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Aprilia RS 125 1993-2006 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Years Covered: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Chassis Codes: RP, RW 👋 Introduction Market Position Segment: Lightweight sportbike, popular for track days, commuting, and beginner riders. Competitive Analysis Rivals: Yamaha YZF-R125 (later models), Honda CBR125R, Suzuki GSX-R125 (later models). Key Features Design: Aggressive styling inspired by larger Aprilia sportbikes, sharp lines, dual headlights. Performance Focus: High-revving 2-stroke engine, capable chassis, sporty ergonomics. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for all Aprilia RS 125 models from 1993 to 2006. Page Count Estimated Pages: 500+ Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF), potentially Printable 📖 Manual Coverage Systems Covered Engine: 2-stroke Rotax 122, 123 engine systems: disassembly, assembly, tuning, diagnostics, lubrication, cooling. Fuel System: Carburetor (Dell'Orto PHBH, VHSA/B), fuel injection (later models), fuel pump, fuel lines, oil injection system. Ignition System: CDI, electronic ignition, spark plugs, stator, rotor, wiring. Transmission: 6-speed sequential gearbox: clutch, gear selector, gearbox components, lubrication, troubleshooting. Chassis: Frame, swingarm, rear suspension (monoshock, linkage), front suspension (telescopic forks, e.g., Marzocchi, Paioli), steering head bearings. Brakes: Hydraulic disc brakes: front and rear calipers, master cylinders, brake lines, fluid specifications, bleeding procedures, rotor specifications. Electrical System: Wiring diagrams, lighting, starting system, charging system (alternator, battery), fuses, relays, instruments, sensors. Bodywork: Fairings, seat, fuel tank, fenders, mounting points, disassembly, reassembly. Wheels And Tires: Wheel types, bearing maintenance, tire fitment, pressures, balancing. Procedures Included Maintenance: Regular servicing, oil changes, filter replacements, chain adjustment, bolt torquing, battery care. Troubleshooting: Diagnostic charts for common issues, electrical faults, engine performance problems, starting difficulties. Engine Rebuild: Piston ring replacement, cylinder head work, crankshaft assembly, seals, gaskets. Suspension Service: Fork oil replacement, seal replacement, shock absorber adjustments. Brake System Overhaul: Caliper rebuild, master cylinder service, hose replacement. Carburetor Adjustment: Jetting, idle speed, mixture screw settings. Technical Depth Depth: Factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts. Diagnostics: In-depth diagnostic procedures, fault code interpretation (if applicable), resistance and voltage checks. Torque Specifications: Precise torque values for all critical fasteners across all systems. Schematics: Detailed electrical wiring diagrams and system schematics. 📊 Manual Specifications File Format Digital Quality: High-resolution, searchable PDF for easy navigation and information retrieval. Print Quality Print Readability: Designed for clear printing of all text, diagrams, and images. Binding Type Digital Format Advantage: Instant download, accessible on multiple devices, easily searchable. Paper Type Original Format Assumption: Likely printed on durable, high-quality paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 2-stroke, single-cylinder Displacement: 124.8 cc (approx.) Bore X Stroke: 54 mm x 54.5 mm (typical) Power Output: Approx. 30-35 HP (depending on market restrictions and specific year) Torque Output: Approx. 20-23 Nm (depending on market restrictions and specific year) Performance Redline: Approx. 10,000-11,000 RPM Fuel System Carburetor Standard: Dell'Orto PHBH 28 or VHSA/B 28 (variable by year/market) Fuel Type: Unleaded gasoline (95 RON recommended), 2-stroke oil for premix or oil injection system. Oil Type: High-quality 2-stroke synthetic engine oil meeting JASO FD or API TC specifications. 🔧 Transmission Standard Type: 6-speed manual, constant mesh Clutch Type: Wet multi-plate clutch Features Gear Ratios: Specific ratios detailed within the manual. Transmission Oil Type: API GL-4 or GL-5, SAE 75W/90 or 10W/40 (check manual for specific recommendation). 📐 Dimensions Exterior Length: Approx. 1940-1990 mm Width: Approx. 720-740 mm Height: Approx. 1050-1110 mm Weights Dry Weight: Approx. 130-140 kg Fuel Tank Capacity: Approx. 11-13 Liters Wheelbase: Approx. 