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APRILIA RS 125 User Manual

APRILIA RS 125
290 pages
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FOREWORD
RS 125
FOREWORD 0
GENERAL INFORMATION 1
ROUTINE MAINTENANCE 2
LUBRICATION 3
FUEL SYSTEM 4
COOLING SYSTEM 5
ENGINE 6
CHASSIS 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING INFORMATION 9
0 - 1
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Table of Contents

Other manuals for APRILIA RS 125

Questions and Answers:

APRILIA RS 125 Specifications

General IconGeneral
Displacement124.8 cc
Transmission6-speed
Front SuspensionUpside-down fork
Rear SuspensionMonoshock
Front BrakeSingle disc
Rear BrakeSingle disc
Dry Weight114 kg
Fuel SystemCarburetor
FrameAluminum perimeter frame
Engine TypeSingle cylinder, 2-stroke

Summary

FOREWORD

FOREWORD

Introduction to the manual, its purpose, and intended audience.

REFERENCE MANUALS

Lists available reference manuals and their part numbers.

ABBREVIATIONS/SYMBOLS/CONVENTIONS

Explains common abbreviations, symbols, and conventions used in the manual.

GENERAL INFORMATION

MANUAL LAYOUT

Describes the structure and organization of the manual.

SAFETY INFORMATION

Details safety conventions, warnings, and precautions.

GENERAL RULES

Outlines basic rules and safety guidelines for maintenance.

DANGEROUS ELEMENTS

Identifies hazardous materials and components with warnings.

RUNNING-IN RECOMMENDATIONS

Provides guidelines for engine and vehicle break-in procedures.

VEHICLE IDENTIFICATION DATA

Explains the location of frame and engine serial numbers.

USING TOOLS AND SPARE PARTS

Advises on using appropriate tools and original spare parts.

PRODUCTS

Lists recommended products and lubricants for maintenance.

STANDS

Instructions for using front and rear service stands.

ROUTINE MAINTENANCE

INTRODUCTION

Explains the importance of routine maintenance for vehicle performance.

REGULAR SERVICE INTERVALS CHART

A comprehensive chart detailing maintenance intervals for various parts.

POINTS TO BE LUBRICATED

Identifies all points requiring lubrication and the type of lubricant.

MULTIFUNCTION COMPUTER

Describes the functions and operation of the multifunction computer display.

NUT, BOLT, SCREW TIGHTENING

General guidelines for tightening various fasteners.

FASTENING ELEMENTS

Specific torque settings and fastener details for different motorcycle components.

BATTERY

Information on battery types, maintenance, inspection, and charging.

ELECTRICAL PARTS

Checks and maintenance for various electrical components.

SPARK PLUGS

Procedures for checking, cleaning, and replacing spark plugs.

AIR CLEANER

Instructions for checking, cleaning, and changing the air cleaner element.

TUBES

Checks and replacement intervals for fuel, oil, brake, and coolant tubes.

FUEL TANK

Procedures for lifting and removing the fuel tank.

COOLANT

Steps for checking and topping up the coolant level.

CLUTCH

Instructions for adjusting the clutch lever free play.

BRAKE FLUID

Procedures for checking and topping up front and rear brake fluid levels.

ADJUSTING THE REAR BRAKE CONTROL LEVER

How to adjust the rear brake pedal height for rider comfort.

ADJUSTING THE GEARBOX LEVER

Procedure for adjusting the gearbox lever height.

THROTTLE

Checking throttle operation and adjusting cable play.

FRONT END

Inspections and adjustments related to the steering and front fork.

TAIL SECTION

Inspection and adjustment of the rear suspension and swinging arm.

WHEELS

Checks for front and rear wheels, including bearings and balancing.

TYRES

Advice on tyre condition, wear, inflation, and replacement.

EXHAUST SYSTEM

Procedures for tightening exhaust manifold nuts.

DRIVE CHAIN

Inspection, cleaning, lubrication, and adjustment of the drive chain.

LUBRICATION

REMOVING THE ENGINE OIL TANK

Step-by-step guide for removing the engine oil tank.

FUEL SYSTEM

FUEL TANK REMOVAL

Procedure for removing the motorcycle's fuel tank.

DRAINING THE FUEL TANK

Safety precautions and steps for draining the fuel tank.

