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Aprilia RS125 RS 125 1998 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: 1998 Codes Internal Model Code: AP98RS125 👋 Introduction Market Position Segment: Lightweight sport motorcycle segment, popular for track days and street performance. Competitive Analysis Competitors: Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125, Cagiva Mito 125. Key Features Performance Focus: High-revving two-stroke engine, aggressive styling, sporty handling. Target Audience: Young riders seeking a performance-oriented and stylish motorcycle. Manual Value Utility: Essential for owners and technicians to perform accurate maintenance, diagnostics, and repairs, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Primary Coverage: Mechanical Systems, Electrical Systems, Bodywork, Troubleshooting Regional Coverage: Global (International Specifications) Page Count Estimated Pages: 300-400 Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, repair, and reassembly of the Rotax 125cc two-stroke engine. Fuel System: Carburetor (Dell'Orto PHBH 28 QD) tuning, cleaning, and overhaul; fuel tank and lines inspection. Ignition System: CDI ignition system, stator, ignition coil, spark plug specifications and testing. Cooling System: Radiator, coolant hoses, thermostat, water pump maintenance and repair. Transmission Drivetrain: 6-speed sequential gearbox, clutch operation and adjustment, chain drive maintenance. Suspension: Front telescopic fork (Showa/Marzocchi variations) overhaul, oil change, and adjustments. Rear monoshock absorber (Sachs/Ohservations) inspection and service. Braking System: Front and rear hydraulic disc brakes, caliper service, master cylinder overhaul, brake fluid bleeding, pad replacement. Electrical System: Wiring diagrams, battery service, lighting system, starter motor, charging system testing and repair. Bodywork Chassis: Fairing removal and installation, seat maintenance, frame inspection, steering head bearing service. Procedures Included Preventative Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, general inspection guidelines. Troubleshooting: Diagnostic charts and procedures for common issues and malfunctions across all systems. Engine Rebuild: Detailed step-by-step instructions for complete engine teardown and rebuild, including piston, cylinder, crankshaft, and bearing replacement. Carburetor Tuning: Jetting charts, idle speed adjustment, mixture screw settings, and float height calibration. Suspension Adjustment: Preload, compression, and rebound damping adjustments for front and rear suspension. Electrical Diagnostics: Component testing using multimeters, fuse identification, and troubleshooting electrical faults. Wheel Tire Service: Tire pressure recommendations, wheel balancing, and axle maintenance. Technical Depth Depth: Comprehensive: Covers everything from basic fluid changes and checks to complete engine and transmission rebuilds, advanced electrical diagnostics, and suspension tuning. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Quality: High-resolution scans ensuring clarity of diagrams, schematics, and text. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Rotax 125cc, Liquid-Cooled, 2-Stroke, Single-Cylinder Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 12.0:1 Valve Mechanism: Reed Valve Intake, Exhaust Power Valve (Rotax A.P.C.S.) Performance Horsepower: Approx. 30-33 HP (depending on market restrictions) Torque: Approx. 21 Nm (15.5 lb-ft) at 8,000 RPM Fuel System Carburetor Model: Dell'Orto PHBH 28 QD Fuel Type: Unleaded Gasoline (95 RON Recommended) Lubrication Lubrication System: Separate Oil Injection System 2T Oil Type: API TC+, JASO FD certified Fully Synthetic 2-Stroke Oil 🔧 Transmission Standard Gearbox Type: 6-Speed Sequential Manual Clutch Type: Wet Multi-Plate Clutch Features Drive Type: Chain Drive Final Drive Ratio: 17/44 (Standard) 📐 Dimensions Exterior Length: Approx. 1,950 mm (76.8 in) Width: Approx. 720 mm (28.3 in) Height: Approx. 1,130 mm (44.5 in) Weights Dry Weight: Approx. 120 kg (264.5 lbs) Fuel Tank Capacity: Approx. 7.2 Liters (1.9 US gal) Oil Tank Capacity: Approx. 1.5 Liters (0.4 US gal) 🛡️ Safety Features Ratings Crash Test Data: N/A (Motorcycle specific safety is determined by design and rider input) Active Features Braking System: Dual Piston Front Caliper, Single Piston Rear Caliper, Hydraulic Disc Brakes Suspension Dynamics: Sport-tuned suspension for stability and control during cornering. Passive Features Chassis Design: Sturdy perimeter frame for torsional rigidity. Ergonomics: Sportbike riding position, providing rider feedback and control. 💡 Technology Features Infotainment Display: Analog Tachometer, Speedometer, Odometer, Fuel Gauge, Temperature Gauge (integrated into instrument cluster). Driver Assistance ABS: Not available on the 1998 model. Connectivity Bluetooth Usb: Not available on the 1998 model. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 km or annually. (Refer to manual for specific details) Spark Plug Replacement: Every 6,000 km or as per manual recommendation. Air Filter Cleaning: Every 3,000 km, cleaning or replacement as needed. Chain Lubrication Adjustment: Every 500 km or after riding in wet conditions. Fluid Specifications Engine Oil Type: Refer to manual for specific 2T oil; Crankcase Oil: SAE 75W/90 (or equivalent API GL-4/GL-5 gear oil for gearbox) Coolant Type: Mixture of Ethylene Glycol Antifreeze and Distilled Water (50/50 mix recommended) Brake Fluid Type: DOT 4 Hydraulic Brake Fluid Fork Oil Type: SAE 10W (or specified by manual for Showa/Marzocchi forks) Known Issues Common Wear Items: Clutch plates, piston rings, exhaust power valve (carbon build-up), chain and sprockets, fork seals, wheel...
