Basic safety rules (Aprilia RS125/3)

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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.

In case you are working indoors, make use of an exhaust gases scavenging system.

Danger! Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of consciousness or even lead to death by asphyxia.

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 flames, sparks and any element that could ignite fuel or provoke explosions.
• DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
• KEEP AWAY FROM CHILDREN.

The original text can be found on the website: Motoinstruction

High-temperature components

The engine and the exhaust system parts become hot and continue to be hot even for some time after the engine has been stopped.

Before handling these parts, wear insulating gloves or wait for the engine and the exhaust system to cool completely down.

Used gearbox and fork oils

Danger!

• In case any maintenance operation should be required, it is advisable to use latex gloves.
• Gear oil may cause serious damage to the skin if handled daily and for long periods.
• Wash your hands carefully after use.
• Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage center.
• In case any maintenance operation should be required, it is advisable to use latex gloves.
• DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
• KEEP AWAY FROM CHILDREN.

Brake fluid

Warning!

• When using the brake fluid, take care not to spill it on the plastic, rubber or painted parts, since it can damage them.
• When carrying out the maintenance operations on the braking system, use a clean cloth to cover these parts.
• Always wear safety goggles when working on the braking system.
• The brake fluid is highly irritant. Avoid contact with your eyes.
• If the brake fluid gets in contact with the skin or the eyes, carefully wash the parts of your body that get in contact with the fluid and consult a doctor.
• KEEP AWAY FROM CHILDREN.

Coolant

The coolant is composed of ethylene glycol that, under certain conditions, can become inflammable and send out invisible flames causing severe burns.

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.
• Even if toxic, coolant has a sweet flavour. Never leave it inside open containers or within the reach of animals to prevent the risk of drinking.
• KEEP AWAY FROM CHILDREN.
• Do not remove the radiator plug when the engine is hot. The coolant is under pressure and could cause severe burns.

Hydrogen gas and battery electrolyte

Danger!

• The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause severe burns in case of contact.
• Always wear tight gloves and protective clothes when handling this fluid.
• If the electrolyte gets in contact with the skin, carefully wash the parts of your body that get in contact with the fluid with abundant fresh water.
• Always use a protection for your eyes since also a very small amount of the battery fluid can cause blindness. In the event of contact with your eyes, carefully wash them with water for fifteen minutes and then consult immediately an eye specialist.
• Should you accidentally drink some fluid, drink abundant water or milk, then drink magnesia milk or vegetable oil and consult immediately a doctor. Battery releases explosive gases. Keep flames, sparks, cigarettes and any other heat source away from the battery. Make sure the room is well-aerated when servicing or recharging the battery.
• KEEP AWAY FROM CHILDREN.
• The battery fluid is corrosive.
• Do not pour it on the plastic parts.
• Make sure that the electrolyte acid is suitable for the type of battery used.

General precautions and information

Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components.

Danger!

• Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the engine and exhaust system to cool down; where possible, lift the motorcycle using adequate equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system which may still be hot to the touch to avoid scalds or burns.
• Never put any mechanical parts or other vehicle components in your mouth when you have both hands busy. None of the motorcycle components is edible. Some components are harmful to the human body or toxic.
• Unless expressly specified otherwise, motorcycle assemblies are refitted or re-assembled by reversing the removal or dismantling procedure. Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly to avoid disturbing any parts unless strictly necessary. Never attempt to polish matte-finished surfaces with lapping compounds.
• Never use fuel instead of solvent to clean the motorcycle.
• Do not clean any rubber or plastic parts or the seat with alcohol, petrol or solvents. Clean with water and neutral detergent.
• Always disconnect the battery negative (-) lead before soldering any electrical components.
• When two or more persons service the same motorcycle together, special care must be taken to avoid personal injury. Read 1.3.1.

Before disassembling any components

Clean off all dirt, mud, and dust and clear any foreign objects from the vehicle before disassembling any components.


Use the model-specific special tools where specified.

Disassembling the components

Never use pliers or similar tools to slacken and/or tighten nuts and bolts. Always use a suitable spanner.

Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection using a distinctive symbol or convention.

Mark each part clearly to avoid confusion when refitting.

Thoroughly clean and wash any components you have removed using a detergent with low flash point.

Mated parts should always be refitted together. These parts will have seated themselves against one another in service as a result of normal wear and tear and should never be mixed up with other similar parts on refitting.

Certain components are matched-pair parts and should always be replaced as a set.

Keep the motorcycle and its components well away from heat sources.

Reassembling the components

Danger!

• Never reuse a circlip or snap ring. These parts must always be renewed once they have been disturbed. When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow fitment to the shaft.
• Make a rule to check that a newly -fitted circlip or snap ring has located fully into its groove.
• 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.

When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten evenly in subsequent steps until achieving the specified torque.

Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have a damaged thread.

Lubricate the bearings abundantly before assembly.

Make a rule to check that all components you have fitted are correctly in place.

After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then operate the motorcycle in a private estate area or in a safe area away from traffic.

Clean all joint surfaces, oil seal edges and gaskets before assembly. Apply a light coat of lithium grease along the edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).

Electrical connectors

To disconnect the electrical connector, follow the procedures below. Failure to comply with these procedures may lead to irreparable damages to the connector and the wiring as well. If present, press the special safety hooks.

Warning! Do not pull cables to disconnect the two connectors.

Grasp the two connectors and disconnect them by pulling them in the two opposite directions.

In case of dirt, rust, moisture, etc., thoroughly clean the inside of the connectors with compressed air.

Make sure that the cables are correctly fitted inside the connectors terminals.

Note. The two connectors have just one correct positioning. Make sure to position them in the right direction.

Then fit the two connectors. Make sure they are correctly coupled (a click will be heard).

Tightening torque settings

Danger!

• Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other suspension parts play a fundamental role to ensure vehicle safety. Make sure that these values are always within the specified limits.
• Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a torque wrench.
• Failure to comply with these recommendations could lead to the loosening and detachment of one of these parts with a consequent locking of the wheel or other serious troubles affecting the vehicle maneuverability, and thus the risk of falls and serious injuries or death.

See this article in russian language

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Article about repair motorcycles «Aprilia RS-series RS 125» (1998-2005): «Basic safety rules»: https://motoinstruction.ru/en/Aprilia/RS/RS125-3/owner/intro/112738 <a href="https://motoinstruction.ru/en/Aprilia/RS/RS125-3/owner/intro/112738">Basic safety rules</a> - article about repair motorcycles «Aprilia RS-series RS 125» (1998-2005) from section «Introduction to manual». [url=https://motoinstruction.ru/en/Aprilia/RS/RS125-3/owner/intro/112738]Basic safety rules[/url] - article about repair motorcycles «Aprilia RS-series RS 125» (1998-2005) from section «Introduction to manual».