COMPLETE REMOVAL OF THE FUEL COCK

How to remove the fuel cock from the fuel tank.

AIR CLEANER REMOVAL

Steps for removing the airbox and air cleaner assembly.

CARBURETOR REMOVAL

Procedure for removing the carburetor from the intake manifold.

COOLING SYSTEM

COOLING SYSTEM DIAGRAM

Diagram illustrating the layout of the cooling system components.

COOLANT CHANGE

Instructions for draining and refilling the cooling system with new coolant.

RADIATOR REMOVAL

Steps for removing and installing the radiator.

COOLANT THERMISTOR REMOVAL

Procedure for removing and replacing the coolant thermistor.

THERMOSTAT REMOVAL

Steps for removing and installing the thermostat.

EXPANSION RESERVOIR REMOVAL

Procedure for removing and installing the expansion reservoir.

ENGINE

EXHAUST PIPE REMOVAL

Steps for removing the exhaust pipe and flange.

ENGINE GENERAL INFORMATION

Technical specifications and general information about the engine.

ENGINE COMPONENTS REMOVABLE WITH ENGINE INSTALLED

Lists engine components that can be removed without removing the engine.

ENGINE REMOVAL

Detailed procedure for removing the engine from the motorcycle frame.

INSTALLING THE ENGINE INTO THE FRAME

Step-by-step guide for reinstalling the engine into the motorcycle frame.

RAVE VALVE SPECIFICATIONS

Details on RAVE valve operation and specifications.

EXHAUST VALVE REMOVAL

Procedure for removing the RAVE exhaust valve assembly.

COMPONENT INSPECTION

Inspection of RAVE valve components like seals and exhaust valve.

EXHAUST VALVE INSTALLATION

Steps for installing the RAVE exhaust valve assembly.

CHASSIS

CHASSIS DIAGRAM

Exploded view diagram of the chassis components.

RIDER SEAT REMOVAL

Procedure for removing and installing the rider's seat.

REMOVING THE SIDE FAIRINGS

Steps for removing the right and left side fairings.

AIR DAM REMOVAL

Procedure for removing the air dam.

FRONT FAIRING REMOVAL

Steps for removing the front fairing and headlight assembly.

WINDSCREEN REMOVAL

Procedure for removing the windscreen.

FUEL TANK FILLER CAP REMOVAL

Steps for removing the fuel tank filler cap.

FUEL TANK FAIRING REMOVAL

Procedure for removing the fuel tank fairing.

SEAT SUBFRAME COVER REMOVAL

Steps for removing the seat subframe cover.

TAIL REMOVAL

Procedure for removing the tail section and passenger seat.

REMOVING THE FRONT MUDGUARD

Steps for removing the front mudguard.

REMOVING THE REAR MUDGUARD

Procedure for removing the rear mudguard.

REMOVING THE SEAT END COVER

Steps for removing the seat end cover.

REMOVING THE NUMBER PLATE BRACKET

Procedure for removing the number plate bracket and associated lights.

CHAIN GUARD REMOVAL

Steps for removing the chain guard.

UPPER CHAIN SLIDER REMOVAL

Procedure for removing the upper chain slider.

LOWER CHAIN SLIDER REMOVAL

Steps for removing the lower chain slider.

AIR SCOOP REMOVAL

Procedure for removing the air scoop.

BATTERY REMOVAL

Steps for safely removing the motorcycle battery.

REMOVING THE ENGINE CONTROL UNIT

Procedure for removing the Engine Control Unit (ECU).

VOLTAGE RECTIFIER REMOVAL

Steps for removing the voltage rectifier.

REMOVING THE RIGHT-HAND LIGHT DIP SWITCH

Procedure for removing the right-hand handlebar light switch.

REMOVING THE LEFT-HAND LIGHT DIP SWITCH

Steps for removing the left-hand handlebar light switch.

REMOVING THE IGNITION SWITCH/STEERING LOCK

Procedure for removing the ignition switch and steering lock.

REMOVING THE INSTRUMENT PANEL

Steps for removing the instrument panel and its components.

HEADLIGHT REMOVAL

Procedure for removing the headlight assembly.

REMOVING THE FRONT DIRECTION INDICATORS

Steps for removing the front direction indicators.

REMOVING THE REAR DIRECTION INDICATORS

Procedure for removing the rear direction indicators.