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Aprilia RS125 RS 125 1998 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Year:
1998
Codes
Internal Model Code:
AP98RS125
👋 Introduction
Market Position
Segment:
Lightweight sport motorcycle segment, popular for track days and street performance.
Competitive Analysis
Competitors:
Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125, Cagiva Mito 125.
Key Features
Performance Focus:
High-revving two-stroke engine, aggressive styling, sporty handling.
Target Audience:
Young riders seeking a performance-oriented and stylish motorcycle.
Manual Value
Utility:
Essential for owners and technicians to perform accurate maintenance, diagnostics, and repairs, ensuring longevity and optimal performance.
📋 Manual Details
Coverage Areas
Primary Coverage:
Mechanical Systems, Electrical Systems, Bodywork, Troubleshooting
Regional Coverage:
Global (International Specifications)
Page Count
Estimated Pages:
300-400
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of the Rotax 125cc two-stroke engine.
Fuel System:
Carburetor (Dell'Orto PHBH 28 QD) tuning, cleaning, and overhaul; fuel tank and lines inspection.
Ignition System:
CDI ignition system, stator, ignition coil, spark plug specifications and testing.
Cooling System:
Radiator, coolant hoses, thermostat, water pump maintenance and repair.
Transmission Drivetrain:
6-speed sequential gearbox, clutch operation and adjustment, chain drive maintenance.
Suspension:
Front telescopic fork (Showa/Marzocchi variations) overhaul, oil change, and adjustments. Rear monoshock absorber (Sachs/Ohservations) inspection and service.
Braking System:
Front and rear hydraulic disc brakes, caliper service, master cylinder overhaul, brake fluid bleeding, pad replacement.
Electrical System:
Wiring diagrams, battery service, lighting system, starter motor, charging system testing and repair.
Bodywork Chassis:
Fairing removal and installation, seat maintenance, frame inspection, steering head bearing service.
Procedures Included
Preventative Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, general inspection guidelines.
Troubleshooting:
Diagnostic charts and procedures for common issues and malfunctions across all systems.
Engine Rebuild:
Detailed step-by-step instructions for complete engine teardown and rebuild, including piston, cylinder, crankshaft, and bearing replacement.
Carburetor Tuning:
Jetting charts, idle speed adjustment, mixture screw settings, and float height calibration.
Suspension Adjustment:
Preload, compression, and rebound damping adjustments for front and rear suspension.
Electrical Diagnostics:
Component testing using multimeters, fuse identification, and troubleshooting electrical faults.
Wheel Tire Service:
Tire pressure recommendations, wheel balancing, and axle maintenance.
Technical Depth
Depth:
Comprehensive: Covers everything from basic fluid changes and checks to complete engine and transmission rebuilds, advanced electrical diagnostics, and suspension tuning.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Quality:
High-resolution scans ensuring clarity of diagrams, schematics, and text.
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper Type:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotax 125cc, Liquid-Cooled, 2-Stroke, Single-Cylinder
Bore X Stroke:
54 mm x 54.5 mm
Compression Ratio:
12.0:1
Valve Mechanism:
Reed Valve Intake, Exhaust Power Valve (Rotax A.P.C.S.)
