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Aprilia RS 125 1998 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 1998 Product Type: Full Service Repair Manual Generation Model Generation: First Generation (Rotax 122) 👋 Introduction Market Position Market Segment: High-performance 125cc sportbike, popular in European markets for its racing heritage and track-day capability. Competitive Analysis Key Competitors: Yamaha YZF-R 125, Honda CBR125R, Suzuki GSX-R125, Cagiva Mito 125. Key Features Vehicle Design Philosophy: Race-inspired styling, aggressive ergonomics, lightweight chassis, and a potent two-stroke engine for its class. Key Features Manual Manual Value Proposition: Provides the necessary technical knowledge to maintain and repair the RS 125, enabling owners to keep their iconic Italian sportbike in peak condition. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive repair, maintenance, and overhaul of the Aprilia RS 125 (1998 model year). Page Count Estimated Page Count: Refer to product packaging for exact count; typically 300-500 pages for full service manuals of this era. Manual Type Manual Type: Service Manual / Repair Manual Language Language: Likely English (standard for major repair manuals, but confirmation recommended). Format Format: Digital (PDF) or Printed Copy (depending on vendor). 📖 Manual Coverage Systems Covered Engine System: Complete engine disassembly, assembly, inspection, and repair. Includes top-end (cylinder, piston, head), bottom-end (crankshaft, connecting rod, bearings), cooling system, lubrication system. Fuel System: Carburetor tuning, jetting, float adjustment, fuel pump, fuel lines, and fuel tank maintenance. Ignition System: CDI unit, spark plug, ignition coil testing, timing checks. Exhaust System: Pipe maintenance, expansion chamber principles, exhaust valve operation and adjustment. Transmission System: Gearbox disassembly, assembly, gear inspection, clutch operation, chain and sprocket maintenance. Cooling System: Radiator, coolant, water pump, thermostat inspection and service. Electrical System: Wiring diagrams, battery maintenance, charging system (alternator, regulator), lighting system, starter system, switchgear. Braking System: Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, brake fluid bleeding, rotor inspection. Suspension System: Front fork disassembly, seal replacement, oil level and type specification, rear shock absorber service, linkage lubrication. Steering System: Headset bearing inspection and adjustment, steering lock operation. Chassis Frame: Frame inspection, swingarm bearings, wheel bearing service. Bodywork Trim: Fairing removal and installation, seat, fuel tank, and other body panel service. Procedures Included Preventative Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, chain lubrication and adjustment, brake fluid checks. Troubleshooting: Diagnostic procedures for common running issues, electrical faults, and mechanical problems. Component Overhaul: Detailed step-by-step instructions for rebuilding key components like the engine, gearbox, and suspension. Adjustments: Carburetor synchronization, clutch cable adjustment, throttle cable adjustment, suspension sag adjustment. Wiring Diagrams: Full electrical schematics for troubleshooting and repairs. Torque Specifications: Critical torque values for engine fasteners, chassis bolts, and suspension components. Technical Depth Depth Level: In-depth technical repair and overhaul procedures suitable for experienced DIY mechanics and professional technicians. Diagnostic Capability: Covers troubleshooting for performance issues, starting problems, and component failures. Rebuild Scope: Enables complete engine, gearbox, and major component rebuilds. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format), typically with searchable text for easy navigation. Print Quality Print Quality Digital: High-resolution scans or professionally produced digital documents with clear diagrams and legible text. Binding Type Binding Type Physical: If printed: Comb-bound, perfect-bound, or spiral-bound for lay-flat usability. Paper Type Paper Type Physical: If printed: Durable, possibly laminated or coated paper to withstand workshop environments. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder. Engine Code: Rotax 122 (common for this generation). Displacement: 125 cc (124.8 cc). Bore X Stroke: 54 mm x 54.5 mm. Compression Ratio: Approximately 12.0:1 (subject to specific tune). Power Delivery: Designed for peak power delivery in the mid-to-high RPM range characteristic of performance two-strokes. Performance Horsepower Estimate: Around 30-34 HP (subject to regional restrictions and specific tuning). Officially, often quoted lower for licensing purposes. Torque Estimate: Approximately 20-22 Nm. Fuel System Carburetor Type: Dell'Orto PHBH 28 (or similar performance carb). Fuel Type: Unleaded gasoline (min 95 octane recommended). Fuel Delivery: Gravity feed with a fuel pump (diaphragm type). Lubrication Oil Mixture: Premix or separate oil injection system (automatic). Oil Type Injection: High-quality two-stroke synthetic oil specifically for racing or high-performance applications. 🔧 Transmission Standard Transmission Type: 6-speed manual sequential gearbox. Clutch Type: Wet multi-plate clutch. Features Gear Ratios: Specific gear ratios will be detailed in the manual, crucial for performance tuning. Final Drive: Chain drive (typically 520 pitch). Transmission Fluid: Gearbox oil (e.g., SAE 75W/90 or specific Aprilia recommendation). 📐 Dimensions Exterior Length: Refer to official specifications; typically around 1950 mm. Width: Refer to official specifications; typically around 720 mm. Height: Refer to official specifications; typically around 1050 mm. Wheelbase: Refer to official specifications; typically around 1370 mm. Weights Dry Weight: Approximately 135 kg (subject to variations). Fuel Capacity: Approx. 14 liters (including reserve). 🛡️ Safety Features Ratings Safety Standards: Designed to meet European safety standards for motorcycles of its class and era. Active Features Braking System Type: Disc brakes...
