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Aprilia RS 125 1993 Repair Service Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 1993 Vehicle Type: Sportbike Motorcycle Chassis Code: Possibly AP0600200 or similar, specific code varies by region/market 👋 Introduction Market Position Segment: Lightweight, high-performance sportbike (125cc class) Target Demographic: Young riders, those seeking sporty styling and performance in a manageable package, often a gateway to supersport riding Competitive Analysis Key Competitors: Yamaha YZF-R125 (later models), Honda CBR125R (later models), Cagiva Mito, Suzuki RG125, Kawasaki KR-1 Key Features Design Philosophy: Aggressive, race-inspired styling mimicking larger Aprilia RSV models of the era Engine Type: High-revving 2-stroke single-cylinder engine, known for strong top-end power Chassis Construction: Deltabox-style aluminum frame (or similar high-strength steel trellis), offering excellent rigidity and handling Braking System: Performance-oriented disc brakes front and rear, often with quality calipers Suspension: Upside-down (USD) front forks and a sophisticated Monoshock rear suspension for superior handling 📋 Manual Details Coverage Areas Manual Type: Repair Service Manual Language: English (assumed, typical for international service manuals) Format: PDF Download Target Audience: Professional Technicians and Experienced DIY Mechanics 📖 Manual Coverage Systems Covered Engine: Complete overhaul, disassembly, assembly, tuning, lubrication, cooling system Fuel System: Carburetor (Dell'Orto PHBH 28/29/30 likely), fuel tank, fuel pump (if applicable), fuel lines Ignition System: CDI ignition, spark plugs, ignition timing, stator, coil Exhaust System: Expansion chamber, muffler, de-carbonizing Transmission: 6-speed gearbox, clutch (wet multi-plate), gear shifting mechanism, lubrication Cooling System: Liquid cooling, radiator, fan, thermostat, coolant specifications Frame And Suspension: Front forks (likely Marzocchi or Paioli), rear shock absorber (Monoshock, possibly Sachs or Bitubo), swingarm, steering head bearings Brakes: Front disc brake (likely Brembo caliper), rear disc brake, brake fluid specifications, bleeding procedures, pad replacement Wheels And Tires: Wheel types (spoked or cast alloy), tire sizes, inflation pressures, wheel bearing maintenance Electrical System: Wiring diagrams, battery, charging system (alternator/stator), lighting, indicators, horn, starter motor (if applicable) Bodywork: Fairings, seat, fuel tank, fenders, graphics, disassembly and reassembly Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, spark plug checks, air filter cleaning Troubleshooting: Diagnostic charts for common problems (e.g., starting issues, poor performance, electrical faults) Component Overhaul: Engine rebuild, carburetor tuning, brake caliper overhaul, suspension servicing Electrical Diagnostics: Tracing wiring faults, testing components (stator, CDI, regulators) Suspension Setup And Adjustment: Fork oil levels, rear shock preload and damping adjustments Wheel And Tire Maintenance: Wheel balancing, tire fitting and removal Technical Depth Engine Rebuild Detail: Detailed procedures for piston ring replacement, cylinder head removal/installation, crankshaft bearing replacement, and timing valve adjustment (if applicable for a 2-stroke) Carburetor Tuning: Jetting charts, adjustment procedures for idle speed, mixture, and float height Diagnostic Charts: Flowcharts and symptom-based troubleshooting guides for common issues Torque Specifications: Comprehensive list of torque values for all critical fasteners Schematics And Diagrams: Detailed wiring diagrams, exploded views of components for easy identification 📊 Manual Specifications File Format File Type: PDF Searchable Text: Likely searchable text for efficient information retrieval Print Quality Image Resolution: High resolution for clear diagrams and illustrations Scalability: Scalable content for detailed viewing Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Completeness Coverage: Comprehensive, designed for professional workshop use ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke, Single Cylinder, Liquid-Cooled Displacement: 125cc (approximately 124.8 cc) Bore X Stroke: Typically 54 mm x 54.5 mm (subject to variation) Compression Ratio: Around 8.0:1 to 8.5:1 (can vary based on tuning and region) Power Output: Approximately 30-33 HP (15 kW limited for A1 license in some markets, but unrestricted versions existed) Torque: Around 2.2 - 2.5 kgf-m (16-18 lb-ft) at peak RPM Performance Redline: Often around 10,500 - 11,500 RPM Fuel System Carburetor Type: Dell'Orto PHBH 28 AS or similar 28mm/30mm carburetor Fuel Type: Unleaded Gasoline (Octane rating specified in manual, likely 95 RON or higher) Fuel Mixture: Premix or Autolube system (oil injection) Oil Type: 2-stroke synthetic oil, specified by Aprilia for autolube systems 🔧 Transmission Standard Transmission Type: 6-Speed Sequential Manual Clutch Type: Wet, Multi-plate Features Final Drive: Chain Drive Gear Ratios: Specific ratios detailed in the manual; typically optimized for sporty performance Transmission Oil Type: Refer to manual for specific grade (e.g., SAE 75W-90 or similar) 📐 Dimensions Exterior Length: Refer to manual (typically around 2000 mm) Width: Refer to manual (typically around 700-750 mm) Height: Refer to manual (typically around 1100-1150 mm) Weights Dry Weight: Approximately 130-140 kg (dry weight, refer to manual for exact figure) Wet Weight: Approximately 145-155 kg (with fluids) Fuel Tank Capacity: Approximately 12-14 Liters 🛡️ Safety Features Ratings Safety Standards: Designed to meet European motorcycle safety standards of the era Active Features Braking System: Dual disc brakes with performance calipers (e.g., Brembo) providing excellent stopping power Suspension Performance: USD forks and Monoshock rear offer stability and control during cornering and braking Passive Features Frame Rigidity: Strong frame construction contributes to rider confidence and stability Lighting: Adequate lighting for visibility...
