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Aprilia RS 125 2004 All Service Repair Manual

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$133.00
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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 2004 Codes Chassis Code Range: ZAPM45XX (specific to 2004 model year, check manual for exact VIN decoding) 👋 Introduction Market Position Segment: Lightweight sportbike, popular for new riders and track day enthusiasts due to its performance and handling. Competitive Analysis Competitors: Yamaha YZF-R125, Honda CBR125R, Kawasaki Ninja 125 (though model availability varied by region and year). Key Features Design Philosophy: Aggressive styling mimicking larger Aprilia sportbikes, focused on rider engagement and agility. Engine Type: Two-stroke, single-cylinder, liquid-cooled, known for its punchy power delivery. Handling: Renowned for its sharp handling and excellent chassis, a hallmark of Aprilia's sportbike heritage. 📋 Manual Details Coverage Areas Documentation Type: Service and Repair Manual Manual Language: English Format: Downloadable Digital File (likely PDF) Page Count Estimated Page Count: Likely 300-500 pages (typical for comprehensive motorcycle service manuals of this era) 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine overhaul, component replacement, tuning, lubrication system, cooling system. Fuel System: Carburetor disassembly, cleaning, adjustment, fuel lines, fuel pump (if applicable). Ignition System: CDI unit, spark plugs, ignition coils, wiring diagrams for ignition. Transmission: Gearbox disassembly, clutch operation, gear linkage, shift drum, final drive. Cooling System: Radiator, coolant hoses, water pump, thermostat, coolant specifications. Exhaust System: Exhaust pipe removal, mufflers, mounting hardware. Brakes: Front and rear brake systems, caliper overhaul, master cylinder, brake fluid specifications, bleeding procedures. Suspension Front: Front fork disassembly, oil change, seal replacement, spring specifications, damping adjustments. Suspension Rear: Monoshock absorber adjustment, linkage system maintenance, rear swingarm. Electrical System: Wiring diagrams, battery maintenance, lighting, starter motor, charging system (alternator/stator). Frame And Bodywork: Fairing removal and installation, frame inspection, fuel tank, seat, handlebars, footpegs. Wheels And Tires: Wheel bearing replacement, tire changing, tire pressure recommendations. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug inspection/replacement, brake fluid changes. Troubleshooting: Diagnosing common mechanical and electrical faults, fault code identification (if applicable). Engine Overhaul: Top-end rebuild (cylinder, piston, rings), bottom-end inspection, crankshaft and connecting rod service. Carburetor Tuning: Jetting specifications, idle speed adjustment, mixture control. Brake System Service: Pad replacement, caliper rebuilding, fluid flushing and replacement. Suspension Servicing: Fork oil replacement, seal installation, shock absorber servicing. Electrical Diagnostics: Using wiring diagrams to trace faults, testing components like stator, regulator, starter. Frame And Body Repair: Fairing repair, panel alignment, mounting procedures. Technical Depth Depth Of Coverage: Comprehensive. Covers everything from basic maintenance to full engine and gearbox rebuilds. Includes detailed diagnostic procedures and torque specifications. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable for quick information retrieval. Print Quality Print Readability: Designed for clear viewing on screen and printable for workshop use. Graphics and diagrams should be high resolution. Binding Type Binding: N/A (Digital format) Paper Type Paper Quality: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, single-cylinder, liquid-cooled, reed valve induction Bore X Stroke: 54 mm x 54.5 mm Displacement: 124.8 cc (125cc class) Compression Ratio: Approx. 7.2:1 (varies slightly by market/tune) Valvetrain: Reed valve induction, exhaust power valve system (APTS - Aprilia Performance Tuning System). Performance Horsepower Est: Approx. 30-34 HP (depending on market restrictions and tuning, often limited to 15 HP in learner-legal configurations) Torque Est: Approx. 23-25 Nm Fuel System Carburetor: Dell'Orto PHBH 28 (or similar 28mm carb), often with APEX power jet system. Fuel Type: Unleaded gasoline, octane rating 95 (RON) or higher recommended. Fuel Mixture: Automatic oil injection system for 2-stroke oil. Lubrication Oil Type: High-quality 2-stroke synthetic or semi-synthetic oil (refer to manual for specific API TC recommendations). 🔧 Transmission Standard Type: 6-speed constant mesh, sequential manual gearbox. Clutch: Wet multi-plate clutch, hydraulically operated. Gear Ratios: Specific ratios detailed in manual; typically close-ratio for sporty performance. Final Drive: Chain drive, with specific sprocket ratios detailed in manual. 📐 Dimensions Exterior Length: Approx. 1950 mm Width: Approx. 710 mm (at handlebars) Height: Approx. 1060 mm (at handlebars) Wheelbase: Approx. 1375 mm Weights Dry Weight: Approx. 131 kg Curb Weight Est: Approx. 139 kg (with all fluids) Max Load Capacity: Refer to manual; typically around 180-200 kg (rider + passenger + luggage). Cargo Cargo Capacity: Minimal, designed for single rider, small under-seat storage may exist. 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles typically do not receive official NCAP-style crash ratings.) Active Features Braking System: Hydraulic disc brakes front and rear. Often with larger diameter front disc for enhanced stopping power. Tires: Sport-oriented radial tires for grip. Recommended pressures listed in manual. Passive Features Lighting: Halogen headlight, taillight, turn signals. Frame Construction: Aluminum alloy twin-spar frame for rigidity and light weight. 💡 Technology Features Infotainment Dashboard: Analog tachometer, speedometer, odometer, trip meter, coolant temperature gauge, turn signal indicators, neutral indicator. Driver Assistance Power Delivery System: Aprilia Performance Tuning System (APTS) - electronically controlled exhaust power valve for improved torque at low...
