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Aprilia RS 125 1993-2006 Online Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Model Variant: Rotax 122 engine Production Years Covered: 1993-2006 Codes Chassis Codes: AP04, AP05, AP06 (specific to generation/updates) 👋 Introduction Market Position Market Segment: Lightweight supersport motorcycle, popular for track days and spirited road riding. Competitive Analysis Competitors: Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125, Kawasaki Ninja 125. Key Features Model Reputation: Renowned for its sharp handling, potent two-stroke engine performance, and aggressive styling, making it a class leader for its era. Manual Value Proposition Target Audience: Aprilia RS 125 owners, mechanics, and enthusiasts seeking to maintain, repair, or restore their motorcycles. 📋 Manual Details Coverage Areas Coverage Description: Comprehensive service and repair information for all aspects of the Aprilia RS 125 from 1993 to 2006, including maintenance, troubleshooting, diagnostics, and repair procedures. Page Count Estimated Page Count: Likely 300-500+ pages (typical for comprehensive service manuals of this era) Manual Type Manual Type: Online Service/Repair Manual Language Language: English (assumed, standard for online service manuals of this type) Format Format: Digital (Online Access/Downloadable PDF) 📖 Manual Coverage Systems Covered Engine Systems: Top-end (cylinder, piston, head), bottom-end (crankshaft, connecting rod, bearings), lubrication, cooling, intake, exhaust, fuel delivery (carburetor tuning and overhaul). Transmission Systems: Clutch (operation, adjustment, replacement), gearbox (gear selection, internal components, lubrication), final drive (chain adjustment and replacement). Chassis Systems: Frame, swingarm, rear suspension (monoshock adjustment and rebuild), front suspension (forks, seals, oil changes), steering system, wheels, tires, brakes (front and rear disc systems, hydraulics, pad replacement). Electrical Systems: Ignition system (CDI, spark plug), lighting (headlight, taillight, indicators), charging system (stator, rectifier/regulator), battery, starter motor, wiring diagrams, fuses. Bodywork And Trim: Fairings, seat, fuel tank, instrumentation, levers, controls. Procedures Included Maintenance Procedures: Oil changes, filter replacements, chain lubrication and adjustment, brake fluid flush, coolant flush, spark plug replacement, air filter cleaning/replacement, carburetor cleaning and synchronization. Repair Procedures: Engine disassembly and reassembly, cylinder head rebuild, piston and ring replacement, crankshaft bearing replacement, transmission gear inspection and replacement, fork seal replacement, brake caliper overhaul, carburetor jetting and tuning. Troubleshooting Guides: Diagnostic flowcharts for common starting issues, running problems, electrical faults, and performance issues. Technical Data And Specs: Torque specifications for all fasteners, engine clearances, carburetor settings, suspension sag, electrical component specifications. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic rider maintenance to full engine rebuilds and advanced electrical diagnostics. Suitable for both DIY enthusiasts and professional mechanics. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Print Quality Recommendation: High resolution for clear diagrams and text, suitable for printing specific sections or the entire manual. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type Recommendation: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder Engine Displacement: 124.8 cc (cubic centimeters) Bore X Stroke: 54 mm x 54.5 mm (approximate, may vary slightly by year) Compression Ratio: 12.5:1 (typical for later models) Ignition System: Digital CDI with electronic advance Cooling System: Liquid-cooled Performance Horsepower: Approx. 30-34 HP (varies by market regulations and specific year/tuning) Torque: Approx. 20-22 Nm (varies by market) Fuel System Carburetor Type: Dell'Orto PHBH 28/30 (common, may vary by specific model year and market) Fuel Type: Unleaded gasoline, minimum 95 RON Fuel Mixture: Premixed fuel and oil (oil injection system) Engine Oil Engine Oil Type: 2-stroke synthetic or semi-synthetic oil meeting JASO FD or API TC specifications 🔧 Transmission Standard Transmission Type: 6-speed manual sequential gearbox Clutch Type: Wet multi-plate clutch Features Gear Ratios: Specific ratios available in the manual, typically optimized for performance. Final Drive: Chain drive, 520 pitch (common) Transmission Oil Gearbox Oil Type: Manual transmission fluid (MTF) or specific gearbox oil, capacity specified in manual. 📐 Dimensions Exterior Length: Approx. 1950 mm (varies slightly by year) Width: Approx. 730 mm (at handlebars) Height: Approx. 1070 mm (at handlebars) Wheelbase: Approx. 1360 mm Weights Dry Weight: Approx. 131 kg Wet Weight: Approx. 142 kg (with fluids) Fuel Tank Capacity: Approx. 13 liters Dimensions Seat Height: Approx. 810 mm 🛡️ Safety Features Ratings Safety Features Description: While specific crash test ratings for this era of lightweight motorcycles are not as standardized as modern cars, the RS 125 features robust braking systems and a stable chassis for its class. Active Features Braking System Front: Single disc, 320 mm diameter, 4-piston caliper (e.g., Brembo or Grimeca depending on year/market) Braking System Rear: Single disc, 220 mm diameter, 2-piston caliper Passive Features Lighting: Halogen headlight, LED taillight (on later models), front and rear turn signals. Tires Front: 110/70-17 (common) Tires Rear: 150/60-17 (common) Suspension Front: Upside-down (USD) telescopic forks, adjustable preload/rebound on some models. Suspension Rear: Monoshock absorber with adjustable preload and rebound damping. 💡 Technology Features Infotainment Infotainment System: N/A (basic instrumentation) Driver Assistance Driver Assistance Features: N/A (no electronic rider aids in the modern sense) Instrumentation Instrument Cluster: Analog tachometer,...
