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1993-2002 Aprilia RS125 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Model Years Covered: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Codes Engine Code General: Rotax 122 Chassis Code General: RS125 👋 Introduction Market Position Target User: DIY mechanics, Aprilia RS125 owners, motorcycle repair shops. Competitive Analysis Value Proposition: Provides comprehensive repair and maintenance information, enabling self-sufficiency and cost savings for owners of the 1993-2002 Aprilia RS125. Key Features Searchability: Quick and easy navigation to specific information via chapter organization and PDF search functionality. Completeness: Covers a wide range of repair and maintenance procedures for the specified model years. Accessibility: Digital format (PDF) compatible with common operating systems for convenient access. Language Support: English language facilitates understanding for a broad user base. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service Repair Page Count Estimated Page Count: Likely several hundred pages (typical for comprehensive workshop manuals of this era, exact count not provided in product info) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Compatibility: Windows, Mac 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, and overhaul procedures for the Rotax 122 engine. Fuel System: Carburetor tuning, fuel pump, fuel lines, and tank servicing. Cooling System: Radiator, coolant circulation, water pump, and thermostat service. Electrical System: Wiring diagrams, ignition system, lighting, charging system, battery, and starter motor. Chassis: Frame, suspension (front forks, rear shock absorber), steering, wheels, and bearings. Brakes: Brake system servicing, including hydraulic components, pads, and fluid. Exhaust System: Removal, installation, and inspection of the exhaust system. Bodywork: Fairing removal, installation, and general body panel adjustments. Procedures Included Maintenance: Periodic maintenance schedules, fluid changes, filter replacement, spark plug checks. Repair: Step-by-step repair instructions for all major vehicle systems. Troubleshooting: Diagnostic flowcharts and common problem identification for various issues. Setting Up: Initial setup and adjustment procedures. Technical Depth Depth: Comprehensive (covers routine maintenance to complete engine rebuilds and diagnostics). 📊 Manual Specifications File Format PDF Quality: Assumed to be good quality for readability and searchability (standard for digital manuals). Searchability: Fully searchable text content within the PDF document. Print Quality Printable: Yes, designed for printing of specific sections or the entire manual. Binding Type Binding: Not Applicable (Digital PDF) Paper Type Paper Type: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder, liquid-cooled Engine Manufacturer: Rotax Engine Family: Rotax 122 Displacement: 124.8 cc (approx.) Bore X Stroke: 54 mm x 54.5 mm (typical for Rotax 122) Compression Ratio: Approximately 8.5:1 to 9.5:1 (varies by specific model year/variant) Power Output: Varies by market and year, typically 28-34 hp (20.9-25.4 kW) at peak RPM (e.g., around 10,000-11,000 RPM). Torque: Varies by market and year, typically 19-22 Nm (approx. 14-16 lb-ft) at peak RPM. Performance Top Speed: Approximately 150-160 km/h (93-99 mph), depending on gearing and rider. Fuel System Carburetor: Dell'Orto PHBH 28 (common) or similar performance-oriented carburetor. Fuel Type: Unleaded gasoline, minimum octane rating of 95 RON (Super Unleaded recommended). Fuel Delivery: Gravity feed with a fuel pump (may be vacuum-operated or electric depending on year). Oil Mixing: Autolube system (separate oil reservoir). Lubrication Engine Oil Type: Two-stroke engine oil specifically formulated for high-performance air-cooled or liquid-cooled engines. Refer to manual for specific API TC or JASO FD/FE ratings. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet multi-plate clutch Final Drive: Chain drive Transmission Oil Type: Two-stroke engine oil (often shared with the autolube system, consult manual for specifics). 📐 Dimensions Exterior Length: Approx. 1960 mm (77.2 in) Width: Approx. 750 mm (29.5 in) Height: Approx. 1070 mm (42.1 in) Wheelbase: Approx. 1370 mm (53.9 in) Seat Height: Approx. 820 mm (32.3 in) Weights Dry Weight: Approx. 130 kg (287 lbs) Fuel Tank Capacity: Approx. 7.5 liters (1.98 US gal) Oil Tank Capacity: Approx. 1.5 liters (0.40 US gal) 🛡️ Safety Features Active Features Braking System Front: Disc brake (e.g., 320mm disc with twin-piston caliper on many models). Braking System Rear: Disc brake (e.g., 220mm disc with single-piston caliper on many models). Passive Features Lighting: Halogen headlamp, taillight, turn signals. Instrumentation: Speedometer, tachometer, coolant temperature gauge, indicator lights. 💡 Technology Features Infotainment Instrument Cluster Features: Analog tachometer, speedometer, coolant temperature gauge, neutral indicator, turn signal indicators, oil level warning light. Driver Assistance Engine Management: CDI ignition system, potentially with mechanical or electronic power valve control depending on the specific sub-model and year. 🔧 Maintenance Service Intervals Oil Change Interval: Depends on mileage and usage, but typically every 3,000-5,000 km for general service. Engine-specific internal maintenance will have different intervals. Spark Plug Replacement: Refer to manual for specific recommendations, but often around 5,000-10,000 km depending on plug type and condition. Air Filter Cleaning Replacement: Check and clean every 3,000-5,000 km, replace as needed. Critical for two-stroke engine longevity. Coolant Flush Interval: Typically every 2 years or 20,000-30,000 km,...
