Complete map of motorcycle repair instructions Aprilia

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Repair motorcycles Aprilia RS-series
Aprilia RS 125 (3 generation, 1998-2005)
Information for owner

Abbreviations, symbols and conventions
Safety information
Basic safety rules
Warnings concerning fuel, lubricants, cooland and other component parts
Running-in recommendations
Vehicle identification data
Using spare parts
Use of products for all operations
Use of special tools for all operations
General tightening torque settings
Technical data of motorcycle
Positioning the vehicle on the front service stand (OPT)
Positioning the vehicle on the rear service stand (OPT)
Lubricant chart
Decals instructions

Maintenance

Regular service intervals chart
Points to be lubricated
Multifunction computer
Nut, bolt, screw tightening
Tightening torques of fastening elements
Battery — precautions
Checking and cleaning the terminals of battery
Checking the battery electrolyte level
Recharging the battery
Long inactivity of the battery
Checking electrical parts
Spark plugs maintenance
Air cleaner maintenance
Fuel lines, oil pipes and tubes
Lifting the fuel tank
Checking and topping up the coolant level
Adjusting the clutch
Checking and topping up the front brake fluid level
Changing the brake fluid
Checking the brake pad wear
Checking and topping up the rear brake fluid
Bleeding the braking systems
Adjusting the rear brake control lever
Adjusting the gearbox lever
Checking for throttle proper operation
Throttle cable play adjustment
Idling adjustment
Cold-start cable play adjustment
Steering maintenance
Front suspension maintenance
Rear swinging arm inspection
Rear suspension maintenance
Rear swinging arm adjustment
Inspecting the rear suspension linkage system
Wheels maintenance
Tyres maintenance
Exhaust manifold nuts
Drive chain maintenance
Chain slack inspection
Adjusting the drive chain
Checking chain and sprockets for wear
Chain cleaning and lubrication
Chain slider inspection

Troubleshooting

Engine troubleshooting information
Carburetor troubleshooting information
Radiator troubleshooting information
Electrical system troubleshooting information
Battery troubleshooting information
Brakes troubleshooting information
Chassis troubleshooting information
Engine and systems

Engine repair

Exhaust pipe removal
Engine general information
Components that can be removed with the engine installed in the frame
Engine removal
Installing the engine into the frame
RAVE valve specifications
Exhaust valve removal (RAVE)
RAVE valve component inspection
Exhaust valve installation (RAVE)

Fuel system

Fuel tank removal
Draining the fuel tank
Complete removal of the fuel cock
Airbox removal
Air cleaner removal
Carburetor removal
Removing the fuel feed filter
Carburetor specifications

Cooling and lube system

Removing the engine oil tank
Cooling system diagram
Coolant change
Radiator — removal and installation
Coolant thermistor — removal and installation
Thermostat — removal and installation
Expansion reservoir — removal and installation
Running gear and frame

Frame and hinged elements

Main elements of chassis
Rider seat — removal and installation
Removing the side fairings
Air dam removal
Front fairing removal
Windscreen removal
Fuel tank filler cap removal
Fuel tank fairing removal
Seat subframe cover removal
Tail section removal
Removing the front mudguard
Removing the rear mudguard
Removing the seat end cover
Removing the number plate bracket
Chain guard removal
Upper chain slider removal
Lower chain slider removal
Air scoop removal
Removing the throttle control
Removing the throttle cable from intermediate pulley to oil pump
Removing the front brake control
Removing the clutch cable
Complete removal of the gear shift lever
Removing the rear brake lever
Removing the handlebars
Removing the instrument panel subframe
Removing the seat latch
Removing the right-hand rider footpeg bracket
Removing the left-hand rider footpeg bracket
Removing the rider footpeg
Removing the passenger footpeg brackets
Passenger footpeg removal
Side stand removal
Seat subframe removal
Frame removal
Frame installation
Routing and connections of wiring, cables and hoses

Front suspension and handlebar

Steering construction
Headstock removal
Steering component inspection
Headstock re-assembly
Front fork construction
Removing the stanchion tubes — sliders
Disassembling the stanchion tubes — sliders
Changing front fork oil
Front fork component inspection
Stanchion tube — slider assembly
Installing stanchions and sliders

Rear suspension

Removing the rear swinging arm
Dismantling the swinging arm
Rear swinging arm component inspection
Reassembling the swinging arm
Installing the swinging arm
Rear shock absorber removal
Rear shock absorber installation
Removing the rear suspension linkages
Dismantling the rear suspension linkage system
Rear suspension component inspection
Removing the drive chain
Refitting the drive chain

Brake system

Front brake construction
Replacing the front brake pads
Front brake disc inspection
Front brake disc removal
Rear brake construction
Replacing the rear brake pads
Rear brake disc inspection
Rear brake disc removal
Removing the brake master cylinder

Wheels and tires

Front wheel construction
Removing the complete front wheel
Front wheel disassembly
Front wheel component inspection
Refitting the complete front wheel
Rear wheel construction
Removing the complete rear wheel
Rear wheel disassembly
Final drive removal
Inspecting the rear wheel components
Refitting the complete rear wheel
Electric equipment

Equipment and devices

Battery removal
Removing the engine control unit
Voltage rectifier removal
Removing the right-hand light dip switch
Removing the left-hand light dip switch
Removing the ignition switch/steering lock
Removing the instrument panel
Headlight removal
Removing the front direction indicators
Removing the rear direction indicators
Warning horn removal
Removing the tail light
Layout of electrical components
Wiring colour codes and electrical connectors
Sensors and rev counter circuit
Visual and acoustic signalling system
Brake lights circuit
Light circuit of motorcycle
Rave valve circuit
Stand logic circuit
Bulb replacement
Replacing the fuses
Beam height setting
Wiring diagram of motorcycle