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Aprilia RS 125 1993-2006 Online Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Model Variant:
Rotax 122 engine
Production Years Covered:
1993-2006
Codes
Chassis Codes:
AP04, AP05, AP06 (specific to generation/updates)
👋 Introduction
Market Position
Market Segment:
Lightweight supersport motorcycle, popular for track days and spirited road riding.
Competitive Analysis
Competitors:
Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125, Kawasaki Ninja 125.
Key Features
Model Reputation:
Renowned for its sharp handling, potent two-stroke engine performance, and aggressive styling, making it a class leader for its era.
Manual Value Proposition
Target Audience:
Aprilia RS 125 owners, mechanics, and enthusiasts seeking to maintain, repair, or restore their motorcycles.
📋 Manual Details
Coverage Areas
Coverage Description:
Comprehensive service and repair information for all aspects of the Aprilia RS 125 from 1993 to 2006, including maintenance, troubleshooting, diagnostics, and repair procedures.
Page Count
Estimated Page Count:
Likely 300-500+ pages (typical for comprehensive service manuals of this era)
Manual Type
Manual Type:
Online Service/Repair Manual
Language
Language:
English (assumed, standard for online service manuals of this type)
Format
Format:
Digital (Online Access/Downloadable PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Top-end (cylinder, piston, head), bottom-end (crankshaft, connecting rod, bearings), lubrication, cooling, intake, exhaust, fuel delivery (carburetor tuning and overhaul).
Transmission Systems:
Clutch (operation, adjustment, replacement), gearbox (gear selection, internal components, lubrication), final drive (chain adjustment and replacement).
Chassis Systems:
Frame, swingarm, rear suspension (monoshock adjustment and rebuild), front suspension (forks, seals, oil changes), steering system, wheels, tires, brakes (front and rear disc systems, hydraulics, pad replacement).
Electrical Systems:
Ignition system (CDI, spark plug), lighting (headlight, taillight, indicators), charging system (stator, rectifier/regulator), battery, starter motor, wiring diagrams, fuses.
Bodywork And Trim:
Fairings, seat, fuel tank, instrumentation, levers, controls.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, chain lubrication and adjustment, brake fluid flush, coolant flush, spark plug replacement, air filter cleaning/replacement, carburetor cleaning and synchronization.
Repair Procedures:
Engine disassembly and reassembly, cylinder head rebuild, piston and ring replacement, crankshaft bearing replacement, transmission gear inspection and replacement, fork seal replacement, brake caliper overhaul, carburetor jetting and tuning.
Troubleshooting Guides:
Diagnostic flowcharts for common starting issues, running problems, electrical faults, and performance issues.
