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Aprilia RS 125 1994 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 1994 Codes Chassis Code Indicator: Typically indicated by VIN 👋 Introduction Market Position Motorcycle Segment: Lightweight Sportbike / Entry-level Supersport Competitive Analysis Key Competitors: Yamaha YZF-R125 (later models), Cagiva Mito 125, Honda RS125R (racing derivative), Suzuki GSX-R125 (later models) Key Features Design Philosophy: Performance-oriented 125cc two-stroke, often race-inspired styling. Target Audience: Young riders, track day enthusiasts, those seeking a sporty and engaging riding experience in the 125cc class. Distinctive Attributes: Aggressive styling, potent two-stroke engine for its class, advanced chassis for the era. 📋 Manual Details Coverage Areas Overall Coverage: Full Service Repair Page Count Estimated Page Count: Indeterminate (based on description 'very detailed') Manual Type Type: Service Repair Manual Language Language: Likely English (standard for international markets) Format Format: Digital (PDF implied by typical sales) 📖 Manual Coverage Systems Covered Engine Systems: Top-end, bottom-end, cooling, lubrication, fuel delivery, ignition, exhaust Transmission Systems: Clutch, gearbox, final drive Chassis Systems: Frame, suspension (front/rear), steering, wheels, brakes Electrical Systems: Wiring diagrams, lighting, instruments, battery, charging system, ignition switch Bodywork And Trim: Fairings, seat, fuel tank, body panels, fasteners Procedures Included Maintenance Procedures: Scheduled servicing, fluid changes, filter replacements, chain adjustment, tire pressure checks Repair Procedures: Component disassembly/reassembly, part replacement, sealing, adjustments Troubleshooting: Diagnostic guides, fault finding, common issues and solutions Rebuilding Refurbishment: Engine rebuilds, carburetor overhauls, suspension overhauls, brake system rebuilds Technical Depth Depth Level: Comprehensive: from basic checks to full engine rebuilds and detailed diagnostics. 📊 Manual Specifications File Format Digital Format: PDF (assumed) Print Quality Print Readability: High resolution for clear diagrams and text (typical for quality digital manuals) Binding Type Digital Binding: N/A (Digital) Paper Type Digital Paper Simulation: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, single-cylinder Displacement: 125 cc Bore X Stroke: Typically 54 mm x 54.5 mm (subject to minor variations) Compression Ratio: Approximately 12.0:1 (may vary with specific engine codes) Valvetrain: Rotary disc valve intake, Reed valve induction Performance Horsepower Output: Approx. 30-33 HP at peak RPM (often restricted for learner categories in some markets) Torque Output: Approx. 20-22 Nm at peak RPM (estimated) Redline: Typically around 10,000 - 11,000 RPM Fuel System Carburetor Type: Dell'Orto PHBH 28 (common fitment), or equivalent Fuel Type: Unleaded gasoline, minimum 95 RON Oil Mixing: Premix or Autolube system (check specific model designation) Cooling System Cooling Method: Liquid Cooling Coolant Type: Ethylene glycol based antifreeze mixture (e.g., 50% coolant, 50% distilled water) Lubrication System Engine Oil Type: 2-stroke engine oil, JASO FD or equivalent (for autolube system) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh sequential gearbox Clutch Type: Wet, multi-plate, cable-actuated Features Gear Ratios: Specific ratios documented in the manual (e.g., 1st: 2.833, 2nd: 1.765, 3rd: 1.333, 4th: 1.130, 5th: 0.957, 6th: 0.850) Final Drive: Chain drive (428 or 520 pitch, check manual) Transmission Oil Type: API GL-4 or GL-5, SAE 75W/90 or 80W/90 gear oil (check manual for specific viscosity and capacity) 📐 Dimensions Exterior Length: Approx. 1990 mm (Varies by specific sub-model) Width: Approx. 700 mm (Varies by specific sub-model) Height: Approx. 1080 mm (Varies by specific sub-model) Weights Dry Weight: Approx. 135 kg (Varies by specific sub-model) Fuel Tank Capacity: Approx. 