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Aprilia RS 125 1993-2006 Factory Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Model Variant: RS 125 Codes Vin Decoder Notes: VIN typically starts with ZD4RS... 👋 Introduction Market Position Segment: Lightweight Supersport Motorcycle Target Audience: Enthusiast riders, track day participants, DIY mechanics Competitive Analysis Key Competitors: Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125 (relevant market comparisons for the era) Key Features Vehicle Appeal: Sporty aesthetics, agile handling, performance-oriented for its class Manual Value Proposition Benefit To Owner: Enables cost-effective maintenance, in-depth understanding of vehicle systems, and efficient troubleshooting 📋 Manual Details Coverage Areas Years Covered: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Specific Models Covered: Aprilia RS 125 (all sub-variants within the specified years) Page Count Estimated Page Count: Over 500 pages (estimated based on comprehensive factory manual content) Manual Type Type: Factory Service and Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Lubrication, Cooling, Exhaust System Chassis: Frame, Suspension (Front & Rear), Steering, Wheels, Tires, Brakes (Front & Rear), Swingarm Electrical: Ignition System, Lighting, Battery, Charging System, Wiring Diagrams, Switches, Instruments Bodywork: Fairings, Seat, Fuel Tank, Body Panels, Fasteners Controls: Throttle, Clutch, Gear Shifter, Brake Levers Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustments, spark plug service Troubleshooting: Diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable) Repair: Engine rebuild, carburetor overhaul, transmission service, brake caliper rebuild, suspension component replacement Installation: Component replacement (e.g., levers, mirrors), fairing reassembly Technical Adjustments: Carburetor tuning, ignition timing adjustments, suspension sag settings Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and chassis overhauls) Diagnostic Level: Advanced diagnostic routines and troubleshooting trees Rebuild Instructions: Detailed step-by-step instructions for major component rebuilds 📊 Manual Specifications File Format Format Details: Searchable PDF with hyperlinked sections for easy navigation Print Quality Quality: High-resolution scans of original factory documentation, ensuring clarity of text and diagrams Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder, liquid-cooled Displacement: 124.8 cc (7.62 cubic inches) Bore X Stroke: 54 mm x 54.5 mm (approximate, may vary slightly by year/market) Compression Ratio: Approx. 8.4:1 (may vary) Performance Horsepower Peak: Approx. 30-34 HP (depending on year and market restrictions) Torque Peak: Approx. 22-24 Nm (depending on year and market restrictions) Fuel System Carburetor: Dell'Orto PHBH 28 (common specification, may vary) Fuel Type: Unleaded Gasoline (minimum Octane rating specified in manual) Fuel Delivery: Carburetor with separate oil injection system Lubrication Oil Type: Two-stroke engine oil (specific API/JASO rating required, e.g., JASO FD) Cooling Cooling System: Liquid Cooling Coolant Type: Ethylene glycol-based antifreeze/coolant (50/50 mixture with distilled water recommended) 🔧 Transmission Standard Type: 6-speed constant mesh manual transmission Optional Optional Types: N/A (all RS 125 models in this range used a 6-speed manual) Features Clutch Type: Wet multi-plate clutch, cable operated Gearbox Oil Type: SAE 10W-30 API GL-4 or GL-5 transmission oil (specifics in manual) 📐 Dimensions Exterior Length: Approx. 1940 mm (may vary slightly by year) Width: Approx. 720 mm (may vary slightly by year) Height: Approx. 1050 mm (may vary slightly by year) Weights Dry Weight: Approx. 130-135 kg (may vary by year and equipment) Fuel Tank Capacity: Approx. 