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1993-2002 Aprilia RS125 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Model Years Covered:
1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002
Codes
Engine Code General:
Rotax 122
Chassis Code General:
RS125
👋 Introduction
Market Position
Target User:
DIY mechanics, Aprilia RS125 owners, motorcycle repair shops.
Competitive Analysis
Value Proposition:
Provides comprehensive repair and maintenance information, enabling self-sufficiency and cost savings for owners of the 1993-2002 Aprilia RS125.
Key Features
Searchability:
Quick and easy navigation to specific information via chapter organization and PDF search functionality.
Completeness:
Covers a wide range of repair and maintenance procedures for the specified model years.
Accessibility:
Digital format (PDF) compatible with common operating systems for convenient access.
Language Support:
English language facilitates understanding for a broad user base.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service Repair
Page Count
Estimated Page Count:
Likely several hundred pages (typical for comprehensive workshop manuals of this era, exact count not provided in product info)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
Compatibility:
Windows, Mac
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, and overhaul procedures for the Rotax 122 engine.
Fuel System:
Carburetor tuning, fuel pump, fuel lines, and tank servicing.
Cooling System:
Radiator, coolant circulation, water pump, and thermostat service.
Electrical System:
Wiring diagrams, ignition system, lighting, charging system, battery, and starter motor.
Chassis:
Frame, suspension (front forks, rear shock absorber), steering, wheels, and bearings.
Brakes:
Brake system servicing, including hydraulic components, pads, and fluid.
Exhaust System:
Removal, installation, and inspection of the exhaust system.
Bodywork:
Fairing removal, installation, and general body panel adjustments.
Procedures Included
Maintenance:
Periodic maintenance schedules, fluid changes, filter replacement, spark plug checks.
Repair:
Step-by-step repair instructions for all major vehicle systems.
Troubleshooting:
Diagnostic flowcharts and common problem identification for various issues.
Setting Up:
Initial setup and adjustment procedures.
Technical Depth
Depth:
Comprehensive (covers routine maintenance to complete engine rebuilds and diagnostics).
📊 Manual Specifications
File Format
PDF Quality:
Assumed to be good quality for readability and searchability (standard for digital manuals).
Searchability:
Fully searchable text content within the PDF document.
Print Quality
Printable:
Yes, designed for printing of specific sections or the entire manual.
Binding Type
Binding:
Not Applicable (Digital PDF)
Paper Type
Paper Type:
Not Applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Two-stroke, single-cylinder, liquid-cooled
Engine Manufacturer:
Rotax
Engine Family:
Rotax 122
Displacement:
124.8 cc (approx.)
Bore X Stroke:
54 mm x 54.5 mm (typical for Rotax 122)
Compression Ratio:
Approximately 8.5:1 to 9.5:1 (varies by specific model year/variant)
Power Output:
Varies by market and year, typically 28-34 hp (20.9-25.4 kW) at peak RPM (e.g., around 10,000-11,000 RPM).
Torque:
Varies by market and year, typically 19-22 Nm (approx. 14-16 lb-ft) at peak RPM.
Performance
Top Speed:
Approximately 150-160 km/h (93-99 mph), depending on gearing and rider.