Technical Data And Specs:
Torque specifications for all fasteners, engine clearances, carburetor settings, suspension sag, electrical component specifications.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from basic rider maintenance to full engine rebuilds and advanced electrical diagnostics. Suitable for both DIY enthusiasts and professional mechanics.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Print Quality
Print Quality Recommendation:
High resolution for clear diagrams and text, suitable for printing specific sections or the entire manual.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type Recommendation:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, two-stroke, single-cylinder
Engine Displacement:
124.8 cc (cubic centimeters)
Bore X Stroke:
54 mm x 54.5 mm (approximate, may vary slightly by year)
Compression Ratio:
12.5:1 (typical for later models)
Ignition System:
Digital CDI with electronic advance
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 30-34 HP (varies by market regulations and specific year/tuning)
Torque:
Approx. 20-22 Nm (varies by market)
Fuel System
Carburetor Type:
Dell'Orto PHBH 28/30 (common, may vary by specific model year and market)
Fuel Type:
Unleaded gasoline, minimum 95 RON
Fuel Mixture:
Premixed fuel and oil (oil injection system)
Engine Oil
Engine Oil Type:
2-stroke synthetic or semi-synthetic oil meeting JASO FD or API TC specifications
🔧 Transmission
Standard
Transmission Type:
6-speed manual sequential gearbox
Clutch Type:
Wet multi-plate clutch
Features
Gear Ratios:
Specific ratios available in the manual, typically optimized for performance.
Final Drive:
Chain drive, 520 pitch (common)
Transmission Oil
Gearbox Oil Type:
Manual transmission fluid (MTF) or specific gearbox oil, capacity specified in manual.
📐 Dimensions
Exterior
Length:
Approx. 1950 mm (varies slightly by year)
Width:
Approx. 730 mm (at handlebars)
Height:
Approx. 1070 mm (at handlebars)
Wheelbase:
Approx. 1360 mm
Weights
Dry Weight:
Approx. 131 kg
Wet Weight:
Approx. 142 kg (with fluids)
Fuel Tank Capacity:
Approx. 13 liters
Dimensions
Seat Height:
Approx. 810 mm
🛡️ Safety Features
Ratings
Safety Features Description:
While specific crash test ratings for this era of lightweight motorcycles are not as standardized as modern cars, the RS 125 features robust braking systems and a stable chassis for its class.
Active Features
Braking System Front:
Single disc, 320 mm diameter, 4-piston caliper (e.g., Brembo or Grimeca depending on year/market)
Braking System Rear:
Single disc, 220 mm diameter, 2-piston caliper
Passive Features
Lighting:
Halogen headlight, LED taillight (on later models), front and rear turn signals.
Tires Front:
110/70-17 (common)
Tires Rear:
150/60-17 (common)
Suspension Front:
Upside-down (USD) telescopic forks, adjustable preload/rebound on some models.
Suspension Rear:
Monoshock absorber with adjustable preload and rebound damping.
💡 Technology Features
Infotainment
Infotainment System:
N/A (basic instrumentation)
Driver Assistance
Driver Assistance Features:
N/A (no electronic rider aids in the modern sense)
Instrumentation
Instrument Cluster:
Analog tachometer, speedometer, odometer, trip meter, coolant temperature gauge, basic indicator lights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or annually (refer to manual for specific interval).
Spark Plug Replacement:
Every 5,000-10,000 km (depending on plug type, e.g., NGK BR9EG).
Chain Maintenance:
Lubricate and adjust every 500-1,000 km.
Coolant Flush:
Every 2 years.
Brake Fluid Flush:
Every 2 years.
Fluid Specifications
Engine Oil Capacity:
Specific capacity for gearbox oil (approx. 0.8-1.0 liter) and 2-stroke oil reservoir (refer to manual).
Fork Oil Type:
Typically SAE 5W or 10W fork oil, capacity specified per fork leg.
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives, 50/50 mix with distilled water.
Known Issues
Common Wear Items:
Piston rings, spark plug, clutch plates, fork seals, rear shock absorber bushings, exhaust power valve mechanism.
Typical Problems:
Carburetor jetting issues due to altitude/temperature changes, power valve sticking, premature wear if oil/fuel mixture is incorrect, electrical connector corrosion.
📚 Vehicle History
Brand Heritage
Brand Focus:
Aprilia is an Italian motorcycle manufacturer renowned for its sporting heritage, particularly in smaller displacement classes and racing.
Model Evolution
Rs 125 Development:
The RS 125 was developed as a homologation special for racing, featuring a potent Rotax engine and advanced chassis for its time, establishing it as a benchmark in the 125cc supersport segment.
Key Updates 1993-2006:
Significant updates included engine performance enhancements, revised bodywork and aerodynamics, improved suspension components, and upgraded braking systems across different model years (e.g., '95, '97, '01 updates).
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Model Recognition:
The Aprilia RS 125 was widely praised in motorcycle press of its time for its performance, handling, and aggressive styling, often considered the benchmark in its class.
Ratings
Performance Ratings:
Consistently rated highly for its class-leading power delivery and track-day capability.
Certifications
Certifications:
N/A (Specific certifications for motorcycles of this era are less common than modern safety standards).
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