13 Liters (including reserve) 🛡️ Safety Features Ratings Crash Test Data: Not applicable for motorcycles in this era; focus is on design and rider protection features Active Features Braking System: Hydraulic disc brakes front and rear Front Brake Specs: Single Disc, Radial Caliper (e.g., Brembo, Grimeca, depending on year/variant) Rear Brake Specs: Single Disc, Caliper Passive Features Frame Construction: Aluminum twin-spar frame Lighting: Halogen headlight, LED or incandescent tail light/indicators 💡 Technology Features Infotainment Infotainment System: N/A (Motorcycle of this era focused on core riding dynamics, not digital features) Driver Assistance Rider Aids: N/A (No electronic rider aids like ABS or traction control typically found on this model range) Instrumentation Dashboard: Analog speedometer, tachometer, engine temperature gauge, fuel level warning light, neutral indicator, turn signal indicators. Lighting Technology: Standard halogen headlight bulb. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km or annually (as per manual recommendations, depending on usage) Spark Plug Replacement: Every 6,000-8,000 km (specific plug type and gap required) Air Filter Cleaning: Every 3,000-5,000 km or as needed based on conditions Chain Lubrication Adjustment: Every 500-1,000 km and after washing/rain Fluid Specifications Brake Fluid Type: DOT 4 (specified in manual, always use fresh fluid) Coolant Capacity: Approx. 1.2 Liters (system capacity) Known Issues Common Wear Items: Clutch plates, exhaust valve mechanism, water pump seals, carburetor diaphragm, front fork seals. Two Stroke Specifics: Requires diligent adherence to oil injection system maintenance and correct two-stroke oil usage to prevent engine damage. Carburetor Maintenance: Carburetors can be sensitive to fuel quality and require periodic cleaning and adjustment for optimal performance....
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Aprilia RS 125 1993-2006 Factory Repair ManualAprilia RS 125 1993-2006 Factory Repair ManualAprilia RS 125 1993-2006 Factory Repair ManualAprilia RS 125 1993-2006 Factory Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Model Variant:
RS 125
Codes
Vin Decoder Notes:
VIN typically starts with ZD4RS...
👋 Introduction
Market Position
Segment:
Lightweight Supersport Motorcycle
Target Audience:
Enthusiast riders, track day participants, DIY mechanics
Competitive Analysis
Key Competitors:
Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125 (relevant market comparisons for the era)
Key Features
Vehicle Appeal:
Sporty aesthetics, agile handling, performance-oriented for its class
Manual Value Proposition
Benefit To Owner:
Enables cost-effective maintenance, in-depth understanding of vehicle systems, and efficient troubleshooting
📋 Manual Details
Coverage Areas
Years Covered:
1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Specific Models Covered:
Aprilia RS 125 (all sub-variants within the specified years)
Page Count
Estimated Page Count:
Over 500 pages (estimated based on comprehensive factory manual content)
Manual Type
Type:
Factory Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Lubrication, Cooling, Exhaust System
Chassis:
Frame, Suspension (Front & Rear), Steering, Wheels, Tires, Brakes (Front & Rear), Swingarm
Electrical:
Ignition System, Lighting, Battery, Charging System, Wiring Diagrams, Switches, Instruments
Bodywork:
Fairings, Seat, Fuel Tank, Body Panels, Fasteners
Controls:
Throttle, Clutch, Gear Shifter, Brake Levers
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustments, spark plug service
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable)
Repair:
Engine rebuild, carburetor overhaul, transmission service, brake caliper rebuild, suspension component replacement
Installation:
Component replacement (e.g., levers, mirrors), fairing reassembly
Technical Adjustments:
Carburetor tuning, ignition timing adjustments, suspension sag settings
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and chassis overhauls)
Diagnostic Level:
Advanced diagnostic routines and troubleshooting trees
Rebuild Instructions:
Detailed step-by-step instructions for major component rebuilds
📊 Manual Specifications
File Format
Format Details:
Searchable PDF with hyperlinked sections for easy navigation
Print Quality
Quality:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Two-stroke, single-cylinder, liquid-cooled
Displacement:
124.8 cc (7.62 cubic inches)
Bore X Stroke:
54 mm x 54.5 mm (approximate, may vary slightly by year/market)
Compression Ratio:
Approx. 8.4:1 (may vary)
