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Aprilia RS 125 1997 Full Service Repair Manual

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$133.00
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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 1997 Generation Model Generation: First Generation (Rotax 122) Codes Engine Code: Rotax 122 (often referred to as 122 EGS or similar variants) 👋 Introduction Market Position Motorcycle Segment: Lightweight sportbike, entry-level performance Competitive Analysis Key Competitors 1997: Yamaha YZF-R125 (though R125 came later, similar displacement class competitors like Cagiva Mito 125, Honda NSR125R, Suzuki RG125 GAMMA) Key Features Design Philosophy: Aggressive styling, sporty handling, performance-oriented 2-stroke engine, representing a premium offering in the 125cc class. Target Audience: Young riders, those seeking a stylish and fun-to-ride motorcycle with a performance edge, often favored for track days or spirited road riding. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service, repair, maintenance, and restoration Page Count Estimated Page Count: Likely 200-400 pages (typical for a full service manual of this era) Manual Type Manual Type: Full Service and Repair Manual Language Language: Likely English (standard for international markets, potentially others depending on origin) Format Digital Format: PDF (assumed for modern digital sales, original may have been printed) 📖 Manual Coverage Systems Covered Engine System Coverage: Engine disassembly, assembly, tuning, cooling system, lubrication system, fuel system (carburetor), exhaust system, starting system, ignition system (CDI), 2-stroke specific lubrication (oil injection). Drivetrain Coverage: Clutch (multi-plate wet), gearbox (6-speed), final drive (chain), gearbox oil specifications. Chassis Coverage: Frame, swingarm, suspension (front telescopic forks, rear monoshock), steering head, wheels, hubs, spokes, bearings. Braking System Coverage: Front and rear disc brake systems, hydraulic components, caliper maintenance, pad replacement, fluid specifications (DOT 3/4), bleeding procedures. Electrical System Coverage: Wiring diagrams, lighting systems (headlight, taillight, turn signals), battery, charging system (alternator/stator), starter motor, fuses, switches, instrumentation. Procedures Included Maintenance Procedures: Regular servicing, oil changes (gearbox, 2-stroke injection), filter replacements (air, fuel), spark plug checks, chain adjustment, brake checks, general cleaning and lubrication. Repair Procedures: Engine rebuild (top-end and bottom-end), carburetor overhaul, suspension fork service, brake caliper rebuild, electrical component replacement, chassis component repairs. Troubleshooting Guides: Diagnostic procedures for common starting, running, electrical, and braking issues, often with symptom-based flowcharts. Technical Depth Diagnostic Capabilities: Detailed diagnostic information for engine performance, electrical faults, and chassis issues, including specific measurements and tolerances. Rebuild Level: Complete engine and gearbox rebuilds, including specifications for piston rings, crankshaft, bearings, seals, and clutch components. Torque Specifications: Precise torque values for all critical fasteners, including cylinder head bolts, crankcase bolts, wheel nuts, and brake caliper mounting bolts. 📊 Manual Specifications File Format Digital File Type: PDF (Portable Document Format) Print Quality Digital Image Resolution: High resolution (typically 300 DPI or higher for clarity of diagrams and text) Binding Type Original Binding Style: Likely saddle-stitched or perfect bound (for printed versions) Paper Type Original Paper Quality: Heavyweight, semi-gloss paper stock (common for workshop manuals to withstand use). ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, single-cylinder Displacement: 125 cc (cubic centimeters) Bore X Stroke: Typically 54 mm x 54.5 mm (check specific manual for exact figure) Compression Ratio: Around 12.5:1 (subject to specific variant and tuning) Performance Horsepower: Approximately 30-33 HP (depending on homologation and market restrictions) Torque: Approximately 18-20 Nm (Newton-meters) (at peak RPM) Fuel System Carburetor Type: Dell'Orto VHSH 30 CS (common specification, can vary) Fuel Type: Unleaded gasoline (RON 95 or higher recommended) Oil System 2 Stroke Oil Injection: Automatic oil injection system for pre-mixing 2-stroke oil with fuel. Cooling System Cooling Method: Liquid cooling with radiator and fan. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh sequential gearbox. Optional Clutch Type: Multi-plate wet clutch. Features Gear Ratios: Specific gear ratios will be detailed in the manual, crucial for performance tuning. Gearbox Oil Spec: API GL-4, SAE 80W/90 hypoid gear oil is typical (verify with manual). 📐 Dimensions Exterior Length: Approximately 1950 mm (check specific manual) Width: Approximately 740 mm (handlebar width, check specific manual) Height: Approximately 1100 mm (seat height, check specific manual) Weights Dry Weight: Approximately 131 kg (dry weight) Fuel Tank Capacity: Approximately 12 Liters Oil Tank Capacity: Approximately 1.2 Liters (for 2-stroke oil injection) 🛡️ Safety Features Ratings Crash Test Standards: Motorcycles of this era did not typically undergo standardized crash testing like automobiles. Active Features Braking System Type: Dual disc front, single disc rear (standard for performance). Tires Front: Typically 110/70-17 (verify with manual for exact spec) Tires Rear: Typically 150/60-17 (verify with manual for exact spec) Passive Features Lighting System: Halogen headlight, LED or incandescent taillight and indicators. 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, speedometer, odometer, and warning lights. Basic but functional for its era. Driver Assistance ABS Availability: ABS was not a standard or common option on 125cc sportbikes of this vintage. Connectivity Connectivity Features: None (motorcycle technology of this era did not include digital connectivity). 🔧 Maintenance Service Intervals Oil Change Interval Gearbox: Every 5,000-10,000 km or annually (refer to manual for precise interval)....