1360-1370 mm 🛡️ Safety Features Ratings Crash Test Info: As a motorcycle, official crash test ratings like those for cars are not applicable. Safety relies on rider skill and adherence to road rules. Active Features Braking System: Dual disc front brake, single disc rear brake providing strong stopping power for its class. Lighting: Halogen headlamp for visibility, brake lights, turn signals. Passive Features Frame Construction: Sturdy perimeter frame designed for rigidity and rider feedback. 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, speedometer, odometer, trip meter, coolant temperature gauge, basic indicator lights. Driver Assistance ABS: ABS was generally not a standard feature on this model during its production run; available on some later specific versions perhaps. Connectivity Integrated Tech: Focus is on mechanical and electrical systems; no digital connectivity or advanced rider aids. 🔧 Maintenance Service Intervals Oil Change Engine: Recommended every 3,000-5,000 km or annually, refer to manual for specifics. Spark Plug Replacement: Recommended every 5,000-7,500 km, or as per manual's spark plug chart. Air Filter Cleaning: Check every 2,500 km, clean or replace as needed. Chain Lubrication: Lubricate every 500 km or after riding in wet conditions. Brake Fluid Flush: Recommended every 1-2 years. Fluid Specifications Coolant: Ethylene glycol based antifreeze coolant mixture (50% water, 50% coolant) – specific Aprilia or equivalent recommended. Fork Oil: Typically...
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Aprilia RS 125 1993-2006 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Years Covered:
1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Codes
Chassis Codes:
RP, RW
👋 Introduction
Market Position
Segment:
Lightweight sportbike, popular for track days, commuting, and beginner riders.
Competitive Analysis
Rivals:
Yamaha YZF-R125 (later models), Honda CBR125R, Suzuki GSX-R125 (later models).
Key Features
Design:
Aggressive styling inspired by larger Aprilia sportbikes, sharp lines, dual headlights.
Performance Focus:
High-revving 2-stroke engine, capable chassis, sporty ergonomics.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service and repair for all Aprilia RS 125 models from 1993 to 2006.
Page Count
Estimated Pages:
500+
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF), potentially Printable
📖 Manual Coverage
Systems Covered
Engine:
2-stroke Rotax 122, 123 engine systems: disassembly, assembly, tuning, diagnostics, lubrication, cooling.
Fuel System:
Carburetor (Dell'Orto PHBH, VHSA/B), fuel injection (later models), fuel pump, fuel lines, oil injection system.
Ignition System:
CDI, electronic ignition, spark plugs, stator, rotor, wiring.
Transmission:
6-speed sequential gearbox: clutch, gear selector, gearbox components, lubrication, troubleshooting.
Chassis:
Frame, swingarm, rear suspension (monoshock, linkage), front suspension (telescopic forks, e.g., Marzocchi, Paioli), steering head bearings.
Brakes:
Hydraulic disc brakes: front and rear calipers, master cylinders, brake lines, fluid specifications, bleeding procedures, rotor specifications.
Electrical System:
Wiring diagrams, lighting, starting system, charging system (alternator, battery), fuses, relays, instruments, sensors.
Bodywork:
Fairings, seat, fuel tank, fenders, mounting points, disassembly, reassembly.
Wheels And Tires:
Wheel types, bearing maintenance, tire fitment, pressures, balancing.
Procedures Included
Maintenance:
Regular servicing, oil changes, filter replacements, chain adjustment, bolt torquing, battery care.
Troubleshooting:
Diagnostic charts for common issues, electrical faults, engine performance problems, starting difficulties.
Engine Rebuild:
Piston ring replacement, cylinder head work, crankshaft assembly, seals, gaskets.
Suspension Service:
Fork oil replacement, seal replacement, shock absorber adjustments.
Brake System Overhaul:
Caliper rebuild, master cylinder service, hose replacement.
Carburetor Adjustment:
Jetting, idle speed, mixture screw settings.
Technical Depth
Depth:
Factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts.
Diagnostics:
In-depth diagnostic procedures, fault code interpretation (if applicable), resistance and voltage checks.
Torque Specifications:
Precise torque values for all critical fasteners across all systems.
Schematics:
Detailed electrical wiring diagrams and system schematics.
📊 Manual Specifications
File Format
Digital Quality:
High-resolution, searchable PDF for easy navigation and information retrieval.
