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Aprilia RS 125 1997 Repair Service Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 1997 Type: Sportbike Codes Chassis Code Range: RP00000 and above Engine Code Prefix: RP 👋 Introduction Market Position Positioning: The Aprilia RS 125 was a highly regarded entry-level sportbike known for its sharp styling, capable chassis, and potent 2-stroke performance, often seen as a step up from more basic 125cc offerings. It competed with bikes like the Yamaha TZR125 and Honda CBR125R (though the CBR125R came later). Competitive Analysis Strengths: Lightweight, nimble handling, strong mid-range power from the 2-stroke engine, aggressive styling mimicking larger Aprilia sportbikes. Weaknesses: 2-stroke engine requires more frequent maintenance and specific oil, can be finicky if not set up correctly, potential for wear on the cylinder and piston with aggressive use. Key Features Design: Aerodynamic fairings, clip-on handlebars, rear-set footpegs, aluminum frame. Engine Type: 2-stroke single cylinder with reed valve induction and advanced exhaust port technology (often featuring an electronically controlled exhaust valve for improved power delivery across the rev range). 📋 Manual Details Coverage Areas Primary Coverage: Mechanical and electrical systems Secondary Coverage: Bodywork, chassis, suspension, brakes, diagnostics Page Count Estimated Pages: Approximately 300-400 pages (typical for this era and complexity) Manual Type Type: Repair Service Manual Purpose: Professional technicians and advanced DIY enthusiasts Language Language: English (standard for international releases) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: 2-stroke, single-cylinder, liquid-cooled engine (Rotax 122) Fuel System: Carburetion (likely Dell'Orto PHBH 28 or similar), fuel tank, fuel lines Ignition System: Electronic ignition, CDI, spark plugs, wiring Exhaust System: Expansion chamber, mufflers, exhaust valve system (ATAC or similar) Cooling System: Liquid cooling, radiator, coolant reservoir, fan, thermostat Transmission: 6-speed constant mesh, clutch operation, gearbox disassembly/assembly Frame And Suspension: Aluminum twin-spar frame, telescopic front forks (likely Marzocchi or Paioli), rear monoshock suspension (likely Sachs or Paioli), swingarm Brakes: Front disc brake (dual piston caliper), rear disc brake (single piston caliper), hydraulic system, brake fluid specifications Electrical System: Battery, alternator, starter motor, lighting (headlight, taillight, indicators), horn, wiring diagrams, fuses Bodywork And Fairings: Fairing removal/installation, seat, fuel tank cover, fenders Wheels And Tires: Wheel removal/installation, tire pressure specifications, common tire sizes Procedures Included Maintenance: Scheduled maintenance checks, oil changes, filter replacements, chain adjustment, spark plug replacement, coolant checks, brake fluid checks Troubleshooting: Diagnostic procedures for common starting, running, and electrical issues Repair: Engine rebuild procedures, transmission overhaul, suspension component replacement, brake system repair, electrical component diagnosis and repair Technical Data And Specs: Torque specifications, clearances, fluid capacities, electrical specifications Technical Depth Depth: Comprehensive, covering everything from basic adjustments to complete engine and transmission rebuilds, including electrical system diagnostics and wiring diagrams. 📊 Manual Specifications File Format Format: PDF Searchable: Typically yes, depending on the source scan quality. Print Quality Quality: Digital reproduction, variable depending on original scan quality. Generally clear enough for detailed examination of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Completeness Scope: Full factory service manual content ⚙️ Engine Specifications Primary Engine Engine Type: Rotax 122, 2-stroke, single-cylinder, liquid-cooled, reed-valve induction Bore X Stroke: 54 mm x 54.5 mm Displacement: 125 cc Compression Ratio: Approx. 12.5:1 (varies slightly by model year/tune) Exhaust Valve System: Rotax Electronic Exhaust Valve (EEV) or similar system for optimized power band. Performance Horsepower: Approx. 30-34 HP at 11,000 RPM (claimed at crank, actual may vary) Torque: Approx. 1.9 kgf-m (13.7 lb-ft) at 10,000 RPM (claimed) Fuel System Carburetor: Dell'Orto PHBH 28 AS or PHBH 28 BD (often with specific jetting for the RS 125) Fuel Type: Unleaded gasoline (minimum 95 RON recommended) 2-Stroke Oil Mixture: Automatic oil injection system, requires specific 2-stroke engine oil (e.g., Castrol TTS or equivalent fully synthetic). 🔧 Transmission Standard Gearbox: 6-speed constant mesh Features Clutch: Wet, multi-plate, cable-actuated Final Drive: Chain drive Gear Ratios: Specific ratios are detailed within the manual for each gear. Transmission Oil Spec: Typically SAE 80W/90 gear oil (check manual for exact specification and quantity). 📐 Dimensions Exterior Overall Length: Approx. 1950 mm (varies slightly by fairing design) Overall Width: Approx. 720 mm (at handlebars) Overall Height: Approx. 1050 mm (at seat) Weights Dry Weight: Approx. 131 kg Wet Weight: Approx. 149 kg (fully fueled and ready to ride) Fuel Tank Capacity: Approx. 14 liters (including reserve) Seat Height: Approx. 810 mm Wheelbase: Approx. 1350 mm 🛡️ Safety Features Ratings Safety Standards: Conforms to relevant European motorcycle safety standards of the era. Active Features Brakes: Powerful dual disc front brake, single disc rear brake with braided stainless steel lines for improved feel and performance. Suspension: High-quality adjustable front forks and rear monoshock contribute to stable handling and rider control. Passive Features Lighting: Adequate halogen headlight, taillight, and turn signals for visibility. Frame Construction: Rigid twin-spar aluminum frame provides excellent chassis stability. 💡 Technology Features Infotainment Dashboard: Analog speedometer and tachometer, odometer,...