Performance
Horsepower Peak:
Approx. 30-34 HP (depending on year and market restrictions)
Torque Peak:
Approx. 22-24 Nm (depending on year and market restrictions)
Fuel System
Carburetor:
Dell'Orto PHBH 28 (common specification, may vary)
Fuel Type:
Unleaded Gasoline (minimum Octane rating specified in manual)
Fuel Delivery:
Carburetor with separate oil injection system
Lubrication
Oil Type:
Two-stroke engine oil (specific API/JASO rating required, e.g., JASO FD)
Cooling
Cooling System:
Liquid Cooling
Coolant Type:
Ethylene glycol-based antifreeze/coolant (50/50 mixture with distilled water recommended)
🔧 Transmission
Standard
Type:
6-speed constant mesh manual transmission
Optional
Optional Types:
N/A (all RS 125 models in this range used a 6-speed manual)
Features
Clutch Type:
Wet multi-plate clutch, cable operated
Gearbox Oil Type:
SAE 10W-30 API GL-4 or GL-5 transmission oil (specifics in manual)
📐 Dimensions
Exterior
Length:
Approx. 1940 mm (may vary slightly by year)
Width:
Approx. 720 mm (may vary slightly by year)
Height:
Approx. 1050 mm (may vary slightly by year)
Weights
Dry Weight:
Approx. 130-135 kg (may vary by year and equipment)
Fuel Tank Capacity:
Approx. 13 Liters (including reserve)
🛡️ Safety Features
Ratings
Crash Test Data:
Not applicable for motorcycles in this era; focus is on design and rider protection features
Active Features
Braking System:
Hydraulic disc brakes front and rear
Front Brake Specs:
Single Disc, Radial Caliper (e.g., Brembo, Grimeca, depending on year/variant)
Rear Brake Specs:
Single Disc, Caliper
Passive Features
Frame Construction:
Aluminum twin-spar frame
Lighting:
Halogen headlight, LED or incandescent tail light/indicators
💡 Technology Features
Infotainment
Infotainment System:
N/A (Motorcycle of this era focused on core riding dynamics, not digital features)
Driver Assistance
Rider Aids:
N/A (No electronic rider aids like ABS or traction control typically found on this model range)
Instrumentation
Dashboard:
Analog speedometer, tachometer, engine temperature gauge, fuel level warning light, neutral indicator, turn signal indicators.
Lighting Technology:
Standard halogen headlight bulb.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or annually (as per manual recommendations, depending on usage)
Spark Plug Replacement:
Every 6,000-8,000 km (specific plug type and gap required)
Air Filter Cleaning:
Every 3,000-5,000 km or as needed based on conditions
Chain Lubrication Adjustment:
Every 500-1,000 km and after washing/rain
Fluid Specifications
Brake Fluid Type:
DOT 4 (specified in manual, always use fresh fluid)
Coolant Capacity:
Approx. 1.2 Liters (system capacity)
Known Issues
Common Wear Items:
Clutch plates, exhaust valve mechanism, water pump seals, carburetor diaphragm, front fork seals.
Two Stroke Specifics:
Requires diligent adherence to oil injection system maintenance and correct two-stroke oil usage to prevent engine damage.
Carburetor Maintenance:
Carburetors can be sensitive to fuel quality and require periodic cleaning and adjustment for optimal performance.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Italian manufacturer with a strong racing heritage, particularly in smaller displacement classes and two-stroke engines.
Model Evolution
Rs 125 Development:
Evolved from earlier Aprilia sport 125 models, establishing itself as a benchmark for performance and handling in the 125cc supersport segment.
Key Changes 1993-2006:
Significant updates included engine revisions (e.g., Rotax 122/123 evolution), chassis improvements, styling updates, and introduction of different brake and suspension components across the years.
Production
Manufacturing Location:
Italy
Market Success:
Highly popular throughout its production run, especially in Europe, known for its track-day capabilities and premium feel.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Consistently recognized as a top performer in its class for handling and track capability by motorcycle publications of the era.
Ratings
Performance Reviews:
Praised for its sharp handling, powerful two-stroke engine, and premium feel, often setting the benchmark for 125cc sportbikes.
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