Fuel System
Carburetor:
Dell'Orto PHBH 28 (common) or similar performance-oriented carburetor.
Fuel Type:
Unleaded gasoline, minimum octane rating of 95 RON (Super Unleaded recommended).
Fuel Delivery:
Gravity feed with a fuel pump (may be vacuum-operated or electric depending on year).
Oil Mixing:
Autolube system (separate oil reservoir).
Lubrication
Engine Oil Type:
Two-stroke engine oil specifically formulated for high-performance air-cooled or liquid-cooled engines. Refer to manual for specific API TC or JASO FD/FE ratings.
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Features
Clutch Type:
Wet multi-plate clutch
Final Drive:
Chain drive
Transmission Oil Type:
Two-stroke engine oil (often shared with the autolube system, consult manual for specifics).
📐 Dimensions
Exterior
Length:
Approx. 1960 mm (77.2 in)
Width:
Approx. 750 mm (29.5 in)
Height:
Approx. 1070 mm (42.1 in)
Wheelbase:
Approx. 1370 mm (53.9 in)
Seat Height:
Approx. 820 mm (32.3 in)
Weights
Dry Weight:
Approx. 130 kg (287 lbs)
Fuel Tank Capacity:
Approx. 7.5 liters (1.98 US gal)
Oil Tank Capacity:
Approx. 1.5 liters (0.40 US gal)
🛡️ Safety Features
Active Features
Braking System Front:
Disc brake (e.g., 320mm disc with twin-piston caliper on many models).
Braking System Rear:
Disc brake (e.g., 220mm disc with single-piston caliper on many models).
Passive Features
Lighting:
Halogen headlamp, taillight, turn signals.
Instrumentation:
Speedometer, tachometer, coolant temperature gauge, indicator lights.
💡 Technology Features
Infotainment
Instrument Cluster Features:
Analog tachometer, speedometer, coolant temperature gauge, neutral indicator, turn signal indicators, oil level warning light.
Driver Assistance
Engine Management:
CDI ignition system, potentially with mechanical or electronic power valve control depending on the specific sub-model and year.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Depends on mileage and usage, but typically every 3,000-5,000 km for general service. Engine-specific internal maintenance will have different intervals.
Spark Plug Replacement:
Refer to manual for specific recommendations, but often around 5,000-10,000 km depending on plug type and condition.
Air Filter Cleaning Replacement:
Check and clean every 3,000-5,000 km, replace as needed. Critical for two-stroke engine longevity.
Coolant Flush Interval:
Typically every 2 years or 20,000-30,000 km, depending on coolant type.
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze (e.g., Motul Motocool Expert, Castrol Radicool) mixed with distilled water in a 50/50 ratio. Consult manual for exact specifications.
Brake Fluid Type:
DOT 4 (or DOT 5.1 if specified) hydraulic brake fluid.
Known Issues
Engine Wear:
High-performance two-strokes are prone to wear if not properly maintained; piston ring and cylinder wear are common with high mileage or poor lubrication.
Carburetor Settings:
Carburetors (like Dell'Orto PHBH) can require fine-tuning due to atmospheric conditions or modifications, impacting performance and fuel efficiency.
Power Valve Issues:
The power valve mechanism can accumulate carbon deposits, leading to sticking and reduced performance if not cleaned regularly.
Electrical Connections:
Corrosion or loose connections in the electrical system can lead to intermittent faults, especially on older bikes.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian manufacturer renowned for its performance-oriented motorcycles, particularly in the sportbike and racing segments.
Model Evolution
Rs125 Significance:
The RS125 was Aprilia's flagship 125cc sportbike, known for its sophisticated chassis, potent Rotax engine, and racing-inspired styling, often seen as a gateway to larger sportbikes.
Production
Production Period:
The 1993-2002 range covers significant iterations of the RS125, with updates to styling, engine management, and components throughout this period.
Key Innovations During Period:
Early models featured more basic electronics, while later versions in this range may incorporate improvements in reed valve systems, exhaust design, and potentially even early forms of electronic power valves (Rotax 'APRC' systems evolved significantly).
🏆 Awards & Recognition
Recognitions
Sportbike Reputation:
The Aprilia RS125 was highly regarded in its class for its handling and performance, often winning magazine shootouts and praised for its track-day capability.
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