WARNING HORN REMOVAL

Steps for removing the warning horn.

REMOVING THE TAIL LIGHT

Procedure for removing the tail light assembly.

REMOVING THE THROTTLE CONTROL

Steps for removing the throttle control assembly from the handlebar.

REMOVING THE THROTTLE CABLE FROM INTERMEDIATE PULLEY TO OIL PUMP

Procedure for removing the throttle cable from the pulley to the oil pump.

REMOVING THE FRONT BRAKE CONTROL

Steps for removing the front brake control assembly.

REMOVING THE FRONT BRAKE CONTROL

Steps for removing the front brake control assembly.

REMOVING THE CLUTCH CABLE

Procedure for removing the clutch cable.

COMPLETE REMOVAL OF THE GEAR SHIFT LEVER

Steps for removing the gear shift lever.

REMOVING THE REAR BRAKE LEVER

Procedure for removing the rear brake lever.

REMOVING THE HANDLEBARS

Steps for removing the left and right handlebars.

REMOVING THE INSTRUMENT PANEL SUB FRAME

Procedure for removing the instrument panel subframe.

REMOVING THE SEAT LATCH

Steps for removing the seat latch mechanism.

REMOVING THE RIGHT-HAND RIDER FOOTPEG BRACKET

Procedure for removing the right rider footpeg bracket.

REMOVING THE LEFT-HAND RIDER FOOTPEG BRACKET

Steps for removing the left rider footpeg bracket.

REMOVING THE RIDER FOOTPEG

Procedure for removing the rider footpeg.

REMOVING THE PASSENGER FOOTPEG BRACKETS

Steps for removing the passenger footpeg brackets.

PASSENGER FOOTPEG REMOVAL

Procedure for removing the passenger footpeg.

SIDE STAND REMOVAL

Steps for removing the side stand assembly.

SEAT SUBFRAME REMOVAL

Procedure for removing the seat subframe.

FRAME REMOVAL

Detailed steps for removing the motorcycle frame.

FRAME INSTALLATION

Procedures for installing the motorcycle frame.

FRONT WHEEL DIAGRAM

Exploded view diagram of the front wheel components.

REMOVING THE COMPLETE FRONT WHEEL

Steps for removing the front wheel assembly.

FRONT WHEEL DISASSEMBLY

Procedures for disassembling the front wheel hub and components.

FRONT WHEEL COMPONENT INSPECTION

Inspection of front wheel components like bearings, seals, spindle, and rim.

REFITTING THE COMPLETE FRONT WHEEL

Steps for refitting the complete front wheel assembly.

REAR WHEEL DIAGRAM

Exploded view diagram of the rear wheel components.

REMOVING THE COMPLETE REAR WHEEL

Steps for removing the rear wheel assembly.

REAR WHEEL DISASSEMBLY

Procedures for disassembling the rear wheel hub and components.

FINAL DRIVE REMOVAL

Steps for removing and refitting the final drive sprocket assembly.

INSPECTING THE REAR WHEEL COMPONENTS

Inspection of rear wheel components like bearings, seals, spindle, and rim.

REFITTING THE COMPLETE REAR WHEEL

Steps for refitting the complete rear wheel assembly.

FRONT BRAKE DIAGRAM

Diagram illustrating the front brake system components.

REPLACING THE FRONT BRAKE PADS

Procedure for replacing the front brake pads.

FRONT BRAKE DISC INSPECTION

How to inspect the front brake disc for wear and run-out.

FRONT BRAKE DISC REMOVAL

Steps for removing the front brake disc.

REAR BRAKE DIAGRAM

Diagram illustrating the rear brake system components.

REPLACING THE REAR BRAKE PADS

Procedure for replacing the rear brake pads.

REAR BRAKE DISC INSPECTION

How to inspect the rear brake disc for wear and run-out.

REAR BRAKE DISC REMOVAL

Steps for removing the rear brake disc.

REMOVING THE BRAKE MASTER CYLINDER

Procedure for removing the rear brake master cylinder.

STEERING DIAGRAM

Diagram illustrating the steering system components.

HEADSTOCK REMOVAL

Steps for removing the headstock assembly.

COMPONENT INSPECTION

Inspection of steering components like bearings and seals.