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Aprilia RS 125 1998 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Year:
1998
Product Type:
Full Service Repair Manual
Generation
Model Generation:
First Generation (Rotax 122)
👋 Introduction
Market Position
Market Segment:
High-performance 125cc sportbike, popular in European markets for its racing heritage and track-day capability.
Competitive Analysis
Key Competitors:
Yamaha YZF-R 125, Honda CBR125R, Suzuki GSX-R125, Cagiva Mito 125.
Key Features Vehicle
Design Philosophy:
Race-inspired styling, aggressive ergonomics, lightweight chassis, and a potent two-stroke engine for its class.
Key Features Manual
Manual Value Proposition:
Provides the necessary technical knowledge to maintain and repair the RS 125, enabling owners to keep their iconic Italian sportbike in peak condition.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive repair, maintenance, and overhaul of the Aprilia RS 125 (1998 model year).
Page Count
Estimated Page Count:
Refer to product packaging for exact count; typically 300-500 pages for full service manuals of this era.
Manual Type
Manual Type:
Service Manual / Repair Manual
Language
Language:
Likely English (standard for major repair manuals, but confirmation recommended).
Format
Format:
Digital (PDF) or Printed Copy (depending on vendor).
📖 Manual Coverage
Systems Covered
Engine System:
Complete engine disassembly, assembly, inspection, and repair. Includes top-end (cylinder, piston, head), bottom-end (crankshaft, connecting rod, bearings), cooling system, lubrication system.
Fuel System:
Carburetor tuning, jetting, float adjustment, fuel pump, fuel lines, and fuel tank maintenance.
Ignition System:
CDI unit, spark plug, ignition coil testing, timing checks.
Exhaust System:
Pipe maintenance, expansion chamber principles, exhaust valve operation and adjustment.
Transmission System:
Gearbox disassembly, assembly, gear inspection, clutch operation, chain and sprocket maintenance.
Cooling System:
Radiator, coolant, water pump, thermostat inspection and service.
Electrical System:
Wiring diagrams, battery maintenance, charging system (alternator, regulator), lighting system, starter system, switchgear.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, brake fluid bleeding, rotor inspection.
Suspension System:
Front fork disassembly, seal replacement, oil level and type specification, rear shock absorber service, linkage lubrication.
Steering System:
Headset bearing inspection and adjustment, steering lock operation.
Chassis Frame:
Frame inspection, swingarm bearings, wheel bearing service.
Bodywork Trim:
Fairing removal and installation, seat, fuel tank, and other body panel service.
Procedures Included
Preventative Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, chain lubrication and adjustment, brake fluid checks.
Troubleshooting:
Diagnostic procedures for common running issues, electrical faults, and mechanical problems.
Component Overhaul:
Detailed step-by-step instructions for rebuilding key components like the engine, gearbox, and suspension.
Adjustments:
Carburetor synchronization, clutch cable adjustment, throttle cable adjustment, suspension sag adjustment.
Wiring Diagrams:
Full electrical schematics for troubleshooting and repairs.
Torque Specifications:
Critical torque values for engine fasteners, chassis bolts, and suspension components.
Technical Depth
Depth Level:
In-depth technical repair and overhaul procedures suitable for experienced DIY mechanics and professional technicians.
Diagnostic Capability:
Covers troubleshooting for performance issues, starting problems, and component failures.
Rebuild Scope:
Enables complete engine, gearbox, and major component rebuilds.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format), typically with searchable text for easy navigation.
Print Quality
Print Quality Digital:
High-resolution scans or professionally produced digital documents with clear diagrams and legible text.
