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Aprilia RS125 Years 1999-2006-Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Model Variants: RS125 (Rotax 122 Engine Variants) Common Model Codes: AP8114324 (Engine), AP8106157 (Chassis) 👋 Introduction Market Position Target Audience: DIY enthusiasts and professional mechanics Purpose: To provide comprehensive guidance for maintaining, diagnosing, and repairing the Aprilia RS 125 Competitive Analysis Advantage: Electronic format allows for easy printing of specific sections, avoiding damage to the original document Value Proposition: Instant download provides immediate access to repair information, saving time and shipping costs Key Features Organization: Numbered table of contents for quick information retrieval Clarity: Bold figure numbers for easy matching of illustrations with instructions Safety Emphasis: Notes, cautions, and warnings highlight critical information 📋 Manual Details Coverage Areas Coverage Years: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Specific Models Covered: Aprilia RS 125 (all variants within the specified years) Page Count Estimated Page Count: Hundreds (Exact number not specified, but described as 'most complete') Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine assembly, disassembly, rebuilding, diagnostics Fuel System: Carburetor tuning, fuel pump, fuel lines, fuel tank maintenance Cooling System: Radiator, hoses, thermostat, coolant specifications Exhaust System: Exhaust pipe, muffler, expansion chamber maintenance Ignition System: CDI unit, spark plug, ignition coil, timing Transmission: Gearbox, clutch assembly, shift mechanism, lubrication Drivetrain: Chain and sprockets, rear wheel hub, maintenance Frame And Suspension: Frame inspection, front forks (upside-down telescopic), rear shock absorber, swingarm Brakes: Front and rear brake systems (disc brakes), hydraulic system, caliper maintenance, fluid replacement Wheels And Tires: Wheel bearings, tire pressure, tire replacement, wheel balancing Electrical System: Battery, charging system, lighting, starter motor, instrumentation, wiring diagrams Bodywork: Fairings, seat, fuel tank, fenders, mounting hardware Controls: Handlebars, levers, pedals, cable adjustments Procedures Included Maintenance: Oil changes, filter replacements, chain lubrication, spark plug checks, brake fluid flush Troubleshooting: Diagnostic procedures for common and uncommon issues across all systems Repair: Detailed step-by-step repair instructions for all major and minor components Overhaul: Engine overhaul, gearbox rebuild, suspension fork rebuild Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams and test procedures Specification Updates: Information on any factory updates or service bulletins relevant to the covered years Technical Depth Depth: Comprehensive from basic maintenance to complete engine rebuilds and advanced electrical diagnostics Detail Level: Detailed substeps, notes, cautions, warnings, numbered instructions Illustrations: Hundreds of detailed illustrations, drawings, and photos Diagnostic Tools: Procedures for using common diagnostic tools and measurements 📊 Manual Specifications File Format Format: PDF Searchable: Likely searchable text within PDF (standard for professional manuals) Print Quality Printability: Printable without restriction Resolution: High resolution, suitable for printing detailed diagrams Binding Type Binding: Digital (PDF) - No physical binding Paper Type Paper Type: N/A (Digital format) Requirements Software Requirements: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, single-cylinder Engine Code: Rotax 122 Displacement: 124.8 cc (7.6 cu in) Bore X Stroke: 54 mm x 54.5 mm (2.13 x 2.15 in) Compression Ratio: Approx. 12.0:1 Performance Horsepower Peak: Approx. 30-34 hp (depending on specific market/variant and emissions regulations) Torque Peak: Approx. 20-22 Nm (depending on specific market/variant) Fuel System Carburetor: Dell'Orto PHBH 28 (common fitment, variations may exist) Fuel Type: Unleaded gasoline (min 95 RON recommended) Oil Mixing: Automatic oil injection system (separate oil tank) Cooling System Cooling Method: Liquid-cooled Engine Component Details Cylinder Material: Aluminum alloy with cast-iron liner Reed Valve System: Petal reed valve intake 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch Type: Wet, multi-plate Gear Ratio Coverage: Manual will provide specific gear ratios for all 6 gears 📐 Dimensions Exterior Length: Approx. 