14 Litres (including reserve) Wheels And Tires Front Wheel Size: 17 inch (typically) Rear Wheel Size: 17 inch (typically) Front Tire Size: 110/70-17 (typical) Rear Tire Size: 150/60-17 (typical) Wheelbase: Approx. 1360 mm 🛡️ Safety Features Ratings Safety Certification: CE markings (European Conformity) for production standards. Active Features Braking System Front: Hydraulic disc brake, 2-piston caliper (e.g., Brembo or Grimeca), disc diameter approx. 260mm Braking System Rear: Hydraulic disc brake, 1-piston caliper, disc diameter approx. 220mm Suspension Front: Upside-down (USD) telescopic forks, non-adjustable or pre-load adjustable (model dependent), approx. 40mm stanchion diameter. Suspension Rear: Monoshock absorber with progressive linkage, adjustable pre-load and rebound damping (model dependent). Passive Features Lighting: Halogen headlight, LED or incandescent tail light and indicators (depending on specific variant). 💡 Technology Features Infotainment Instrument Panel: Analog tachometer, speedometer, coolant temperature gauge, indicator lights. Driver Assistance ABS Availability: Not typically available on 1994 models. Connectivity Usb Charging: Not available on 1994 models. 🔧 Maintenance Service Intervals Oil Change Interval Transmission: Every 6,000 - 10,000 km or annually (consult manual) Spark Plug Replacement: Every 3,000 - 5,000 km (dependent on plug type and usage) Air Filter Cleaning/Replacement: Every 3,000 - 6,000 km (depending on conditions) Chain Lubrication Adjustment: Every 500 - 1000 km or after wet rides Fluid Specifications Brake Fluid Type: DOT 4 Coolant Capacity: Approx. 1.0 - 1.2 Litres (consult manual) Known Issues Common Wear Items: Piston rings, exhaust powervalve (carbon buildup), clutch plates, water pump seals, CDI unit failure (age-related). Two Stroke Specific Maintenance: Regular decarbonization of exhaust and powervalve, proper oil/fuel mixture or autolube system function are critical. Electrical Aging: Wiring harness degradation, stator or rectifier...
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Aprilia RS 125 1994 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Year:
1994
Codes
Chassis Code Indicator:
Typically indicated by VIN
👋 Introduction
Market Position
Motorcycle Segment:
Lightweight Sportbike / Entry-level Supersport
Competitive Analysis
Key Competitors:
Yamaha YZF-R125 (later models), Cagiva Mito 125, Honda RS125R (racing derivative), Suzuki GSX-R125 (later models)
Key Features
Design Philosophy:
Performance-oriented 125cc two-stroke, often race-inspired styling.
Target Audience:
Young riders, track day enthusiasts, those seeking a sporty and engaging riding experience in the 125cc class.
Distinctive Attributes:
Aggressive styling, potent two-stroke engine for its class, advanced chassis for the era.
📋 Manual Details
Coverage Areas
Overall Coverage:
Full Service Repair
Page Count
Estimated Page Count:
Indeterminate (based on description 'very detailed')
Manual Type
Type:
Service Repair Manual
Language
Language:
Likely English (standard for international markets)
Format
Format:
Digital (PDF implied by typical sales)
📖 Manual Coverage
Systems Covered
Engine Systems:
Top-end, bottom-end, cooling, lubrication, fuel delivery, ignition, exhaust
Transmission Systems:
Clutch, gearbox, final drive
Chassis Systems:
Frame, suspension (front/rear), steering, wheels, brakes
Electrical Systems:
Wiring diagrams, lighting, instruments, battery, charging system, ignition switch
Bodywork And Trim:
Fairings, seat, fuel tank, body panels, fasteners
Procedures Included
Maintenance Procedures:
Scheduled servicing, fluid changes, filter replacements, chain adjustment, tire pressure checks
Repair Procedures:
Component disassembly/reassembly, part replacement, sealing, adjustments
Troubleshooting:
Diagnostic guides, fault finding, common issues and solutions
Rebuilding Refurbishment:
Engine rebuilds, carburetor overhauls, suspension overhauls, brake system rebuilds
Technical Depth
Depth Level:
Comprehensive: from basic checks to full engine rebuilds and detailed diagnostics.