Binding Type
Binding Type Physical:
If printed: Comb-bound, perfect-bound, or spiral-bound for lay-flat usability.
Paper Type
Paper Type Physical:
If printed: Durable, possibly laminated or coated paper to withstand workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, two-stroke, single-cylinder.
Engine Code:
Rotax 122 (common for this generation).
Displacement:
125 cc (124.8 cc).
Bore X Stroke:
54 mm x 54.5 mm.
Compression Ratio:
Approximately 12.0:1 (subject to specific tune).
Power Delivery:
Designed for peak power delivery in the mid-to-high RPM range characteristic of performance two-strokes.
Performance
Horsepower Estimate:
Around 30-34 HP (subject to regional restrictions and specific tuning). Officially, often quoted lower for licensing purposes.
Torque Estimate:
Approximately 20-22 Nm.
Fuel System
Carburetor Type:
Dell'Orto PHBH 28 (or similar performance carb).
Fuel Type:
Unleaded gasoline (min 95 octane recommended).
Fuel Delivery:
Gravity feed with a fuel pump (diaphragm type).
Lubrication
Oil Mixture:
Premix or separate oil injection system (automatic).
Oil Type Injection:
High-quality two-stroke synthetic oil specifically for racing or high-performance applications.
🔧 Transmission
Standard
Transmission Type:
6-speed manual sequential gearbox.
Clutch Type:
Wet multi-plate clutch.
Features
Gear Ratios:
Specific gear ratios will be detailed in the manual, crucial for performance tuning.
Final Drive:
Chain drive (typically 520 pitch).
Transmission Fluid:
Gearbox oil (e.g., SAE 75W/90 or specific Aprilia recommendation).
📐 Dimensions
Exterior
Length:
Refer to official specifications; typically around 1950 mm.
Width:
Refer to official specifications; typically around 720 mm.
Height:
Refer to official specifications; typically around 1050 mm.
Wheelbase:
Refer to official specifications; typically around 1370 mm.
Weights
Dry Weight:
Approximately 135 kg (subject to variations).
Fuel Capacity:
Approx. 14 liters (including reserve).
🛡️ Safety Features
Ratings
Safety Standards:
Designed to meet European safety standards for motorcycles of its class and era.
Active Features
Braking System Type:
Disc brakes front and rear. Dual piston caliper front, single piston caliper rear.
Tire Size Front:
110/70-17
Tire Size Rear:
150/60-17
Passive Features
Lighting:
Halogen headlight, LED tail light.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, speedometer, odometer, trip meter, temperature gauge, warning lights. Basic but functional for its era.
Driver Assistance
ABS:
Not typically equipped on this model year.
Connectivity
Smartphone Integration:
N/A (pre-smartphone era).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual; typically every 3,000-5,000 km or annually.
Spark Plug Replacement:
Refer to manual; often around 5,000-10,000 km depending on plug type.
Air Filter Cleaning:
Refer to manual; typically every 3,000-6,000 km or as needed in dusty conditions.
Chain Maintenance:
Lubrication and adjustment every 500-1,000 km, inspection more frequently.
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze mixture (50/50 with distilled water).
Brake Fluid Type:
DOT 4.
Fork Oil Type:
Specific viscosity grade as per manual (e.g., SAE 10W or 15W).
Known Issues
Common Wear Items:
Piston rings, spark plugs, clutch plates, exhaust valve (carbon buildup), wheel bearings, head bearings.
Two Stroke Specifics:
Requires diligent attention to fuel/oil mixture, proper warm-up/cool-down, and periodic decarbonization of the exhaust port and power valve.
Electrical Reliability:
Older models may have aging wiring harnesses or rectifier/regulator issues; manual provides diagnostic steps.
📚 Vehicle History
Brand Heritage
Brand Focus:
Aprilia has a strong heritage in motorcycle racing, particularly in the Grand Prix 125cc class, which influenced the RS 125's design.
Model Evolution
Rs 125 Lineage:
The RS 125 lineage is an enduring model for Aprilia, known for its consistent performance and track-oriented design updates through various generations.
Production
Manufacturing Location:
Italy.
Production Period:
The RS 125 was produced for many years, with the first generation starting in the early 1990s and continuing through various updates.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The RS 125 is generally praised for its performance and handling, often considered one of the best 125cc sportbikes of its generation.
Ratings
Motorcycle Journal Reviews:
Often received high marks in contemporary reviews for its GP-inspired features and exhilarating performance.
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