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Aprilia RS 125 1997 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Year:
1997
Type:
Sportbike
Codes
Chassis Code Range:
RP00000 and above
Engine Code Prefix:
RP
👋 Introduction
Market Position
Positioning:
The Aprilia RS 125 was a highly regarded entry-level sportbike known for its sharp styling, capable chassis, and potent 2-stroke performance, often seen as a step up from more basic 125cc offerings. It competed with bikes like the Yamaha TZR125 and Honda CBR125R (though the CBR125R came later).
Competitive Analysis
Strengths:
Lightweight, nimble handling, strong mid-range power from the 2-stroke engine, aggressive styling mimicking larger Aprilia sportbikes.
Weaknesses:
2-stroke engine requires more frequent maintenance and specific oil, can be finicky if not set up correctly, potential for wear on the cylinder and piston with aggressive use.
Key Features
Design:
Aerodynamic fairings, clip-on handlebars, rear-set footpegs, aluminum frame.
Engine Type:
2-stroke single cylinder with reed valve induction and advanced exhaust port technology (often featuring an electronically controlled exhaust valve for improved power delivery across the rev range).
📋 Manual Details
Coverage Areas
Primary Coverage:
Mechanical and electrical systems
Secondary Coverage:
Bodywork, chassis, suspension, brakes, diagnostics
Page Count
Estimated Pages:
Approximately 300-400 pages (typical for this era and complexity)
Manual Type
Type:
Repair Service Manual
Purpose:
Professional technicians and advanced DIY enthusiasts
Language
Language:
English (standard for international releases)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
2-stroke, single-cylinder, liquid-cooled engine (Rotax 122)
Fuel System:
Carburetion (likely Dell'Orto PHBH 28 or similar), fuel tank, fuel lines
Ignition System:
Electronic ignition, CDI, spark plugs, wiring
Exhaust System:
Expansion chamber, mufflers, exhaust valve system (ATAC or similar)
Cooling System:
Liquid cooling, radiator, coolant reservoir, fan, thermostat
Transmission:
6-speed constant mesh, clutch operation, gearbox disassembly/assembly
Frame And Suspension:
Aluminum twin-spar frame, telescopic front forks (likely Marzocchi or Paioli), rear monoshock suspension (likely Sachs or Paioli), swingarm
Brakes:
Front disc brake (dual piston caliper), rear disc brake (single piston caliper), hydraulic system, brake fluid specifications
Electrical System:
Battery, alternator, starter motor, lighting (headlight, taillight, indicators), horn, wiring diagrams, fuses
Bodywork And Fairings:
Fairing removal/installation, seat, fuel tank cover, fenders
Wheels And Tires:
Wheel removal/installation, tire pressure specifications, common tire sizes
Procedures Included
Maintenance:
Scheduled maintenance checks, oil changes, filter replacements, chain adjustment, spark plug replacement, coolant checks, brake fluid checks
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues
Repair:
Engine rebuild procedures, transmission overhaul, suspension component replacement, brake system repair, electrical component diagnosis and repair
Technical Data And Specs:
Torque specifications, clearances, fluid capacities, electrical specifications
Technical Depth
Depth:
Comprehensive, covering everything from basic adjustments to complete engine and transmission rebuilds, including electrical system diagnostics and wiring diagrams.
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Typically yes, depending on the source scan quality.
Print Quality
Quality:
Digital reproduction, variable depending on original scan quality. Generally clear enough for detailed examination of diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Completeness
Scope:
Full factory service manual content
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotax 122, 2-stroke, single-cylinder, liquid-cooled, reed-valve induction
Bore X Stroke:
54 mm x 54.5 mm
Displacement:
125 cc
Compression Ratio:
Approx. 12.5:1 (varies slightly by model year/tune)
Exhaust Valve System:
Rotax Electronic Exhaust Valve (EEV) or similar system for optimized power band.