📊 Manual Specifications
File Format
Digital Format:
PDF (assumed)
Print Quality
Print Readability:
High resolution for clear diagrams and text (typical for quality digital manuals)
Binding Type
Digital Binding:
N/A (Digital)
Paper Type
Digital Paper Simulation:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
125 cc
Bore X Stroke:
Typically 54 mm x 54.5 mm (subject to minor variations)
Compression Ratio:
Approximately 12.0:1 (may vary with specific engine codes)
Valvetrain:
Rotary disc valve intake, Reed valve induction
Performance
Horsepower Output:
Approx. 30-33 HP at peak RPM (often restricted for learner categories in some markets)
Torque Output:
Approx. 20-22 Nm at peak RPM (estimated)
Redline:
Typically around 10,000 - 11,000 RPM
Fuel System
Carburetor Type:
Dell'Orto PHBH 28 (common fitment), or equivalent
Fuel Type:
Unleaded gasoline, minimum 95 RON
Oil Mixing:
Premix or Autolube system (check specific model designation)
Cooling System
Cooling Method:
Liquid Cooling
Coolant Type:
Ethylene glycol based antifreeze mixture (e.g., 50% coolant, 50% distilled water)
Lubrication System
Engine Oil Type:
2-stroke engine oil, JASO FD or equivalent (for autolube system)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh sequential gearbox
Clutch Type:
Wet, multi-plate, cable-actuated
Features
Gear Ratios:
Specific ratios documented in the manual (e.g., 1st: 2.833, 2nd: 1.765, 3rd: 1.333, 4th: 1.130, 5th: 0.957, 6th: 0.850)
Final Drive:
Chain drive (428 or 520 pitch, check manual)
Transmission Oil Type:
API GL-4 or GL-5, SAE 75W/90 or 80W/90 gear oil (check manual for specific viscosity and capacity)
📐 Dimensions
Exterior
Length:
Approx. 1990 mm (Varies by specific sub-model)
Width:
Approx. 700 mm (Varies by specific sub-model)
Height:
Approx. 1080 mm (Varies by specific sub-model)
Weights
Dry Weight:
Approx. 135 kg (Varies by specific sub-model)
Fuel Tank Capacity:
Approx. 14 Litres (including reserve)
Wheels And Tires
Front Wheel Size:
17 inch (typically)
Rear Wheel Size:
17 inch (typically)
Front Tire Size:
110/70-17 (typical)
Rear Tire Size:
150/60-17 (typical)
Wheelbase:
Approx. 1360 mm
🛡️ Safety Features
Ratings
Safety Certification:
CE markings (European Conformity) for production standards.
Active Features
Braking System Front:
Hydraulic disc brake, 2-piston caliper (e.g., Brembo or Grimeca), disc diameter approx. 260mm
Braking System Rear:
Hydraulic disc brake, 1-piston caliper, disc diameter approx. 220mm
Suspension Front:
Upside-down (USD) telescopic forks, non-adjustable or pre-load adjustable (model dependent), approx. 40mm stanchion diameter.
Suspension Rear:
Monoshock absorber with progressive linkage, adjustable pre-load and rebound damping (model dependent).
Passive Features
Lighting:
Halogen headlight, LED or incandescent tail light and indicators (depending on specific variant).
💡 Technology Features
Infotainment
Instrument Panel:
Analog tachometer, speedometer, coolant temperature gauge, indicator lights.
Driver Assistance
ABS Availability:
Not typically available on 1994 models.
Connectivity
Usb Charging:
Not available on 1994 models.
🔧 Maintenance
Service Intervals
Oil Change Interval Transmission:
Every 6,000 - 10,000 km or annually (consult manual)
Spark Plug Replacement:
Every 3,000 - 5,000 km (dependent on plug type and usage)
Air Filter Cleaning/Replacement:
Every 3,000 - 6,000 km (depending on conditions)
Chain Lubrication Adjustment:
Every 500 - 1000 km or after wet rides
Fluid Specifications
Brake Fluid Type:
DOT 4
Coolant Capacity:
Approx. 1.0 - 1.2 Litres (consult manual)
Known Issues
Common Wear Items:
Piston rings, exhaust powervalve (carbon buildup), clutch plates, water pump seals, CDI unit failure (age-related).
Two Stroke Specific Maintenance:
Regular decarbonization of exhaust and powervalve, proper oil/fuel mixture or autolube system function are critical.
Electrical Aging:
Wiring harness degradation, stator or rectifier failure can occur on older models.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Italy
Aprilia Legacy:
Known for sporty motorcycles, racing heritage in smaller displacement classes (e.g., GP 125).
Model Evolution
Rs 125 Lineage:
The RS 125 series began in the early 1990s, evolving from earlier models like the AF1. The 1994 model represents an early iteration of the modern RS 125 design.
Production
Production Period Start:
Early 1990s
Manufacturing Location:
Aprilia factory, Noale, Italy
🏆 Awards & Recognition
Recognitions
Performance Accolades:
Highly regarded in its class for sporty performance and handling, often winning comparisons in period motorcycle publications.
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