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Aprilia RS 125 1997 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Year:
1997
Generation
Model Generation:
First Generation (Rotax 122)
Codes
Engine Code:
Rotax 122 (often referred to as 122 EGS or similar variants)
👋 Introduction
Market Position
Motorcycle Segment:
Lightweight sportbike, entry-level performance
Competitive Analysis
Key Competitors 1997:
Yamaha YZF-R125 (though R125 came later, similar displacement class competitors like Cagiva Mito 125, Honda NSR125R, Suzuki RG125 GAMMA)
Key Features
Design Philosophy:
Aggressive styling, sporty handling, performance-oriented 2-stroke engine, representing a premium offering in the 125cc class.
Target Audience:
Young riders, those seeking a stylish and fun-to-ride motorcycle with a performance edge, often favored for track days or spirited road riding.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Comprehensive service, repair, maintenance, and restoration
Page Count
Estimated Page Count:
Likely 200-400 pages (typical for a full service manual of this era)
Manual Type
Manual Type:
Full Service and Repair Manual
Language
Language:
Likely English (standard for international markets, potentially others depending on origin)
Format
Digital Format:
PDF (assumed for modern digital sales, original may have been printed)
📖 Manual Coverage
Systems Covered
Engine System Coverage:
Engine disassembly, assembly, tuning, cooling system, lubrication system, fuel system (carburetor), exhaust system, starting system, ignition system (CDI), 2-stroke specific lubrication (oil injection).
Drivetrain Coverage:
Clutch (multi-plate wet), gearbox (6-speed), final drive (chain), gearbox oil specifications.
Chassis Coverage:
Frame, swingarm, suspension (front telescopic forks, rear monoshock), steering head, wheels, hubs, spokes, bearings.
Braking System Coverage:
Front and rear disc brake systems, hydraulic components, caliper maintenance, pad replacement, fluid specifications (DOT 3/4), bleeding procedures.
Electrical System Coverage:
Wiring diagrams, lighting systems (headlight, taillight, turn signals), battery, charging system (alternator/stator), starter motor, fuses, switches, instrumentation.
Procedures Included
Maintenance Procedures:
Regular servicing, oil changes (gearbox, 2-stroke injection), filter replacements (air, fuel), spark plug checks, chain adjustment, brake checks, general cleaning and lubrication.
Repair Procedures:
Engine rebuild (top-end and bottom-end), carburetor overhaul, suspension fork service, brake caliper rebuild, electrical component replacement, chassis component repairs.
Troubleshooting Guides:
Diagnostic procedures for common starting, running, electrical, and braking issues, often with symptom-based flowcharts.
Technical Depth
Diagnostic Capabilities:
Detailed diagnostic information for engine performance, electrical faults, and chassis issues, including specific measurements and tolerances.
Rebuild Level:
Complete engine and gearbox rebuilds, including specifications for piston rings, crankshaft, bearings, seals, and clutch components.
Torque Specifications:
Precise torque values for all critical fasteners, including cylinder head bolts, crankcase bolts, wheel nuts, and brake caliper mounting bolts.
📊 Manual Specifications
File Format
Digital File Type:
PDF (Portable Document Format)
Print Quality
Digital Image Resolution:
High resolution (typically 300 DPI or higher for clarity of diagrams and text)
Binding Type
Original Binding Style:
Likely saddle-stitched or perfect bound (for printed versions)
Paper Type
Original Paper Quality:
Heavyweight, semi-gloss paper stock (common for workshop manuals to withstand use).