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Aprilia RS 125 1993 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Year:
1993
Vehicle Type:
Sportbike Motorcycle
Chassis Code:
Possibly AP0600200 or similar, specific code varies by region/market
👋 Introduction
Market Position
Segment:
Lightweight, high-performance sportbike (125cc class)
Target Demographic:
Young riders, those seeking sporty styling and performance in a manageable package, often a gateway to supersport riding
Competitive Analysis
Key Competitors:
Yamaha YZF-R125 (later models), Honda CBR125R (later models), Cagiva Mito, Suzuki RG125, Kawasaki KR-1
Key Features
Design Philosophy:
Aggressive, race-inspired styling mimicking larger Aprilia RSV models of the era
Engine Type:
High-revving 2-stroke single-cylinder engine, known for strong top-end power
Chassis Construction:
Deltabox-style aluminum frame (or similar high-strength steel trellis), offering excellent rigidity and handling
Braking System:
Performance-oriented disc brakes front and rear, often with quality calipers
Suspension:
Upside-down (USD) front forks and a sophisticated Monoshock rear suspension for superior handling
📋 Manual Details
Coverage Areas
Manual Type:
Repair Service Manual
Language:
English (assumed, typical for international service manuals)
Format:
PDF Download
Target Audience:
Professional Technicians and Experienced DIY Mechanics
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, disassembly, assembly, tuning, lubrication, cooling system
Fuel System:
Carburetor (Dell'Orto PHBH 28/29/30 likely), fuel tank, fuel pump (if applicable), fuel lines
Ignition System:
CDI ignition, spark plugs, ignition timing, stator, coil
Exhaust System:
Expansion chamber, muffler, de-carbonizing
Transmission:
6-speed gearbox, clutch (wet multi-plate), gear shifting mechanism, lubrication
Cooling System:
Liquid cooling, radiator, fan, thermostat, coolant specifications
Frame And Suspension:
Front forks (likely Marzocchi or Paioli), rear shock absorber (Monoshock, possibly Sachs or Bitubo), swingarm, steering head bearings
Brakes:
Front disc brake (likely Brembo caliper), rear disc brake, brake fluid specifications, bleeding procedures, pad replacement
Wheels And Tires:
Wheel types (spoked or cast alloy), tire sizes, inflation pressures, wheel bearing maintenance
Electrical System:
Wiring diagrams, battery, charging system (alternator/stator), lighting, indicators, horn, starter motor (if applicable)
Bodywork:
Fairings, seat, fuel tank, fenders, graphics, disassembly and reassembly
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, spark plug checks, air filter cleaning
Troubleshooting:
Diagnostic charts for common problems (e.g., starting issues, poor performance, electrical faults)
Component Overhaul:
Engine rebuild, carburetor tuning, brake caliper overhaul, suspension servicing
Electrical Diagnostics:
Tracing wiring faults, testing components (stator, CDI, regulators)
Suspension Setup And Adjustment:
Fork oil levels, rear shock preload and damping adjustments
Wheel And Tire Maintenance:
Wheel balancing, tire fitting and removal
Technical Depth
Engine Rebuild Detail:
Detailed procedures for piston ring replacement, cylinder head removal/installation, crankshaft bearing replacement, and timing valve adjustment (if applicable for a 2-stroke)
Carburetor Tuning:
Jetting charts, adjustment procedures for idle speed, mixture, and float height
Diagnostic Charts:
Flowcharts and symptom-based troubleshooting guides for common issues
Torque Specifications:
Comprehensive list of torque values for all critical fasteners
Schematics And Diagrams:
Detailed wiring diagrams, exploded views of components for easy identification
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Likely searchable text for efficient information retrieval
Print Quality
Image Resolution:
High resolution for clear diagrams and illustrations
Scalability:
Scalable content for detailed viewing
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
Completeness
Coverage:
Comprehensive, designed for professional workshop use
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-Stroke, Single Cylinder, Liquid-Cooled
Displacement:
125cc (approximately 124.8 cc)
Bore X Stroke:
Typically 54 mm x 54.5 mm (subject to variation)
Compression Ratio:
Around 8.0:1 to 8.5:1 (can vary based on tuning and region)
Power Output:
Approximately 30-33 HP (15 kW limited for A1 license in some markets, but unrestricted versions existed)
Torque:
Around 2.2 - 2.5 kgf-m (16-18 lb-ft) at peak RPM