Starting and charging system

Battery — installation and maintenance
Ignition system circuit and troubleshooting
Ignition system test readings
Charge system layout and power supply
Charge system test readings
Starter circuit and troubleshooting

Repair motorcycles Aprilia Shiver
Aprilia SL 750 (2007-2016)
Information for owner

Introduction to manual

General safety rules
Maintenance rules — general precautions and information
Engine running-in
Vehicle identification data
Special tools for motorcycle repair

Control devices

Location of main components
Dashboard
Light indicators
Digital LCD display
Emergency signals
Selecting a control program
Control buttons
Additional functions
Egnition lock
The beep button
Turn signal switch
Button overtaking
Emergency button
Start button
Engine switch
Anti-lock braking system (ABS)
Using the immobilizer
Seat opening
Motorcycle identification numbers

Operation manual

Checks before driving
Refueling
Adjusting the rear shock absorbers
Front fork adjustment
Adjusting the front brake handle
Adjusting the rear brake pedal
Adjusting the clutch handle
Running in a new motorcycle
Engine starting
Electronic control RIDE BY WIRE
Starting/driving
Stopping the engine
Parking a motorcycle
Muffler with catalyst
Installing the motorcycle on a stand
Recommendations for preventing theft
Basic safety rules
Boarding a vehicle
Disembarking from a vehicle

Technical characteristics

Maintenance

Routine maintenance chart
Spark plug — installation
Engine oil — check
Engine oil — replacement
Engine oil filter — replacement
Air filter — replacement
Checking the valve clearance
Troubleshooting procedures
Engine and systems

Engine repair

Engine removal — vehicle preparation
Removing the engine from the vehicle
Installing the engine to the vehicle
Removing the starter motor
Removing the flywheel cover
Removing the flywheel cover components
Magneto flywheel removal
Freewheel — removal and installation
Water pump removal
Removing the head cover
Removing the cylinder head
Removing the overhead camshaft
Removing the valves
Checking the overhead camshaft
Valve and springs check
Checking the cylinder head
Removing the chain tensioner
Timing chain removal
Removing the chain sliders
Checking the timing chain
Installing the chain tensioner
Timing chain installation
Removing the cylinder
Disassembling the piston
Checking the cylinder
Checking the piston
Fitting the piston
Installing the cylinder
Selecting the base gasket
Installing the cylinder head
Installing the head cover
Splitting the crankcase halves
Removing the crankshaft
Inspecting the crankcase halves
Inspecting the crankshaft components
Crankcase — removal and installation
Installing the crankshaft
Refitting the crankcase halves

Lubrication system

Old generation oil pump removal
New generation oil pump removal
Oil pump inspection
Old generation oil pump installing
New generation oil pump installing

Cooling system

Electric fan removal
Coolant replacement
Water pump removal
Water pump installation
Removing the radiator
Removing the expansion tank
Thermostatic valve

Fuel system

Fuel pump characteristics
Throttle body characteristics
Removing the throttle body
Using axone for injection system

Transmission

Gearbox diagram
Gearbox shafts diagram
Disassembling the gearbox
Checking the gear selector
Gearbox selector shaft — removal and installation
Removing the clutch cover
Disassembling the clutch
Checking the clutch plates
Checking the clutch housing
Assembling the clutch
Drive chain adjusting
Running gear and frame

Frame and hinged elements

Removing the tail pipe
Removing the manifold — tail pipe
Removing the exhaust manifold
Removing the lambda sensor
Seat — removal and installation
Headlight assy — removal and installation
Taillight assy — removal and installation
Side body panels
License plate holder
Air box — removal and installation
Fuel tank — removal and installation
Front mudguard — removal and installation
Instrument cluster support
Tail guard — removal and installation

Front suspension and handlebar

Removing the front wheel
Checking the front wheel
Removing the fork legs
Front fork draining oil
Disassembling the front fork
Checking the components of front fork
Reassembling the front fork
Filling oil in front fork
Steering bearing adjusting play

Rear suspension

Removing the rear wheel
Checking the rear wheel
Removing rear shock absorbers
Removing rear swinging arm

Brake system

Front brake pads removal
Rear brake pads removal
Bleeding front braking system
Bleeding rear braking system
Electric equipment

Equipment and devices

Electrical components arrangement
Electrical system installation
Special checks for the correct connection and laying of cables
Electrical components — front side
Electrical components — central part
Electrical components — back side
General wiring diagram
Electrical system — checks and inspections
Dashboard — checks and inspections
Service warning light reset
Fuel reserve sensor
Lights characteristic
Fuses designation
Control unit
Vehicle speed sensor
Engine revolution sensor
Throttle grip position sensor — removal
Intake air pressure sensor
Engine temperature sensor
Intake air temperature sensor
Lambda sensor — function and operation
Injector — function and operation
Ignition coil — function and operation
Throttle body — function and operation
Engine oil pressure sensor
Gear in neutral sensor
Clutch lever sensor
Side stand sensor
Bank angle sensor/fall sensor
Instrument panel air temperature sensor
Electric fan circuit
Run / stop switch
Throttle control unit
Connectors pin out
CAN line — function and troubleshooting

Repair manuals for:

Aprilia BMW Ducati Harley Honda Kawasaki Suzuki Triumph Yamaha