Performance
Horsepower:
Approx. 30-34 HP at 11,000 RPM (claimed at crank, actual may vary)
Torque:
Approx. 1.9 kgf-m (13.7 lb-ft) at 10,000 RPM (claimed)
Fuel System
Carburetor:
Dell'Orto PHBH 28 AS or PHBH 28 BD (often with specific jetting for the RS 125)
Fuel Type:
Unleaded gasoline (minimum 95 RON recommended)
2-Stroke Oil Mixture:
Automatic oil injection system, requires specific 2-stroke engine oil (e.g., Castrol TTS or equivalent fully synthetic).
🔧 Transmission
Standard
Gearbox:
6-speed constant mesh
Features
Clutch:
Wet, multi-plate, cable-actuated
Final Drive:
Chain drive
Gear Ratios:
Specific ratios are detailed within the manual for each gear.
Transmission Oil Spec:
Typically SAE 80W/90 gear oil (check manual for exact specification and quantity).
📐 Dimensions
Exterior
Overall Length:
Approx. 1950 mm (varies slightly by fairing design)
Overall Width:
Approx. 720 mm (at handlebars)
Overall Height:
Approx. 1050 mm (at seat)
Weights
Dry Weight:
Approx. 131 kg
Wet Weight:
Approx. 149 kg (fully fueled and ready to ride)
Fuel Tank Capacity:
Approx. 14 liters (including reserve)
Seat Height:
Approx. 810 mm
Wheelbase:
Approx. 1350 mm
🛡️ Safety Features
Ratings
Safety Standards:
Conforms to relevant European motorcycle safety standards of the era.
Active Features
Brakes:
Powerful dual disc front brake, single disc rear brake with braided stainless steel lines for improved feel and performance.
Suspension:
High-quality adjustable front forks and rear monoshock contribute to stable handling and rider control.
Passive Features
Lighting:
Adequate halogen headlight, taillight, and turn signals for visibility.
Frame Construction:
Rigid twin-spar aluminum frame provides excellent chassis stability.
💡 Technology Features
Infotainment
Dashboard:
Analog speedometer and tachometer, odometer, trip meter, coolant temperature warning light, neutral indicator, high beam indicator, turn signal indicators.
Driver Assistance
Rider Aids:
No electronic rider aids (e.g., ABS, traction control) present on this model.
🔧 Maintenance
Service Intervals
Oil Change Engine:
2-stroke engine requires 2-stroke oil injection; check oil reservoir level regularly. Engine oil changes are not applicable in the traditional sense, but internal component wear is the primary concern.
Spark Plug Replacement:
Every 5,000-7,000 km or as per manual recommendation (specific plug type required).
Air Filter Cleaning:
Every 3,000-5,000 km, or more frequently in dusty conditions.
Coolant Flush:
Every 2 years or 20,000 km.
Chain Adjustment:
Check and adjust every 1,000 km or as needed.
Brake Fluid Change:
Every 2 years.
Fluid Specifications
Engine Oil:
Fully synthetic 2-stroke motorcycle oil with JASO FD or ISO-L-EGD rating.
Cooling System:
Mixture of distilled water and ethylene glycol-based antifreeze (50/50 ratio typically recommended).
Brake Fluid:
DOT 4
Transmission Oil:
SAE 80W/90 gear oil
Known Issues
Exhaust Valve Stiffness:
The electronically controlled exhaust valve can become stiff or seize due to carbon build-up, affecting performance. Regular cleaning is essential.
Carburetor Tuning:
Can be sensitive to altitude, temperature, and modifications. Proper jetting is critical for optimal performance and reliability.
Cylinder Wear:
Aggressive riding can lead to accelerated wear on the cylinder and piston, potentially requiring re-boring and piston replacement.
Electrical Connections:
Older models may suffer from corroded electrical connectors or failing rectifier/regulator units, leading to charging issues.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia has a rich racing heritage, particularly in the 125cc and 250cc classes, which heavily influenced the design and engineering of the RS 125. This lineage provided a sporty DNA.
Model Evolution
Evolution:
The RS 125 was part of a lineage of Aprilia sportbikes that evolved significantly over the years. Early models had different engine configurations and styling, with the 1997 model representing a mature iteration of the Rotax 122-powered sportbike.
Production
Production Period:
The RS 125 platform, powered by the Rotax 122 engine, was produced for many years, with significant updates occurring throughout the 1990s and early 2000s. The 1997 model is a key variant within this production run.
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Historical Reputation:
The Aprilia RS 125 (across its various iterations) is widely recognized as one of the most exciting and capable 125cc sportbikes of its era, often winning 'bike of the year' awards in enthusiast publications for its class-leading performance and handling.
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