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Aprilia RS 125 2004 Repair Service Manual

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$133.00
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$133.00
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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 2004 Type: Sportbike 👋 Introduction Market Position Positioning: The Aprilia RS 125 is a highly regarded entry-level sportbike, known for its sharp styling, track-inspired handling, and performance that punches above its weight class. It caters to younger riders, aspiring racers, and those seeking an engaging riding experience in a lightweight package. Competitive Analysis Competitors: Direct competitors in its era included models like the Yamaha YZF-R125, Honda CBR125R, and KTM RC 125, all vying for dominance in the premium 125cc sportbike segment. Key Features Features: Aggressive sportbike styling, perimeter frame, potent two-stroke engine, capable suspension, and strong braking performance, all contributing to its sporty demeanor. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Chassis: Yes Electrical System: Yes Bodywork: Yes Suspension: Yes Brakes: Yes Fuel System: Yes Cooling System: Yes Exhaust System: Yes Troubleshooting: Yes Maintenance Procedures: Yes Engine Rebuild: Yes Wiring Diagrams: Yes Page Count Page Count: Extensive (specific count not provided, but implied comprehensive) Manual Type Manual Type: Repair Service Manual Language Language: English (implied by product description) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, inspection, and repair of all engine components including crankshaft, connecting rods, pistons, cylinders, valves, and camshafts. Engine Management: Carburetor tuning, adjustment, and overhaul. Ignition system diagnosis and repair. Fuel and oil delivery systems. Transmission And Drivetrain: Clutch operation, adjustment, and replacement. Gearbox inspection, disassembly, and reassembly. Chain and sprocket maintenance. Brake System: Hydraulic brake system components, fluid replacement, bleeding procedures, caliper and master cylinder servicing, pad and disc replacement. Suspension And Steering: Front fork servicing, seal replacement, oil levels. Rear shock absorber inspection and adjustment. Steering head bearing maintenance and adjustment. Electrical System: Wiring diagrams for all circuits, battery maintenance, charging system (stator and regulator/rectifier), lighting, ignition, and instrumentation. Cooling System: Radiator, coolant hoses, water pump, and thermostat inspection and replacement. Coolant type and capacity specifications. Fuel And Lubrication: Fuel tank, lines, and petcock maintenance. Two-stroke oil injection system diagnosis and servicing. Oil specifications and mixing ratios. Bodywork And Frame: Fairing removal and installation, seat, fuel tank mounting, frame inspection, and related components. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, brake fluid checks, tire pressure checks, spark plug inspection. Scheduled Maintenance: Detailed service intervals for all major components and systems. Diagnostic Procedures: Troubleshooting guides for common issues, electrical fault finding, and mechanical problem diagnosis. Component Overhaul: Step-by-step instructions for rebuilding the engine, gearbox, carburetor, and brake system components. Adjustments: Carburetor jetting and idle speed adjustments, clutch cable adjustment, throttle cable adjustment, suspension sag adjustments. Special Tool Usage: Identification and recommended usage of specialized tools required for certain procedures. Technical Depth Depth: Professional Technician Level, covering full rebuilds, advanced diagnostics, and detailed specifications. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Yes (typical for professional PDF manuals) Print Quality Quality: High-resolution, clear diagrams and text Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder Displacement: 124.8 cc (7.6 cu in) Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 12.4:1 (typical for this era) Power Output: Approx. 31-34 HP (23-25 kW) at 10,500 rpm (varies by market regulations) Torque: Approx. 19.2 Nm (14.2 lb-ft) at 10,000 rpm Lubrication: Pre-mix or separate oil injection system Performance Top Speed: Approx. 100-115 mph (160-185 km/h) Fuel System Fuel Delivery: Dell'Orto PHBH 28 (or similar model) carburetor Fuel Type: Unleaded gasoline, minimum 95 RON Fuel Tank Capacity: Approx. 13 Liters (3.4 US gal) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet, multi-plate, cable-actuated Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1950 mm (76.8 in) Width: Approx. 740 mm (29.1 in) Height: Approx. 1070 mm (42.1 in) (seat height) Wheelbase: Approx. 1360 mm (53.5 in) Weights Dry Weight: Approx. 140 kg (308.6 lbs) Wet Weight: Approx. 155 kg (341.7 lbs) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety is typically assessed through independent reviews and rider experience rather than formal crash test ratings like cars). Active Features Active Safety: Effective dual-disc front brakes and single rear disc brakes for strong stopping power. Responsive handling and chassis geometry. Passive Features Passive Safety: Perimeter frame design offering good rigidity and crash protection for the engine. Sportbike ergonomics can aid rider control. 💡 Technology Features Infotainment Infotainment System: Basic analogue instrumentation: speedometer, tachometer, odometer, trip meter, and essential indicator lights (neutral, turn signals, oil level, high beam). Driver Assistance Driver Assistance Features: N/A (Motorcycle of this era does not feature electronic driver assistance systems). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km (2,000-3,000 miles) or annually, depending on usage (engine oil for gearbox). Spark Plug Check: Every 3,000-5,000 km (2,000-3,000 miles) Air Filter Cleaning: Every...
