🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 1999 Product Name: Aprilia RS 125 1999 Repair Service Manual Codes Vin Prefix: ZDA 👋 Introduction Market Position Segment: Lightweight sportbike segment, popular for track days, commuting, and accessible performance. Historical Significance: The RS 125 was a flagship model for Aprilia in its class, known for its advanced technology and racing pedigree. Competitive Analysis Competitors 1999: Honda RS125R (though more race-focused), Yamaha TZR125, Cagiva Mito 125, Suzuki RG125, Gilera SP01. Key Features Design: Aggressive sportbike styling, clip-on handlebars, aggressive riding posture. Engine Type: High-performance 125cc two-stroke, liquid-cooled, reed valve induction. Suspension: Upside-down front forks and adjustable monoshock rear suspension for superior handling. Braking: Dual disc brakes at the front and a single disc at the rear, offering strong stopping power. Performance Focus: Designed for agility and exhilarating performance, especially in the upper rev range. 📋 Manual Details Coverage Areas General Coverage: Comprehensive repair and service information for the 1999 Aprilia RS 125. Target Audience: Professional technicians and experienced DIY enthusiasts. Page Count Estimated Pages: High (exact count not specified but typical for comprehensive service manuals, likely 300+ pages). Manual Type Type: Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, troubleshooting, and overhaul procedures for the Rotax 125cc two-stroke engine. Fuel System: Carburetor tuning (Dell'Orto PHBH 28 VD), fuel pump, fuel lines, and tank maintenance. Ignition System: CDI ignition system, spark plug specifications, timing adjustments, and troubleshooting. Cooling System: Radiator, water pump, coolant specifications, and bleed procedures. Exhaust System: Expansion chamber, muffler maintenance, and sealing. Transmission: Clutch operation, gearbox disassembly/assembly, gear selection, and gearbox oil specifications. Chassis: Frame inspection, steering head bearing maintenance, and suspension adjustments. Front Suspension: Telescopic front fork (e.g., Marzocchi), oil specifications, seal replacement, and internal component service. Rear Suspension: Monoshock rear suspension (e.g., Sachs or Paioli), linkage maintenance, shock absorber service, and spring preload adjustment. Brakes: Front and rear brake caliper service, master cylinder overhaul, brake fluid specifications, pad replacement, and bleeding procedures. Wheels And Tires: Tire pressure, wheel bearing inspection, rim maintenance, and spoke tensioning (if applicable to cast wheels). Electrical System: Wiring diagrams, lighting system, battery maintenance, starter system, and fuse identification. Bodywork: Fairing removal and installation, seat, tank cover, and minor body panel repairs. Troubleshooting: Diagnostic charts for common starting, running, and electrical issues. Procedures Included Preventative Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, and brake fluid flushes. Scheduled Maintenance: Recommended service intervals for key components. Disassembly Assembly: Step-by-step guides for major component removal and reinstallation. Overhaul Rebuild: Detailed instructions for engine top-end rebuilds, gearbox overhauls, and suspension servicing. Diagnostics: Systematic troubleshooting guides to identify and resolve faults. Component Testing: Procedures for testing ignition coil resistance, starter motor operation, and sensor functionality. Technical Depth Depth: Comprehensive. Covers everything from basic adjustments and fluid changes to complete engine rebuilds and complex electrical diagnostics. Detail Level: Extremely detailed, with torque specifications, clearances, and specific tool requirements. 📊 Manual Specifications File Format Format: PDF Searchable: Typically yes for PDF manuals, allowing for keyword searches. Print Quality Quality: High-resolution scans, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Rotax 123, 2-stroke, liquid-cooled, single cylinder Displacement: 124.8 cc (7.62 cubic inches) Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: Approx. 8.4:1 (depending on variant/tune) Power Output: Approx. 30-32 HP (15kW restricted for L-plates in some regions, but factory is higher). Torque: Approx. 20 Nm (14.8 lb-ft) at ~8000 RPM. Induction System: Reed valve controlled intake, Dell'Orto PHBH 28 VD carburetor Lubrication: Premix (oil injected via separate pump) or direct premix. Performance Top Speed: Approx. 100-110 mph (160-177 km/h) depending on gearing and rider. Fuel System Carburetor Model: Dell'Orto PHBH 28 VD Fuel Type: Unleaded gasoline (95 RON or higher recommended) Fuel Tank Capacity: Approx. 7.2 Liters (1.9 US gallons) 🔧 Transmission Standard Type: 6-speed constant mesh Clutch: Wet multi-plate clutch Final Drive: Chain drive Features Gear Ratios: Specific ratios available in the manual, crucial for performance tuning. Gearbox Oil Spec: Typically SAE 10W-40 API SG or higher (confirm specific Aprilia specification in manual). 📐 Dimensions Exterior Length: Approx. 1950 mm Width: Approx. 740 mm (at handlebars) Height: Approx. 1130 mm (at seat) Wheelbase: Approx. 1360 mm Weights Dry Weight: Approx. 132 kg (291 lbs) Wet Weight: Approx. 148 kg (326 lbs) (with all fluids) 🛡️ Safety Features Ratings Safety Certification: CE certified for sale in European markets. Specific crash test data not typically published for this class of motorcycle. Active Features Braking System: Dual front discs (e.g., 320mm) with 4-piston calipers, single rear disc (e.g., 220mm) with 2-piston caliper. Tires: Sport-oriented radial tires (e.g., 110/70-17 front, 150/60-17 rear). Passive Features...