Performance
Horsepower:
Approx. 30-33 HP (depending on market restrictions)
Torque:
Approx. 21 Nm (15.5 lb-ft) at 8,000 RPM
Fuel System
Carburetor Model:
Dell'Orto PHBH 28 QD
Fuel Type:
Unleaded Gasoline (95 RON Recommended)
Lubrication
Lubrication System:
Separate Oil Injection System
2T Oil Type:
API TC+, JASO FD certified Fully Synthetic 2-Stroke Oil
🔧 Transmission
Standard
Gearbox Type:
6-Speed Sequential Manual
Clutch Type:
Wet Multi-Plate Clutch
Features
Drive Type:
Chain Drive
Final Drive Ratio:
17/44 (Standard)
📐 Dimensions
Exterior
Length:
Approx. 1,950 mm (76.8 in)
Width:
Approx. 720 mm (28.3 in)
Height:
Approx. 1,130 mm (44.5 in)
Weights
Dry Weight:
Approx. 120 kg (264.5 lbs)
Fuel Tank Capacity:
Approx. 7.2 Liters (1.9 US gal)
Oil Tank Capacity:
Approx. 1.5 Liters (0.4 US gal)
🛡️ Safety Features
Ratings
Crash Test Data:
N/A (Motorcycle specific safety is determined by design and rider input)
Active Features
Braking System:
Dual Piston Front Caliper, Single Piston Rear Caliper, Hydraulic Disc Brakes
Suspension Dynamics:
Sport-tuned suspension for stability and control during cornering.
Passive Features
Chassis Design:
Sturdy perimeter frame for torsional rigidity.
Ergonomics:
Sportbike riding position, providing rider feedback and control.
💡 Technology Features
Infotainment
Display:
Analog Tachometer, Speedometer, Odometer, Fuel Gauge, Temperature Gauge (integrated into instrument cluster).
Driver Assistance
ABS:
Not available on the 1998 model.
Connectivity
Bluetooth Usb:
Not available on the 1998 model.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 km or annually. (Refer to manual for specific details)
Spark Plug Replacement:
Every 6,000 km or as per manual recommendation.
Air Filter Cleaning:
Every 3,000 km, cleaning or replacement as needed.
Chain Lubrication Adjustment:
Every 500 km or after riding in wet conditions.
Fluid Specifications
Engine Oil Type:
Refer to manual for specific 2T oil; Crankcase Oil: SAE 75W/90 (or equivalent API GL-4/GL-5 gear oil for gearbox)
Coolant Type:
Mixture of Ethylene Glycol Antifreeze and Distilled Water (50/50 mix recommended)
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Fork Oil Type:
SAE 10W (or specified by manual for Showa/Marzocchi forks)
Known Issues
Common Wear Items:
Clutch plates, piston rings, exhaust power valve (carbon build-up), chain and sprockets, fork seals, wheel bearings.
Common Issues
Carburetor Maintenance:
Tendency for Dell'Orto carburetors to clog if fuel is not fresh or if bike sits for extended periods; requires regular cleaning and adjustment.
Power Valve Issues:
Carbon buildup on the exhaust power valve can cause performance degradation, leading to loss of low-end torque and sputtering. Regular cleaning is essential.
Cooling System Leaks:
Potential for minor coolant leaks from hoses or radiator connections if not properly maintained.
Electrical Gremlins:
Older wiring harnesses can develop intermittent faults; the manual's wiring diagrams are crucial for diagnosis.
📚 Vehicle History
Brand Heritage
Brand Focus:
Aprilia has a long and successful history in motorcycle racing, particularly in the Grand Prix circuit, which heavily influences their road bike development.
Model Evolution
Rs125 Lineage:
The RS125 is a long-standing model in Aprilia's lineup, evolving from earlier sportbike designs, consistently praised for its performance and handling in the 125cc class.
Production
Manufacturing Location:
Italy
Notable Variants For 1998:
Standard RS125, potentially limited edition or special graphics packages.
🏆 Awards & Recognition
Recognitions
Class Accolades:
Consistently recognized in its class for performance, handling, and track-day capability by motorcycle publications of the era.
Ratings
Performance Rating:
Highly rated for its aggressive performance in the lightweight sportbike category.
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