Table Of Contents - APRILIA RS4 125 Service Station Manual

Table of Contents

Index Of Topics4
Characteristics5
Safety Rules6
Carbon Monoxide6
Hot Components6
Coolant6
Maintenance Rules7
Used Engine Oil And Transmission Oil7
Brake And Clutch Fluid7
Battery Electrolyte And Hydrogen Gas7
Before Disassembling Components8
Components Removal8
Reassembling Components8
Electrical Connectors8
Running-In9
Vehicle Identification9
Tightening Torques9
Engine10
Dimensions And Mass10
Chassis Number10
Transmission11
Capacities11
Gear Ratios11
Electrical System11
Spark Plug11
Warning Lights12
Frame And Suspensions12
Wheels And Tyres12
Central Part21
Special Tools44
Maintenance49
Maintenance Chart50
Scheduled Maintenance Table50
Engine Oil Check52
Engine Oil Replacement53
Engine Oil Filter54
Recommended Products54
Gearbox Oil55
Air Filter55
Cooling System56
Air Filter Cleaning56
Level Check57
Top-Up57
Braking System Level Check58
Brake Fluid Check59
Front Brake Fluid Top-Up61
Rear Brake Fluid Top-Up61
Clutch System62
Adjusting The Lever62
Components Arrangement64
Electrical System Installation65
Scope And Applicability65
Small Parts And Mountings66
Special Checks For The Correct Connection And Laying Of Cables66
Front Side67
Wiring Diagram67
Running Of Headlight Cables68
Headlight Cable Running68
Speed Sensor69
Left And Right Positioning Of Cables70
Lights Detail72
Key Switch72
Instrument Panel73
Regulator Positioning73
Flywheel Positioning74
Pre-Fitting Chassis75
Fuel Reserve Probe Pre-Fitting76
Battery Area Components81
Running Rear Brake Sensor82
Lambda Probe And Engine Oil Sensor Cable Run83
Starter Motor Cable Run84
Neutral Cable Detail84
Fuel Tank Cable Harness85
Back Side87
Quick Shift Preparation87
Rear Light Pre-Fitting87
Rear Light Unit88
Diagnostics Cable Detail89
Tail Fairing Cable Harness Clamp90
General Wiring Diagram92
Checks And Inspections94
Dashboard95
Diagnosis95
Low Fuel95
Water Temperature96
Ignition Circuit97
Battery Recharge Circuit98
Recharging System98
Measurement Of Resistance (With Engine Off)99
Empty Voltage100
Short Circuit Current101
Voltage Regulator Check102
Cold Short Circuit Current102
Start-Up System Check103
Starter Motor - Check103
Start-Up Relay Check104
Starter Command104
Electrical Errors104
Horn Control105
Level Indicators105
Lights List106
Rear Light107
Front Headlamp107
Fuses108
Control Unit108
Battery108
Auxiliary Fuses108
Battery Preparation110
Electrolyte Preparation110
Procedure For Filling The Battery With Acid110
Recharging The New Battery111
Engine Rpm Sensor114
Engine Temperature Sensor115
Lambda Sensor117
Injector119
Fuel Pump119
Coil120
Neutral Sensor122
Side Stand Sensor122
Electric Fan Circuit122
Connectors123
Ecu124
Engine From Vehicle126
Vehicle Preparation127
Removing The Engine From The Vehicle127
Installing The Engine To The Vehicle133
Gearbox140
Gearbox Shafts140
Disassembling The Gearbox140
Checking The Primary Shaft140
Checking The Desmodromic Drum141
Assembling The Gearbox141
Starter Motor142
Removing The Starter Motor143
Installing The Starter Motor143
Generator Side143
Removing The Flywheel Cover144
Magneto Flywheel Removal145
Freewheel Removal147
Installing The Flywheel147
Clutch Side148
Removing The Clutch Cover149
Disassembling The Clutch151
Checking The Clutch Plates153
Checking The Clutch Housing153
Checking The Clutch Hub154
Checking The Springs155
Assembling The Clutch155
Crankcase157
Balancing Countershaft Removal158
Balancing Countershaft Fitting159
Crankcase Opening160
Bearing Removal163
Crankcase Check164
Crankshaft Check165
Balancing Countershaft Check166
Bushing Selection166
Bearing Fitting166
Crankcase Closing167
Left Crankcase167
Head And Timing171
Removing The Head Cover172
Removing The Timing Control174
Cylinder Head175
Removing The Overhead Camshaft175
Removing The Valves177
Checking The Overhead Camshaft178
Valve Check178
Inspecting The Valve Sealings181
Inspecting The Valve Housings182
Valve Sealing Surface182
Inspecting The Springs And Half-Cones183
Checking The Cylinder Head183
Installing The Valves183
Checking The Chain Tensioner184
Checking The Chain184
Cylinder-Piston Assembly184
Removing The Cylinder185
Disassembling The Piston186
Checking The Piston187
Inspecting The Wrist Pin188
Inspecting The Piston Rings188
Checking The Connecting Rod Small End189
Fitting The Piston189
Installing The Cylinder190
Selecting The Base Gasket191
Installing The Cylinder Head191
Base Gasket Selection191
Lubrication194
Conceptual Diagrams195
Power Supply198
Fuel Tank Inspection200
Fuel Tank Diagram201
Removing The Throttle Body202
Suspensions204
Front205
Removing The Front Wheel207
Checking The Front Wheel207
Installing The Front Wheel209
Handlebar210
Front Fork210
Removing The Fork Legs210
Disassembling The Fork211
Checking The Components216
Reassembling The Fork218
Installing The Fork Legs221
Removing The Rear Wheel225
Checking The Rear Wheel227
Flexible Coupling227
Sprocket227
Installing The Rear Wheel228
Shock Absorbers228
Shock Absorbers Removing229
Chassis230
Swinging Arm232
Installing234
Pinion234
Swingarm Pin234
Drive Chain238
Chain Tensioner241
Side Stand243
Stand Rod Removal243
Remove Stand Together With The Plate243
Exhaust244
Removing The Tail Pipe244
Removing The Exhaust Manifold246
Braking System247
Front Brake Pump248
Front Caliper248
Rear Braking System249
Rear Brake Calliper249
Front Brake Calliper251
Rear Brake Disc252
Disc Inspection252
Front Brake Disc253
Front Brake Pads254
Rear Brake Pads256
Bleeding The Braking System257
Changing The Brake Fluid259
Rear Brake Pump260
Rimozione261
Radiator263
Circuit Diagram264
Water Pump264
Electric Fan265
Coolant Replacement265
Removing The Expansion Tank271
Bodywork273
Tank274
Driving Mirrors275
Instrument Panel Support Removal276
Headlight Assy.276
Headlight Fairing277
Front Wheelhouse279
Taillight Assy.280
Footrest281
Side Fairings281
License Plate Holder282
Air Box283
Rear Mudguard284
Lower Cowl285
Fuel Tank286
Rear Wheelhouse287
Radiator Cover288
Tail Guard289
Pre-Delivery290
Aesthetic Inspection291
Tightening Torques Inspection291
Levels Check292
Road Test293
Static Test293
Functional Inspection293
Specific Operations For The Vehicle294
Index296