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Aprilia RS 125 2004 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Year:
2004
Type:
Sportbike
👋 Introduction
Market Position
Positioning:
The Aprilia RS 125 is a highly regarded entry-level sportbike, known for its sharp styling, track-inspired handling, and performance that punches above its weight class. It caters to younger riders, aspiring racers, and those seeking an engaging riding experience in a lightweight package.
Competitive Analysis
Competitors:
Direct competitors in its era included models like the Yamaha YZF-R125, Honda CBR125R, and KTM RC 125, all vying for dominance in the premium 125cc sportbike segment.
Key Features
Features:
Aggressive sportbike styling, perimeter frame, potent two-stroke engine, capable suspension, and strong braking performance, all contributing to its sporty demeanor.
📋 Manual Details
Coverage Areas
Engine:
Yes
Transmission:
Yes
Chassis:
Yes
Electrical System:
Yes
Bodywork:
Yes
Suspension:
Yes
Brakes:
Yes
Fuel System:
Yes
Cooling System:
Yes
Exhaust System:
Yes
Troubleshooting:
Yes
Maintenance Procedures:
Yes
Engine Rebuild:
Yes
Wiring Diagrams:
Yes
Page Count
Page Count:
Extensive (specific count not provided, but implied comprehensive)
Manual Type
Manual Type:
Repair Service Manual
Language
Language:
English (implied by product description)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair of all engine components including crankshaft, connecting rods, pistons, cylinders, valves, and camshafts.
Engine Management:
Carburetor tuning, adjustment, and overhaul. Ignition system diagnosis and repair. Fuel and oil delivery systems.
Transmission And Drivetrain:
Clutch operation, adjustment, and replacement. Gearbox inspection, disassembly, and reassembly. Chain and sprocket maintenance.
Brake System:
Hydraulic brake system components, fluid replacement, bleeding procedures, caliper and master cylinder servicing, pad and disc replacement.
Suspension And Steering:
Front fork servicing, seal replacement, oil levels. Rear shock absorber inspection and adjustment. Steering head bearing maintenance and adjustment.
Electrical System:
Wiring diagrams for all circuits, battery maintenance, charging system (stator and regulator/rectifier), lighting, ignition, and instrumentation.
Cooling System:
Radiator, coolant hoses, water pump, and thermostat inspection and replacement. Coolant type and capacity specifications.
Fuel And Lubrication:
Fuel tank, lines, and petcock maintenance. Two-stroke oil injection system diagnosis and servicing. Oil specifications and mixing ratios.
Bodywork And Frame:
Fairing removal and installation, seat, fuel tank mounting, frame inspection, and related components.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, brake fluid checks, tire pressure checks, spark plug inspection.
Scheduled Maintenance:
Detailed service intervals for all major components and systems.
Diagnostic Procedures:
Troubleshooting guides for common issues, electrical fault finding, and mechanical problem diagnosis.
Component Overhaul:
Step-by-step instructions for rebuilding the engine, gearbox, carburetor, and brake system components.
Adjustments:
Carburetor jetting and idle speed adjustments, clutch cable adjustment, throttle cable adjustment, suspension sag adjustments.
Special Tool Usage:
Identification and recommended usage of specialized tools required for certain procedures.
Technical Depth
Depth:
Professional Technician Level, covering full rebuilds, advanced diagnostics, and detailed specifications.