Print Quality
Print Readability:
Designed for clear printing of all text, diagrams, and images.
Binding Type
Digital Format Advantage:
Instant download, accessible on multiple devices, easily searchable.
Paper Type
Original Format Assumption:
Likely printed on durable, high-quality paper suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
124.8 cc (approx.)
Bore X Stroke:
54 mm x 54.5 mm (typical)
Power Output:
Approx. 30-35 HP (depending on market restrictions and specific year)
Torque Output:
Approx. 20-23 Nm (depending on market restrictions and specific year)
Performance
Redline:
Approx. 10,000-11,000 RPM
Fuel System
Carburetor Standard:
Dell'Orto PHBH 28 or VHSA/B 28 (variable by year/market)
Fuel Type:
Unleaded gasoline (95 RON recommended), 2-stroke oil for premix or oil injection system.
Oil Type:
High-quality 2-stroke synthetic engine oil meeting JASO FD or API TC specifications.
🔧 Transmission
Standard
Type:
6-speed manual, constant mesh
Clutch Type:
Wet multi-plate clutch
Features
Gear Ratios:
Specific ratios detailed within the manual.
Transmission Oil Type:
API GL-4 or GL-5, SAE 75W/90 or 10W/40 (check manual for specific recommendation).
📐 Dimensions
Exterior
Length:
Approx. 1940-1990 mm
Width:
Approx. 720-740 mm
Height:
Approx. 1050-1110 mm
Weights
Dry Weight:
Approx. 130-140 kg
Fuel Tank Capacity:
Approx. 11-13 Liters
Wheelbase:
Approx. 1360-1370 mm
🛡️ Safety Features
Ratings
Crash Test Info:
As a motorcycle, official crash test ratings like those for cars are not applicable. Safety relies on rider skill and adherence to road rules.
Active Features
Braking System:
Dual disc front brake, single disc rear brake providing strong stopping power for its class.
Lighting:
Halogen headlamp for visibility, brake lights, turn signals.
Passive Features
Frame Construction:
Sturdy perimeter frame designed for rigidity and rider feedback.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, speedometer, odometer, trip meter, coolant temperature gauge, basic indicator lights.
Driver Assistance
ABS:
ABS was generally not a standard feature on this model during its production run; available on some later specific versions perhaps.
Connectivity
Integrated Tech:
Focus is on mechanical and electrical systems; no digital connectivity or advanced rider aids.
🔧 Maintenance
Service Intervals
Oil Change Engine:
Recommended every 3,000-5,000 km or annually, refer to manual for specifics.
Spark Plug Replacement:
Recommended every 5,000-7,500 km, or as per manual's spark plug chart.
Air Filter Cleaning:
Check every 2,500 km, clean or replace as needed.
Chain Lubrication:
Lubricate every 500 km or after riding in wet conditions.
Brake Fluid Flush:
Recommended every 1-2 years.
Fluid Specifications
Coolant:
Ethylene glycol based antifreeze coolant mixture (50% water, 50% coolant) – specific Aprilia or equivalent recommended.
Fork Oil:
Typically SAE 5W or 10W fork oil, refer to manual for exact viscosity and volume.
Known Issues
Power Valve:
Rotax 'Power Jet' or 'ATAC' exhaust power valve can become sticky or seize if not properly maintained and cleaned, affecting performance.
Carburetor Tuning:
Dell'Orto carbs can be sensitive to altitude and temperature, requiring periodic adjustment for optimal performance.
Electrical Connections:
Older wiring harnesses can develop corrosion or loose connections, leading to intermittent electrical faults.
Cylinder Wear:
Due to the high-strung nature of 2-stroke engines, regular monitoring of cylinder bore and piston ring wear is crucial.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer with a strong racing heritage, particularly in smaller displacement classes.
Model Evolution
Development Lineage:
The RS 125 built upon Aprilia's experience with performance-oriented 125cc two-strokes, offering a potent blend of speed and handling.
Production
Manufacturing Origin:
Italy
Production Period Covered:
Continual evolution from the early 1990s through the mid-2000s, with updates to styling and engine management.
🏆 Awards & Recognition
Recognitions
Motorsport Influence:
The RS 125 platform has a significant racing pedigree in FIM 125cc Grand Prix classes, which influenced its design and performance.
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