1945 mm (76.6 in) Width: Approx. 700 mm (27.6 in) Height: Approx. 1145 mm (45.1 in) Weights Dry Weight: Approx. 130 kg (286.6 lbs) Fuel Capacity: Approx. 14.2 liters (3.75 US gal) Wheelbase Wheelbase: Approx. 1360 mm (53.5 in) 🛡️ Safety Features Ratings Safety Certification: CE approved (for European markets) Active Features Braking System: Dual-disc front brake, single-disc rear brake Lighting: Halogen headlight, LED tail light Passive Features Frame Construction: Aluminum alloy perimeter frame 💡 Technology Features Infotainment Instrumentation: Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature warning light, neutral indicator. Driver Assistance Safety Systems: Primarily mechanical safety systems; no electronic rider aids typical of modern motorcycles. 🔧 Maintenance Service Intervals Oil Change: Every 3,000 - 5,000 km (Manual will specify precise interval and oil type) Spark Plug Check: Every 3,000 - 5,000 km (Manual will specify plug type and gap) Chain Maintenance: Regular cleaning, lubrication, and tension adjustment (refer to manual for frequency) Fluid Specifications Engine Oil: 2-stroke engine oil, JASO FD or API TC certified (Manual will specify precise grade and viscosity) Coolant: Ethylene glycol-based antifreeze mixture (Manual will specify ratio and type) Brake Fluid: DOT 4 or DOT 5.1 (Manual will specify) Transmission Oil:...
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Aprilia RS125 Years 1999-2006-Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Model Variants:
RS125 (Rotax 122 Engine Variants)
Common Model Codes:
AP8114324 (Engine), AP8106157 (Chassis)
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts and professional mechanics
Purpose:
To provide comprehensive guidance for maintaining, diagnosing, and repairing the Aprilia RS 125
Competitive Analysis
Advantage:
Electronic format allows for easy printing of specific sections, avoiding damage to the original document
Value Proposition:
Instant download provides immediate access to repair information, saving time and shipping costs
Key Features
Organization:
Numbered table of contents for quick information retrieval
Clarity:
Bold figure numbers for easy matching of illustrations with instructions
Safety Emphasis:
Notes, cautions, and warnings highlight critical information
📋 Manual Details
Coverage Areas
Coverage Years:
1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Specific Models Covered:
Aprilia RS 125 (all variants within the specified years)
Page Count
Estimated Page Count:
Hundreds (Exact number not specified, but described as 'most complete')
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine assembly, disassembly, rebuilding, diagnostics
Fuel System:
Carburetor tuning, fuel pump, fuel lines, fuel tank maintenance
Cooling System:
Radiator, hoses, thermostat, coolant specifications
Exhaust System:
Exhaust pipe, muffler, expansion chamber maintenance
Ignition System:
CDI unit, spark plug, ignition coil, timing
Transmission:
Gearbox, clutch assembly, shift mechanism, lubrication
Drivetrain:
Chain and sprockets, rear wheel hub, maintenance
Frame And Suspension:
Frame inspection, front forks (upside-down telescopic), rear shock absorber, swingarm
Brakes:
Front and rear brake systems (disc brakes), hydraulic system, caliper maintenance, fluid replacement
Wheels And Tires:
Wheel bearings, tire pressure, tire replacement, wheel balancing
Electrical System:
Battery, charging system, lighting, starter motor, instrumentation, wiring diagrams
Bodywork:
Fairings, seat, fuel tank, fenders, mounting hardware
Controls:
Handlebars, levers, pedals, cable adjustments
Procedures Included
Maintenance:
Oil changes, filter replacements, chain lubrication, spark plug checks, brake fluid flush
Troubleshooting:
Diagnostic procedures for common and uncommon issues across all systems
Repair:
Detailed step-by-step repair instructions for all major and minor components
Overhaul:
Engine overhaul, gearbox rebuild, suspension fork rebuild
