178

    ELECTRIC SYSTEM RS125 WARNING Cutting the jumper across the grey and red wires of the Rave control unit will set solenoid actuation threshold to 7,800 rpm. • Check that the piston moves freely. • Start the engine and keep it at idling speed. •...

  • Page 179

    ELECTRIC SYSTEM RS125 WARNING On reassembly, make sure to match the connector (4) to the correct component. Use a tester (placed in diode test mode) to check across the two male terminals inside the diode as shown in the figure. Correct reading (layout A): 0 –...

  • Page 180

    ELECTRIC SYSTEM RS125 15. Rear right turn indicator Turn indicator light: Mini lamps (cannot be replaced) 16. RAVE CONTROL UNIT ( • Remove the tail guard, see (REMOVING THE TAIL GUARD). • Disconnect the connector. • Start the engine and turn on the low beam. •...

  • Page 181

    ELECTRIC SYSTEM RS125 18. MIXER OIL LEVEL SENSOR Measure resistance across the two terminals using a tester: - a full tank will give infinite resistance (∞). - an empty tank will give 0 Ω 19. SPARK PLUG Standard ( NGK R BR10EG Standard NGK BR8ES Spark plug gap...

  • Page 182

    ELECTRIC SYSTEM RS125 • If display gives the correct readouts, change the thermistor. • Otherwise replace the display. Key: 6) Resistor 7) Thermistor 21. SIDE STAND SWITCH Measure resistance across the two terminals using a tester: - with the stand down, resistance should be infinite (∞). - with the stand folded up, resistance should be 0 Ω...

  • Page 183

    ELECTRIC SYSTEM RS125 24. PICK-UP SENSOR Pick-up test • Disconnect the pick-up terminal connector. • Measure resistance across the yellow/white and blue/violet wire terminals with a hand-held tester set to the 1000 Ω scale: Resistance reading should be between 190 and 300 Ω. •...

  • Page 184

    ELECTRIC SYSTEM RS125 27. FRONT LEFT TURN INDICATOR Turn indicator light: Mini lamps (cannot be replaced) 28. SAFETY DIODE (horn) Use a tester placed in ohmmeter mode to check the continuity of contacts according to the diagram below. Diode test •...

  • Page 185: Ignition System

    ELECTRIC SYSTEM RS125 7.1.2. IGNITION SYSTEM TROUBLESHOOTING • Check the condition of the 7.5 A and 20 A fuses. NOTE For instructions on how to test electric components, see (ELECTRIC PARTS TROUBLESHOOTING CHART). • Check the spark plug and replace as required. •...

  • Page 186: Charging System And Main Power Supply

    ELECTRIC SYSTEM RS125 7.1.3. CHARGING SYSTEM AND MAIN POWER SUPPLY Charging system test • Start the engine and rev it up to 6000 rpm. • Connect a tester placed into voltmeter mode across battery terminals. • Turn on the low beam. •...

  • Page 187

    ELECTRIC SYSTEM RS125 Test data Flywheel test • Disconnect the alternator wiring connector. • Start the engine and rev it up to 5000 rpm. • Use the hand-held tester to measure voltage (VAC) across the three yellow wires. A reading lower than 53 V indicates a faulty alternator.

  • Page 188: Starter Circuit

    ELECTRIC SYSTEM RS125 7.1.4. STARTER CIRCUIT TROUBLESHOOTING NOTE For instructions on how to test electric components, see (ELECTRIC PARTS TROUBLESHOOTING CHART). • Check the condition of the fuses. • Check the starter button. • Check the starter relay. • Check the starter motor. •...

  • Page 189: Stoplight Circuit

    ELECTRIC SYSTEM RS125 7.1.5. STOPLIGHT CIRCUIT Key: Front brake switch Rear brake switch Fuse (15 A) Fuse (20 A) Battery Tail light Stoplights NOTE For instructions on how to test electric components, see (ELECTRIC PARTS TROUBLESHOOTING CHART). TROUBLESHOOTING • Check the condition of the 15-A and 20-A fuses. •...

  • Page 190

    ELECTRIC SYSTEM RS125 Switches Use a tester to check the continuity of the switches according to the diagram below. Change the switch assembly if continuity is not as specified. Stoplight switch on front brake Wires Position Operated Stoplight switch on rear brake Wires Position Operated...

  • Page 191: Rave Valve Circuit

    ELECTRIC SYSTEM RS125 7.1.6. RAVE VALVE CIRCUIT The solenoid controlled by the Rave control unit opens the exhaust valve at 8100 rpm. TROUBLESHOOTING NOTE For instructions on how to test electric components, see (ELECTRIC PARTS TROUBLESHOOTING CHART). • Check the condition of the 15-A fuse •...

  • Page 192: Wiring Diagram

    ELECTRIC SYSTEM RS125 7.1.7. WIRING DIAGRAM 7 - 22...

  • Page 193

    ELECTRIC SYSTEM RS125 Key: WIRE COLOUR CODES Multiple connectors orange Fuel level sensor light blue blue Serial diagnosis connector Electronic instrument panel white Water temperature sensor Yellow Oil level sensor grey Speed sensor brown Repeater black Left dimmer switch green 10.

  • Page 194

    Piaggio & C. S.p.A. via G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com...

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