📊 Manual Specifications
File Format
File Format:
PDF
Searchable Text:
Yes (typical for professional PDF manuals)
Print Quality
Quality:
High-resolution, clear diagrams and text
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, two-stroke, single-cylinder
Displacement:
124.8 cc (7.6 cu in)
Bore X Stroke:
54 mm x 54.5 mm
Compression Ratio:
12.4:1 (typical for this era)
Power Output:
Approx. 31-34 HP (23-25 kW) at 10,500 rpm (varies by market regulations)
Torque:
Approx. 19.2 Nm (14.2 lb-ft) at 10,000 rpm
Lubrication:
Pre-mix or separate oil injection system
Performance
Top Speed:
Approx. 100-115 mph (160-185 km/h)
Fuel System
Fuel Delivery:
Dell'Orto PHBH 28 (or similar model) carburetor
Fuel Type:
Unleaded gasoline, minimum 95 RON
Fuel Tank Capacity:
Approx. 13 Liters (3.4 US gal)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Features
Clutch Type:
Wet, multi-plate, cable-actuated
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 1950 mm (76.8 in)
Width:
Approx. 740 mm (29.1 in)
Height:
Approx. 1070 mm (42.1 in) (seat height)
Wheelbase:
Approx. 1360 mm (53.5 in)
Weights
Dry Weight:
Approx. 140 kg (308.6 lbs)
Wet Weight:
Approx. 155 kg (341.7 lbs)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety is typically assessed through independent reviews and rider experience rather than formal crash test ratings like cars).
Active Features
Active Safety:
Effective dual-disc front brakes and single rear disc brakes for strong stopping power. Responsive handling and chassis geometry.
Passive Features
Passive Safety:
Perimeter frame design offering good rigidity and crash protection for the engine. Sportbike ergonomics can aid rider control.
💡 Technology Features
Infotainment
Infotainment System:
Basic analogue instrumentation: speedometer, tachometer, odometer, trip meter, and essential indicator lights (neutral, turn signals, oil level, high beam).
Driver Assistance
Driver Assistance Features:
N/A (Motorcycle of this era does not feature electronic driver assistance systems).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km (2,000-3,000 miles) or annually, depending on usage (engine oil for gearbox).
Spark Plug Check:
Every 3,000-5,000 km (2,000-3,000 miles)
Air Filter Cleaning:
Every 3,000-5,000 km (2,000-3,000 miles)
Chain Maintenance:
Lubricate and adjust every 500-1000 km (300-600 miles)
Brake Fluid Flush:
Every 2 years
Fluid Specifications
Engine Oil Type:
API GL-4 or GL-5, SAE 75W-90 (gearbox oil)
Coolant Type:
Ethylene glycol-based antifreeze mixture (50/50 with distilled water)
Brake Fluid Type:
DOT 4
Two Stroke Oil:
High-quality synthetic two-stroke motorcycle oil, as specified by Aprilia
Known Issues
Common Issues:
Carburetor jetting sensitivity to altitude and temperature, potential for wear in the power valve mechanism, clutch wear, and vibration-related issues on longer rides.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia has a storied history in motorcycle racing, particularly in the Grand Prix circuit, with numerous championships in smaller displacement classes. This racing pedigree heavily influences the design and performance of their road bikes, including the RS 125.
Model Evolution
Evolution:
The RS 125 has been a staple in Aprilia's lineup for many years, undergoing several updates and revisions. The 2004 model represents a mature iteration of the design, building upon previous versions with refinements to styling, engine performance, and chassis dynamics.
Production
Production Years:
The Aprilia RS 125 has been in continuous production since the early 1990s, with significant updates occurring throughout its lifecycle. The 2004 model is part of the second generation of the RS 125.
🏆 Awards & Recognition
Recognitions
Awards And Recognitions:
While specific awards for the 2004 model are not widely documented, the RS 125 platform has consistently received accolades in performance tests and rider reviews for its class-leading handling and sporty character.
Ratings
Rider Ratings:
Consistently rated highly by riders for its engaging performance, sharp looks, and the thrill of its two-stroke engine.
Certifications
Certifications:
Compliant with European emissions and safety standards for its model year.
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