HEADSTOCK RE-ASSEMBLY

Procedures for reassembling the headstock.

FRONT FORK DIAGRAM

Exploded view diagram of the front fork components.

REMOVING THE STANCHION TUBES – SLIDERS

Steps for removing the fork stanchion tubes and sliders.

DISASSEMBLING THE STANCHION TUBES – SLIDERS

Procedures for disassembling the fork stanchion tubes and sliders.

CHANGING FRONT FORK OIL

Steps for changing the front fork oil.

COMPONENT INSPECTION

Inspection of fork stanchion tubes and sliders.

STANCHION TUBE – SLIDER ASSEMBLY

Procedures for assembling stanchion tubes and sliders.

INSTALLING STANCHIONS AND SLIDERS

Steps for installing stanchions and sliders back into the yokes.

REAR SWINGING ARM REMOVAL

Detailed procedure for removing the rear swinging arm.

DISMANTLING THE SWINGING ARM

Steps for disassembling the swinging arm bearings and components.

COMPONENT INSPECTION

Inspection of swinging arm components like bearings, seals, and spindle.

REASSEMBLING THE SWINGING ARM

Procedures for reassembling the swinging arm.

INSTALLING THE SWINGING ARM

Steps for installing the swinging arm onto the frame.

REAR SUSPENSION REMOVAL

Procedure for removing the rear shock absorber.

REAR SHOCK ABSORBER INSTALLATION

Steps for installing the rear shock absorber.

REMOVING THE REAR SUSPENSION LINKAGES

Procedure for removing the rear suspension linkage assembly.

DISMANTLING THE REAR SUSPENSION LINKAGE SYSTEM

Steps for disassembling the rear suspension linkage system.

COMPONENT INSPECTION

Inspection of rear suspension linkage components.

DRIVE CHAIN REMOVAL

Procedure for removing the drive chain.

DRIVE CHAIN REASSEMBLY

Steps for refitting the drive chain.

ELECTRICAL SYSTEM

LAYOUT OF COMPONENTS

Identifies the location of major electrical components on the motorcycle.

FOREWORD

Introduction to the electrical system section.

BATTERY

Information on battery installation, maintenance, inspection, and testing.

IGNITION SYSTEM

Details of the ignition system, troubleshooting, and tests.

CHARGE SYSTEM

Information on the charge system layout, testing, and troubleshooting.

STARTER CIRCUIT

Details of the starter circuit, troubleshooting, and tests.

SENSORS AND REV COUNTER

Information on sensors, rev counter circuit, and testing.

VISUAL AND ACOUSTIC SIGNALS

Explains visual and acoustic signals like indicators and horn.

BRAKE LIGHTS CIRCUIT

Diagram and troubleshooting for the brake lights circuit.

LIGHT CIRCUIT

Diagram and troubleshooting for the motorcycle's light circuits.

RAVE VALVE CIRCUIT

Details of the RAVE valve control unit and solenoid circuit.

STAND LOGIC CIRCUIT

Explains the logic circuit for the stand and neutral switches.

BULB REPLACEMENT

Procedures for replacing parking, high beam, low beam, tail, and indicator bulbs.

REPLACING THE FUSES

Instructions on how to check and replace fuses.

BEAM HEIGHT SETTING

Procedure for adjusting the headlight beam height.

WIRING DIAGRAM

Comprehensive wiring diagram for the motorcycle's electrical system.

TROUBLESHOOTING INFORMATION

TROUBLESHOOTING INFORMATION

Introduction to the troubleshooting section.

ENGINE TROUBLESHOOTING

Common engine problems, their causes, and remedies.

CARBURETOR TROUBLESHOOTING

Common carburetor issues, causes, and solutions.

RADIATOR TROUBLESHOOTING

Troubleshooting for engine overheating or failure to warm up.

ELECTRICAL SYSTEM TROUBLESHOOTING

Common electrical system problems and their fixes.

BATTERY TROUBLESHOOTING

Troubleshooting steps for battery issues like rapid discharge.

BRAKES TROUBLESHOOTING

Common brake problems, causes, and remedies.

CHASSIS TROUBLESHOOTING

Common chassis-related problems like steering and suspension issues.

HOSE ROUTING

Diagrams showing the routing of brake, fuel, oil, clutch, and throttle cables/hoses.

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