🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Model Years Covered: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Sub Model Variants: Rotax 122 engine variants (e.g., Rotax 122E, Rotax 122E-V) Codes Chassis Codes: AP03, AP06 (common identifiers, specific year codes may vary) 👋 Introduction Market Position Segment: Lightweight supersport motorcycle, popular in the 125cc class for track days and road riding. Target Audience: Enthusiast owners, independent workshops, and DIY mechanics seeking detailed repair and maintenance information. Competitive Analysis Key Competitors: Yamaha TZR 125, Honda NSR 125, Cagiva Mito 125. Key Features Performance Focus: The RS 125 is renowned for its sporty handling and potent Rotax engine, making it a favorite for performance-oriented riders. Manual Value Proposition: Provides comprehensive, manufacturer-level technical data essential for maintaining the performance and longevity of this iconic 125cc sportbike. 📋 Manual Details Coverage Areas Manual Type: Service Repair Manual Language: English Format: Digital (likely PDF, though physical format is not specified) Page Count: Estimated 300-500+ pages (typical for comprehensive service manuals of this era) Manual Specifications File Format Quality: High-resolution scans or native digital format ensuring clarity of text and diagrams; searchable text capability likely. Print Quality Recommendation: Designed for clear printing on standard paper, with professional-grade diagrams and illustrations. Binding Type Suitability: Ideal for digital access; if printed, a spiral or comb binding would be most practical for workshop use. Paper Type Suitability: Standard copier paper for digital printouts; durable paper recommended for physical copies. 📖 Manual Coverage Systems Covered Engine Overhaul: Complete disassembly, inspection, repair, and reassembly of the Rotax 122 two-stroke engine. Cooling System: Radiator, water pump, coolant flow, thermostat, hoses, and bleeding procedures. Fuel System: Carburetor (Dell'Orto PHBH/PHBL variants) tuning, cleaning, and rebuilding; fuel tank, lines, and petcock service. Ignition System: CDI ignition system, spark plug selection and gap, coil testing, and troubleshooting. Exhaust System: Expansion chamber design principles, service, and de-carbonization. Transmission And Clutch: Gearbox disassembly and reassembly, clutch operation, cable adjustment, and friction plate replacement. Suspension Front: Front fork service, oil changes, seal replacement, spring inspection, and adjustment procedures (e.g., Marzocchi, Paioli). Suspension Rear: Monoshock rear suspension service, linkage lubrication, shock absorber inspection, and spring pre-load adjustment. Braking System Front: Hydraulic disc brake system, caliper service, master cylinder overhaul, fluid replacement, bleeding, and pad replacement. Braking System Rear: Hydraulic disc brake system, caliper service, master cylinder overhaul, fluid replacement, bleeding, and pad replacement. Wheel And Tires: Wheel bearing inspection and replacement, tire mounting and balancing, and rim specifications. Electrical System: Wiring diagrams, lighting, indicators, horn, battery maintenance, charging system (stator, regulator/rectifier), and starter system. Frame And Bodywork: Chassis inspection, fairing removal and installation, seat and tank mounting, and general body panel care. Procedures Included Preventative Maintenance: Detailed schedules for oil changes, filter replacements, chain adjustment, lubrication points, and general inspections. Troubleshooting Guide: Systematic approach to diagnosing common starting, running, electrical, and braking issues with potential causes and solutions. Engine Rebuild Procedures: Step-by-step instructions for piston, con-rod, crankshaft, cylinder, and head servicing. Carburetor Rebuild: Instructions for dismantling, cleaning, replacing jets, needles, and gaskets. Suspension Fork Rebuild: Guide for replacing fork seals, bushings, and oil. Brake System Overhaul: Instructions for caliper piston removal/installation, master cylinder seal replacement, and brake bleeding. Electrical Troubleshooting: Using wiring diagrams to diagnose and repair faults in the electrical system. Torque Specifications: All critical fasteners torqued to manufacturer specifications for engine, chassis, and suspension components. Technical Depth Diagnostic Capabilities: Advanced diagnostics for engine performance, ignition timing, and electrical systems. Repair Scope: Covers routine maintenance, minor repairs, major overhauls, and complete component rebuilds. Diagnostic Tools: Recommended diagnostic tools and techniques (e.g., feeler gauges, multimeters, compression testers). ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder Engine Family: Rotax 122 Bore X Stroke: 54 mm x 54.5 mm (approximate, may vary slightly by sub-model) Displacement: 125 cc Compression Ratio: Approx. 8.2:1 to 8.9:1 (depending on variant and exhaust system) Power Output: Typically 30-34 HP @ 10,500 RPM (for unrestricted models, power restrictions varied by market) Torque: Approx. 20-22 Nm @ 9,000 RPM Performance Top Speed: Up to 160 km/h (approx. 100 mph, depending on rider, conditions, and restrictions) Fuel System Carburetor Type: Dell'Orto PHBH 28 / PHBL 28 (common, specific model dependent) Fuel Type: Unleaded gasoline, minimum 95 RON recommended. Oil Mixing: Autolube two-stroke oil injection system. Specific oil grade: API TC+ or JASO FD certified synthetic two-stroke oil. 🔧 Transmission Standard Gearbox Type: 6-speed constant mesh, sequential return type Features Clutch Type: Wet multi-plate clutch, cable operated Gear Ratios: Specific ratios are detailed in the manual; typically includes a close-ratio gearbox for sporty performance. Final Drive: Chain drive, with specific sprocket sizes documented in the manual. Transmission Oil: Specific gearbox oil type and grade (e.g., SAE 75W/90 GL-4) and capacity detailed in the manual. 📐 Dimensions Exterior Length: Approx. 1950...