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Aprilia RS125 Workshop Service Repair Manual RS 125 # 1

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: Various (implied comprehensive coverage) Codes Product Code: RS125 # 1 👋 Introduction Market Position Segment: Lightweight Supersport / Performance Motorcycle Competitive Analysis Competitors: Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125, Kawasaki Ninja 125. Key Features Design Philosophy: Race-inspired styling, sporty handling, efficient two-stroke (earlier models) or four-stroke (later models) engine, lightweight chassis. Target Audience: Beginner motorcyclists, track day enthusiasts, riders seeking a stylish and agile sportbike experience. Manual Utility Value Proposition: Empowers owners to perform a wide range of maintenance and repair tasks, saving on dealership labor costs and ensuring optimal performance. 📋 Manual Details Coverage Areas Scope: Workshop Service and Repair Page Count Estimated Pages: Likely 300+ (typical for comprehensive workshop manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English (implied by product description) Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, top-end overhaul, bottom-end overhaul, piston/ring replacement, valve adjustment, crankshaft service, cylinder head repair. Fuel System: Carburetor tuning and overhaul (likely Dell'Orto PHBH/VHST variants), fuel pump operation, fuel lines, fuel tank maintenance. Ignition System: CDI ignition system, spark plug selection and gap, ignition timing, stator and rotor service, wiring diagrams. Cooling System: Radiator service, coolant type and capacity, water pump overhaul, thermostat operation, fan operation. Exhaust System: Exhaust pipe removal and installation, mufflers, expansion chambers (if applicable to specific model variations). Transmission: Gearbox disassembly and reassembly, gear selection mechanism, clutch operation, clutch friction plate replacement, chain and sprockets. Chassis Frame: Frame inspection, headstock bearing service, swingarm service, pivot point lubrication. Suspension Front: Telescopic fork service, oil change and level, seal replacement, spring inspection, damping adjustment (if applicable). Suspension Rear: Monoshock absorber service, linkage maintenance, spring preload adjustment, damping adjustment (if applicable). Brakes Front: Brake caliper service and overhaul, brake pad replacement, disc inspection and replacement, master cylinder service, brake fluid type and bleeding procedure. Brakes Rear: Brake caliper service and overhaul, brake pad replacement, disc inspection and replacement, master cylinder service, brake fluid type and bleeding procedure. Wheels Tires: Wheel bearing service, tire inspection and replacement, wheel balancing, spoke tension adjustment (if applicable). Electrical System: Battery maintenance, starter motor, lighting system (headlight, taillight, indicators), wiring diagrams for all circuits, fuse replacement, electrical troubleshooting. Bodywork Fairings: Fairing removal and installation, graphic application, seat maintenance, fuel tank removal and installation. Procedures Included Preventative Maintenance: Routine checks, lubrication points, filter replacement, fluid changes, spark plug replacement. Troubleshooting: Diagnostic charts for common problems, fault finding procedures for engine, electrical, and mechanical systems. Repair Overhaul: Step-by-step instructions for component disassembly, repair, and reassembly. Diagnostics: Methods for diagnosing specific issues, electrical system testing, mechanical component checks. Adjustments: Carburetor adjustment, chain adjustment, brake lever adjustment, clutch lever adjustment, suspension adjustments. Torque Specifications: Detailed torque values for all critical fasteners. Wiring Diagrams: Comprehensive electrical schematics for all model variations. Technical Depth Depth: Comprehensive from basic maintenance to full engine rebuilds and detailed electrical troubleshooting. 📊 Manual Specifications File Format Format: PDF Print Quality Resolution: High-resolution, suitable for printing all pages. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, 2-stroke (early models), or 4-stroke (later models, often liquid-cooled). Displacement: Approximately 125cc Bore X Stroke: Varies by specific model year and engine version (e.g., 54 mm x 54.5 mm for some Rotax engines). Compression Ratio: Varies by engine (e.g., 12.0:1 for some 4-stroke models). Cooling System: Liquid-cooled Performance Horsepower: Typically around 15 hp (restricted for A1 license in many regions), with potential for higher output in unrestricted versions. Torque: Specific values vary, but focus on usability in the mid-range for this class. Fuel System Carburetion: Often Dell'Orto PHBH or VHST series (e.g., 28mm or 30mm), or fuel injection on later 4-stroke models. Fuel Type: Unleaded Gasoline (RON 95 or higher recommended) 🔧 Transmission Standard Type: 6-speed constant mesh sequential gearbox Optional Optional Types: N/A Features Clutch Type: Wet multi-plate clutch (cable operated) Final Drive: Chain drive 📐 Dimensions Exterior Length: Varies by model year (e.g., approx. 1950 mm). Width: Varies by model year (e.g., approx. 720 mm). Height: Varies by model year (e.g., approx. 1060 mm). Wheelbase: Varies by model year (e.g., approx. 1360 mm). Weights Dry Weight: Varies by model year (e.g., approx. 117 kg). Wet Weight: Varies by model year (e.g., approx. 130 kg). Capacities Fuel Tank Capacity: Approximately 10.5 - 11 liters 🛡️ Safety Features Ratings Safety Standard: Manufactured to meet European safety standards (e.g., Euro 3/4/5 depending on year). Active Features Braking System: Disc brakes front and rear, often with ByBre or Brembo calipers. ABS: Optional on some later models or specific market variants. Passive Features Lighting: Halogen or LED headlight, taillight, and indicators. 💡 Technology Features Infotainment Instrument Cluster: Digital/analog combination or fully digital display showing speed, RPM, fuel level, trip meters, and warning lights....