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams and test procedures
Specification Updates:
Information on any factory updates or service bulletins relevant to the covered years
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine rebuilds and advanced electrical diagnostics
Detail Level:
Detailed substeps, notes, cautions, warnings, numbered instructions
Illustrations:
Hundreds of detailed illustrations, drawings, and photos
Diagnostic Tools:
Procedures for using common diagnostic tools and measurements
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Likely searchable text within PDF (standard for professional manuals)
Print Quality
Printability:
Printable without restriction
Resolution:
High resolution, suitable for printing detailed diagrams
Binding Type
Binding:
Digital (PDF) - No physical binding
Paper Type
Paper Type:
N/A (Digital format)
Requirements
Software Requirements:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, single-cylinder
Engine Code:
Rotax 122
Displacement:
124.8 cc (7.6 cu in)
Bore X Stroke:
54 mm x 54.5 mm (2.13 x 2.15 in)
Compression Ratio:
Approx. 12.0:1
Performance
Horsepower Peak:
Approx. 30-34 hp (depending on specific market/variant and emissions regulations)
Torque Peak:
Approx. 20-22 Nm (depending on specific market/variant)
Fuel System
Carburetor:
Dell'Orto PHBH 28 (common fitment, variations may exist)
Fuel Type:
Unleaded gasoline (min 95 RON recommended)
Oil Mixing:
Automatic oil injection system (separate oil tank)
Cooling System
Cooling Method:
Liquid-cooled
Engine Component Details
Cylinder Material:
Aluminum alloy with cast-iron liner
Reed Valve System:
Petal reed valve intake
🔧 Transmission
Standard
Type:
6-speed constant mesh
Features
Clutch Type:
Wet, multi-plate
Gear Ratio Coverage:
Manual will provide specific gear ratios for all 6 gears
📐 Dimensions
Exterior
Length:
Approx. 1945 mm (76.6 in)
Width:
Approx. 700 mm (27.6 in)
Height:
Approx. 1145 mm (45.1 in)
Weights
Dry Weight:
Approx. 130 kg (286.6 lbs)
Fuel Capacity:
Approx. 14.2 liters (3.75 US gal)
Wheelbase
Wheelbase:
Approx. 1360 mm (53.5 in)
🛡️ Safety Features
Ratings
Safety Certification:
CE approved (for European markets)
Active Features
Braking System:
Dual-disc front brake, single-disc rear brake
Lighting:
Halogen headlight, LED tail light
Passive Features
Frame Construction:
Aluminum alloy perimeter frame
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature warning light, neutral indicator.
Driver Assistance
Safety Systems:
Primarily mechanical safety systems; no electronic rider aids typical of modern motorcycles.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 - 5,000 km (Manual will specify precise interval and oil type)
Spark Plug Check:
Every 3,000 - 5,000 km (Manual will specify plug type and gap)
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment (refer to manual for frequency)
Fluid Specifications
Engine Oil:
2-stroke engine oil, JASO FD or API TC certified (Manual will specify precise grade and viscosity)
Coolant:
Ethylene glycol-based antifreeze mixture (Manual will specify ratio and type)
Brake Fluid:
DOT 4 or DOT 5.1 (Manual will specify)
Transmission Oil:
Specific gear oil (Manual will specify type, viscosity, and capacity)
Known Issues
Common Wear Items:
Clutch plates, piston rings, exhaust gaskets, chain and sprockets due to performance nature
Potential Problems:
Carburetor jetting sensitivity, exhaust valve operation (power valve), radiator performance under stress
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian motorcycle manufacturer known for its performance-oriented sportbikes.
Model Evolution
Rs 125 Lineage:
The RS 125 has a long-standing history as a popular entry-level sportbike, often favored for its aggressive styling and handling, mimicking larger sportbikes.
Key Updates Within Years:
Minor cosmetic and technical updates occurred across these model years, which this manual will address.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Sportbike Segment:
Consistently praised for its handling and racing pedigree in the 125cc sportbike class.
Ratings
User Reviews:
Highly regarded by owners for its performance potential and sharp aesthetics, often considered a 'baby superbike'.
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