Performance
Redline:
Often around 10,500 - 11,500 RPM
Fuel System
Carburetor Type:
Dell'Orto PHBH 28 AS or similar 28mm/30mm carburetor
Fuel Type:
Unleaded Gasoline (Octane rating specified in manual, likely 95 RON or higher)
Fuel Mixture:
Premix or Autolube system (oil injection)
Oil Type:
2-stroke synthetic oil, specified by Aprilia for autolube systems
🔧 Transmission
Standard
Transmission Type:
6-Speed Sequential Manual
Clutch Type:
Wet, Multi-plate
Features
Final Drive:
Chain Drive
Gear Ratios:
Specific ratios detailed in the manual; typically optimized for sporty performance
Transmission Oil Type:
Refer to manual for specific grade (e.g., SAE 75W-90 or similar)
📐 Dimensions
Exterior
Length:
Refer to manual (typically around 2000 mm)
Width:
Refer to manual (typically around 700-750 mm)
Height:
Refer to manual (typically around 1100-1150 mm)
Weights
Dry Weight:
Approximately 130-140 kg (dry weight, refer to manual for exact figure)
Wet Weight:
Approximately 145-155 kg (with fluids)
Fuel Tank Capacity:
Approximately 12-14 Liters
🛡️ Safety Features
Ratings
Safety Standards:
Designed to meet European motorcycle safety standards of the era
Active Features
Braking System:
Dual disc brakes with performance calipers (e.g., Brembo) providing excellent stopping power
Suspension Performance:
USD forks and Monoshock rear offer stability and control during cornering and braking
Passive Features
Frame Rigidity:
Strong frame construction contributes to rider confidence and stability
Lighting:
Adequate lighting for visibility (headlight, tail light, brake lights, indicators)
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, speedometer, odometer, coolant temperature gauge, and indicator lights. No digital infotainment features.
Driver Assistance
ABS:
No Anti-lock Braking System (ABS) on this model year.
Connectivity
Bluetooth Wifi:
No Bluetooth or Wi-Fi connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual; typically every 3000-5000 km or annually for gearbox oil.
Air Filter Cleaning:
Refer to manual; typically every 5000-8000 km or as needed based on operating conditions.
Spark Plug Replacement:
Refer to manual; typically every 6000-10000 km.
Chain Lubrication Adjustment:
Frequent checks recommended, lubrication every 500-1000 km, adjustment as needed.
Brake Fluid Replacement:
Refer to manual; typically every 2 years.
Fluid Specifications
Engine Oil:
2-stroke synthetic oil specifically for autolube systems (e.g., Motul 710 2T, Castrol TTS).
Transmission Oil:
Refer to manual for specific viscosity grade (e.g., SAE 75W-90 GL-4).
Coolant:
Ethylene glycol-based antifreeze with corrosion inhibitors (e.g., 50% coolant, 50% distilled water).
Brake Fluid:
DOT 4 synthetic brake fluid.
Known Issues
2 Stroke Engine Wear:
Like all high-performance 2-strokes, the engine requires diligent maintenance, particularly piston rings and cylinder wear, especially if ridden hard or poorly maintained.
Carburetor Tuning Sensitivity:
Carburetors can be sensitive to altitude, temperature, and exhaust modifications, requiring periodic re-tuning.
Electrical Component Aging:
Older electrical components like the stator or CDI unit can degrade over time.
Suspension Seals:
Fork seals and rear shock seals can wear, leading to leaks and degraded damping.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer with a strong heritage in racing, particularly in Grand Prix motorcycle racing, known for innovative designs and performance-oriented motorcycles.
Model Evolution
Rs 125 Lineage:
The RS 125 model line has a long and successful history for Aprilia, starting with earlier iterations and evolving into the technologically advanced and stylish sportbikes known today. The 1993 model represents an early generation of this iconic 125cc sportbike.
Production
Manufacturing Location:
Italy
Production Period:
The RS 125 was produced for many years, with significant updates and revisions throughout its lifecycle. The 1993 model is part of the initial or early phase of this model's production.
🏆 Awards & Recognition
Recognitions
Motorsport Success:
Aprilia has a significant history of success in motorcycle racing, including numerous championships in the 125cc class, which influences the performance and design of their road-going models like the RS 125.
Ratings
Performance Reviews:
Contemporary reviews often praised the RS 125 for its sharp handling, high-revving engine, and aggressive styling, making it a popular choice among younger riders and aspiring racers.
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