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Aprilia RS125 Workshop Service Repair Manual RS 125 # 1
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Year:
Various (implied comprehensive coverage)
Codes
Product Code:
RS125 # 1
👋 Introduction
Market Position
Segment:
Lightweight Supersport / Performance Motorcycle
Competitive Analysis
Competitors:
Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125, Kawasaki Ninja 125.
Key Features
Design Philosophy:
Race-inspired styling, sporty handling, efficient two-stroke (earlier models) or four-stroke (later models) engine, lightweight chassis.
Target Audience:
Beginner motorcyclists, track day enthusiasts, riders seeking a stylish and agile sportbike experience.
Manual Utility
Value Proposition:
Empowers owners to perform a wide range of maintenance and repair tasks, saving on dealership labor costs and ensuring optimal performance.
📋 Manual Details
Coverage Areas
Scope:
Workshop Service and Repair
Page Count
Estimated Pages:
Likely 300+ (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English (implied by product description)
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, top-end overhaul, bottom-end overhaul, piston/ring replacement, valve adjustment, crankshaft service, cylinder head repair.
Fuel System:
Carburetor tuning and overhaul (likely Dell'Orto PHBH/VHST variants), fuel pump operation, fuel lines, fuel tank maintenance.
Ignition System:
CDI ignition system, spark plug selection and gap, ignition timing, stator and rotor service, wiring diagrams.
Cooling System:
Radiator service, coolant type and capacity, water pump overhaul, thermostat operation, fan operation.
Exhaust System:
Exhaust pipe removal and installation, mufflers, expansion chambers (if applicable to specific model variations).
Transmission:
Gearbox disassembly and reassembly, gear selection mechanism, clutch operation, clutch friction plate replacement, chain and sprockets.
Chassis Frame:
Frame inspection, headstock bearing service, swingarm service, pivot point lubrication.
Suspension Front:
Telescopic fork service, oil change and level, seal replacement, spring inspection, damping adjustment (if applicable).
Suspension Rear:
Monoshock absorber service, linkage maintenance, spring preload adjustment, damping adjustment (if applicable).
Brakes Front:
Brake caliper service and overhaul, brake pad replacement, disc inspection and replacement, master cylinder service, brake fluid type and bleeding procedure.
Brakes Rear:
Brake caliper service and overhaul, brake pad replacement, disc inspection and replacement, master cylinder service, brake fluid type and bleeding procedure.
Wheels Tires:
Wheel bearing service, tire inspection and replacement, wheel balancing, spoke tension adjustment (if applicable).
Electrical System:
Battery maintenance, starter motor, lighting system (headlight, taillight, indicators), wiring diagrams for all circuits, fuse replacement, electrical troubleshooting.
Bodywork Fairings:
Fairing removal and installation, graphic application, seat maintenance, fuel tank removal and installation.
Procedures Included
Preventative Maintenance:
Routine checks, lubrication points, filter replacement, fluid changes, spark plug replacement.
Troubleshooting:
Diagnostic charts for common problems, fault finding procedures for engine, electrical, and mechanical systems.
Repair Overhaul:
Step-by-step instructions for component disassembly, repair, and reassembly.