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
125 cc (cubic centimeters)
Bore X Stroke:
Typically 54 mm x 54.5 mm (check specific manual for exact figure)
Compression Ratio:
Around 12.5:1 (subject to specific variant and tuning)
Performance
Horsepower:
Approximately 30-33 HP (depending on homologation and market restrictions)
Torque:
Approximately 18-20 Nm (Newton-meters) (at peak RPM)
Fuel System
Carburetor Type:
Dell'Orto VHSH 30 CS (common specification, can vary)
Fuel Type:
Unleaded gasoline (RON 95 or higher recommended)
Oil System
2 Stroke Oil Injection:
Automatic oil injection system for pre-mixing 2-stroke oil with fuel.
Cooling System
Cooling Method:
Liquid cooling with radiator and fan.
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh sequential gearbox.
Optional
Clutch Type:
Multi-plate wet clutch.
Features
Gear Ratios:
Specific gear ratios will be detailed in the manual, crucial for performance tuning.
Gearbox Oil Spec:
API GL-4, SAE 80W/90 hypoid gear oil is typical (verify with manual).
📐 Dimensions
Exterior
Length:
Approximately 1950 mm (check specific manual)
Width:
Approximately 740 mm (handlebar width, check specific manual)
Height:
Approximately 1100 mm (seat height, check specific manual)
Weights
Dry Weight:
Approximately 131 kg (dry weight)
Fuel Tank Capacity:
Approximately 12 Liters
Oil Tank Capacity:
Approximately 1.2 Liters (for 2-stroke oil injection)
🛡️ Safety Features
Ratings
Crash Test Standards:
Motorcycles of this era did not typically undergo standardized crash testing like automobiles.
Active Features
Braking System Type:
Dual disc front, single disc rear (standard for performance).
Tires Front:
Typically 110/70-17 (verify with manual for exact spec)
Tires Rear:
Typically 150/60-17 (verify with manual for exact spec)
Passive Features
Lighting System:
Halogen headlight, LED or incandescent taillight and indicators.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, speedometer, odometer, and warning lights. Basic but functional for its era.
Driver Assistance
ABS Availability:
ABS was not a standard or common option on 125cc sportbikes of this vintage.
Connectivity
Connectivity Features:
None (motorcycle technology of this era did not include digital connectivity).
🔧 Maintenance
Service Intervals
Oil Change Interval Gearbox:
Every 5,000-10,000 km or annually (refer to manual for precise interval).
Spark Plug Replacement:
Every 5,000-8,000 km or as needed based on inspection (check manual for specific plug type and gap).
Chain Lubrication And Adjustment:
Every 500-1000 km and after washing/wet conditions.
Air Filter Cleaning Or Replacement:
Every 5,000-10,000 km or as per manual recommendation based on operating conditions.
Fluid Specifications
Coolant Type:
Mixture of distilled water and ethylene glycol-based antifreeze (typically 50/50 ratio, see manual for specific Aprilia approved coolant).
Brake Fluid Type:
DOT 4 or DOT 3 (verify with manual, DOT 4 is preferred for higher boiling point).
2 Stroke Oil Type:
High-quality, fully synthetic 2-stroke racing oil designed for high-performance liquid-cooled engines. Specific Aprilia recommendations are best.
Known Issues
Common Engine Wear Items:
Piston rings and piston wear due to the nature of 2-stroke engines and high-revving operation. Clutch wear. Reed valve issues.
Carburetor Tuning Sensitivity:
The Dell'Orto carburetor can be sensitive to altitude, temperature, and modifications, requiring periodic re-jetting or adjustment.
Electrical Gremlins:
Age-related issues with wiring connectors, regulator/rectifier, and stator can occur, often detailed in troubleshooting sections.
Suspension Seals:
Front fork seals can degrade over time, leading to oil leaks.
📚 Vehicle History
Brand Heritage
Aprilia Heritage:
Italian manufacturer with a strong racing pedigree, particularly in smaller displacement classes (125cc and 250cc).
Model Evolution
Rs 125 Lineage:
The RS 125 was a flagship model in Aprilia's lightweight sportbike range, evolving from earlier models like the AF1 series. The 1997 model represents a refinement of the highly successful Rotax 122 engine platform.
Production
Production Location:
Italy
Production Era:
The Rotax 122 engine powered Aprilia's 125cc models for many years, with the RS 125 being a dominant force in its segment throughout the 1990s and early 2000s.
🏆 Awards & Recognition
Recognitions
Motorcycle Awards:
The Aprilia RS 125 consistently received accolades for its handling, performance, and race-derived styling, often winning comparions in its class.
Ratings
Performance Ratings:
Highly rated for agility, braking performance, and top-end speed within the 125cc sportbike category.
Certifications
Emissions Standards:
Met the prevailing emissions standards for motorcycles in its target markets for 1997.
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