🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 1993-2002 👋 Introduction Market Position Target Audience: Enthusiast owners, independent repair shops, and DIY mechanics looking for in-depth technical guidance. Competitive Analysis Value Proposition: Provides factory-level repair information, saving owners significant costs compared to dealership service. Key Features Original Documentation: Factory-derived content ensures accuracy and completeness, mirroring official Aprilia workshop manuals. Rebuild Guidance: Essential for comprehensive engine and transmission rebuilds, a common task for this model. 📋 Manual Details Coverage Areas Manual Type: Service Repair Manual Language: English Format: Downloadable Digital File (likely PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, tuning, lubrication, cooling, and fuel systems. Transmission: Clutch, gearbox, shifting mechanism, lubrication, and troubleshooting. Chassis: Frame, suspension (front forks, rear shock), steering system, wheels, and bearings. Brakes: Front and rear braking systems, hydraulic lines, caliper maintenance, pad replacement, and bleeding procedures. Electrical System: Ignition system, lighting, battery, charging system, starter motor, wiring diagrams, and component testing. Bodywork: Fairings, body panels, seat, fuel tank, and related fasteners. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, spark plug checks, coolant levels, and general inspections. Troubleshooting: Diagnostic procedures for common problems, fault finding guides, and symptom analysis. Repair And Rebuild: Detailed step-by-step instructions for major component repairs and full engine/gearbox rebuilds. Technical Specifications: Torque values, clearances, fluid capacities, and component measurements. Technical Depth Depth Of Coverage: Comprehensive Factory Repair Manual, covering everything from basic maintenance to complete restoration and engine rebuilding. 📊 Manual Specifications File Format File Type: Digital Download (Likely PDF) Searchability: Likely text-searchable PDF for efficient information retrieval. Print Capability: Printable for workshop use. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder Displacement: Approx. 125cc (specific bore/stroke may vary slightly by year/sub-model) Bore X Stroke: Typically around 54mm x 54.5mm Power Output: Varied, but generally in the 28-33 hp range depending on market and specific tuning. Restricted versions existed for younger riders. Torque Output: Specific torque figures will be detailed in the manual, crucial for engine tuning and assembly. Fuel System Carburetor: Typically Dell'Orto PHBH or similar performance-oriented carburetor (e.g., 28-30mm). Reed Valve System: Performance reed block and cage design is a key component for two-stroke efficiency. Exhaust System: Expansion chamber exhaust is critical for two-stroke power delivery and tuning. Ignition System Ignition Type: Digital CDI (Capacitor Discharge Ignition) with variable timing. 🔧 Transmission Standard Transmission Gearbox Type: 6-speed constant mesh sequential gearbox. Clutch Type: Wet, multi-plate clutch. Features Gear Ratios: Detailed gear ratios for all six speeds will be provided in the manual for performance analysis and potential modification. 📐 Dimensions Exterior Wheelbase: Approximately 1370 mm (53.9 inches). Seat Height: Around 800-820 mm (31.5-32.3 inches). Weights Dry Weight: Approximately 130-140 kg (287-309 lbs) depending on year and specification. 🛡️ Safety Features Active Features Braking System: Disc brakes front and rear. Typically a 320mm disc with a 4-piston caliper front, and a 240mm disc with a 2-piston caliper rear. Passive Features Frame Construction: Aluminum twin-spar frame provides rigidity and lightweight construction. 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, speedometer, odometer, and essential warning lights. Driver Assistance ABS: Anti-lock braking system (ABS) was not a standard feature on these early models. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-5,000 km or annually, with specific recommendations in the manual. Spark Plug Replacement: Intervals will be specified, often related to mileage or performance checks. Chain Maintenance: Regular cleaning, lubrication, and tension adjustment are critical for longevity and performance. Fluid Specifications Engine Oil Type: 2-stroke synthetic or semi-synthetic oil specifically formulated for high-performance air-cooled or liquid-cooled engines. API TC or JASO FD standards are critical. Coolant Type: Ethylene glycol based antifreeze/coolant, typically a 50/50 mix with distilled water. Brake Fluid Type: DOT 4 or DOT 5.1 hydraulic brake fluid. Gearbox Oil Type: Specific gearbox oil viscosity and type (e.g., 10W-40 or 75W-90 API GL-4/GL-5) will be detailed, crucial for transmission health. Known Issues Common Wear Items: Piston rings, piston, cylinder wear, exhaust power valve issues, and carburetor tuning sensitivity are common for this era of 125cc two-strokes. Carburetor Tuning: The Dell'Orto carburetors often require precise jetting and adjustment for optimal performance and to prevent lean conditions. Power Valve Maintenance: The exhaust power valve mechanism can accumulate carbon deposits, requiring regular cleaning for proper engine performance. Torque Specifications Cylinder Head Torque: Specific torque sequence and values for cylinder head bolts are vital for proper sealing. Clutch Nut Torque: Correct torque for the primary drive and clutch retaining nut. 📚 Vehicle History Brand Heritage Aprilia Legacy: Aprilia has a strong racing heritage, particularly in smaller displacement classes, which influenced the sporty nature of the RS 125. Model Evolution Design Philosophy: The RS 125 was designed as a lightweight, high-performance sportbike, often styled...