Diagnostics:
Methods for diagnosing specific issues, electrical system testing, mechanical component checks.
Adjustments:
Carburetor adjustment, chain adjustment, brake lever adjustment, clutch lever adjustment, suspension adjustments.
Torque Specifications:
Detailed torque values for all critical fasteners.
Wiring Diagrams:
Comprehensive electrical schematics for all model variations.
Technical Depth
Depth:
Comprehensive from basic maintenance to full engine rebuilds and detailed electrical troubleshooting.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Resolution:
High-resolution, suitable for printing all pages.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Configuration:
Single-cylinder, 2-stroke (early models), or 4-stroke (later models, often liquid-cooled).
Displacement:
Approximately 125cc
Bore X Stroke:
Varies by specific model year and engine version (e.g., 54 mm x 54.5 mm for some Rotax engines).
Compression Ratio:
Varies by engine (e.g., 12.0:1 for some 4-stroke models).
Cooling System:
Liquid-cooled
Performance
Horsepower:
Typically around 15 hp (restricted for A1 license in many regions), with potential for higher output in unrestricted versions.
Torque:
Specific values vary, but focus on usability in the mid-range for this class.
Fuel System
Carburetion:
Often Dell'Orto PHBH or VHST series (e.g., 28mm or 30mm), or fuel injection on later 4-stroke models.
Fuel Type:
Unleaded Gasoline (RON 95 or higher recommended)
🔧 Transmission
Standard
Type:
6-speed constant mesh sequential gearbox
Optional
Optional Types:
N/A
Features
Clutch Type:
Wet multi-plate clutch (cable operated)
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Varies by model year (e.g., approx. 1950 mm).
Width:
Varies by model year (e.g., approx. 720 mm).
Height:
Varies by model year (e.g., approx. 1060 mm).
Wheelbase:
Varies by model year (e.g., approx. 1360 mm).
Weights
Dry Weight:
Varies by model year (e.g., approx. 117 kg).
Wet Weight:
Varies by model year (e.g., approx. 130 kg).
Capacities
Fuel Tank Capacity:
Approximately 10.5 - 11 liters
🛡️ Safety Features
Ratings
Safety Standard:
Manufactured to meet European safety standards (e.g., Euro 3/4/5 depending on year).
Active Features
Braking System:
Disc brakes front and rear, often with ByBre or Brembo calipers.
ABS:
Optional on some later models or specific market variants.
Passive Features
Lighting:
Halogen or LED headlight, taillight, and indicators.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital/analog combination or fully digital display showing speed, RPM, fuel level, trip meters, and warning lights.
Driver Assistance
ABS:
Available on select later models as an option.
Connectivity
Connectivity Features:
Typically none, focused on core motorcycle performance.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 - 5,000 km or annually, depending on usage and oil type.
Spark Plug Replacement:
Every 5,000 - 10,000 km or as per manual recommendation.
Air Filter Cleaning Replacement:
Every 3,000 - 6,000 km, or more frequently in dusty conditions.
Valve Clearance Check:
Every 6,000 - 12,000 km for 4-stroke models (if applicable).
Fluid Specifications
Engine Oil:
10W-40 or 15W-50 Synthetic or Semi-Synthetic Motorcycle Oil (API SG or higher, JASO MA/MA2).
Coolant:
Ethylene glycol based coolant with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid:
DOT 4
2-Stroke Oil:
High-quality, JASO FD certified 2-stroke premix or injection oil (for 2-stroke models).
Known Issues
Common Problems:
Carburetor jetting sensitivity to altitude/temperature, potential for reed valve wear (2-stroke), clutch wear under heavy use, electrical connector corrosion.
Maintenance Tips:
Regular cleaning of the air filter, ensuring correct 2-stroke oil mix, checking chain tension, keeping cooling system clean.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer with a strong heritage in racing and performance motorcycles.
Model Evolution
Development:
The RS125 has been in production for several decades, evolving from a potent two-stroke to a more modern four-stroke powerplant, adapting to emissions regulations and performance enhancements.
Production
Origin:
Italy
🏆 Awards & Recognition
Recognitions
Racing Heritage:
The RS125 platform has a significant racing history, particularly in 125cc Grand Prix classes, contributing to its sporty reputation.
Ratings
User Reviews:
Generally praised for its handling, aggressive styling, and engaging ride for its class.
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