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Aprilia RS 125 2004 All Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Year:
2004
Codes
Chassis Code Range:
ZAPM45XX (specific to 2004 model year, check manual for exact VIN decoding)
👋 Introduction
Market Position
Segment:
Lightweight sportbike, popular for new riders and track day enthusiasts due to its performance and handling.
Competitive Analysis
Competitors:
Yamaha YZF-R125, Honda CBR125R, Kawasaki Ninja 125 (though model availability varied by region and year).
Key Features
Design Philosophy:
Aggressive styling mimicking larger Aprilia sportbikes, focused on rider engagement and agility.
Engine Type:
Two-stroke, single-cylinder, liquid-cooled, known for its punchy power delivery.
Handling:
Renowned for its sharp handling and excellent chassis, a hallmark of Aprilia's sportbike heritage.
📋 Manual Details
Coverage Areas
Documentation Type:
Service and Repair Manual
Manual Language:
English
Format:
Downloadable Digital File (likely PDF)
Page Count
Estimated Page Count:
Likely 300-500 pages (typical for comprehensive motorcycle service manuals of this era)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full engine overhaul, component replacement, tuning, lubrication system, cooling system.
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel lines, fuel pump (if applicable).
Ignition System:
CDI unit, spark plugs, ignition coils, wiring diagrams for ignition.
Transmission:
Gearbox disassembly, clutch operation, gear linkage, shift drum, final drive.
Cooling System:
Radiator, coolant hoses, water pump, thermostat, coolant specifications.
Exhaust System:
Exhaust pipe removal, mufflers, mounting hardware.
Brakes:
Front and rear brake systems, caliper overhaul, master cylinder, brake fluid specifications, bleeding procedures.
Suspension Front:
Front fork disassembly, oil change, seal replacement, spring specifications, damping adjustments.
Suspension Rear:
Monoshock absorber adjustment, linkage system maintenance, rear swingarm.
Electrical System:
Wiring diagrams, battery maintenance, lighting, starter motor, charging system (alternator/stator).
Frame And Bodywork:
Fairing removal and installation, frame inspection, fuel tank, seat, handlebars, footpegs.
Wheels And Tires:
Wheel bearing replacement, tire changing, tire pressure recommendations.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug inspection/replacement, brake fluid changes.
Troubleshooting:
Diagnosing common mechanical and electrical faults, fault code identification (if applicable).
Engine Overhaul:
Top-end rebuild (cylinder, piston, rings), bottom-end inspection, crankshaft and connecting rod service.
Carburetor Tuning:
Jetting specifications, idle speed adjustment, mixture control.
Brake System Service:
Pad replacement, caliper rebuilding, fluid flushing and replacement.
Suspension Servicing:
Fork oil replacement, seal installation, shock absorber servicing.
Electrical Diagnostics:
Using wiring diagrams to trace faults, testing components like stator, regulator, starter.
Frame And Body Repair:
Fairing repair, panel alignment, mounting procedures.
Technical Depth
Depth Of Coverage:
Comprehensive. Covers everything from basic maintenance to full engine and gearbox rebuilds. Includes detailed diagnostic procedures and torque specifications.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable for quick information retrieval.
Print Quality
Print Readability:
Designed for clear viewing on screen and printable for workshop use. Graphics and diagrams should be high resolution.
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Quality:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, single-cylinder, liquid-cooled, reed valve induction
Bore X Stroke:
54 mm x 54.5 mm
Displacement:
124.8 cc (125cc class)
Compression Ratio:
Approx. 7.2:1 (varies slightly by market/tune)
Valvetrain:
Reed valve induction, exhaust power valve system (APTS - Aprilia Performance Tuning System).
Performance
Horsepower Est:
Approx. 30-34 HP (depending on market restrictions and tuning, often limited to 15 HP in learner-legal configurations)
Torque Est:
Approx. 23-25 Nm
Fuel System
Carburetor:
Dell'Orto PHBH 28 (or similar 28mm carb), often with APEX power jet system.
Fuel Type:
Unleaded gasoline, octane rating 95 (RON) or higher recommended.
Fuel Mixture:
Automatic oil injection system for 2-stroke oil.
Lubrication
Oil Type:
High-quality 2-stroke synthetic or semi-synthetic oil (refer to manual for specific API TC recommendations).
🔧 Transmission
Standard
Type:
6-speed constant mesh, sequential manual gearbox.
Clutch:
Wet multi-plate clutch, hydraulically operated.
Gear Ratios:
Specific ratios detailed in manual; typically close-ratio for sporty performance.
Final Drive:
Chain drive, with specific sprocket ratios detailed in manual.
📐 Dimensions
Exterior
Length:
Approx. 1950 mm
Width:
Approx. 710 mm (at handlebars)
Height:
Approx. 1060 mm (at handlebars)
Wheelbase:
Approx. 1375 mm
Weights
Dry Weight:
Approx. 131 kg
Curb Weight Est:
Approx. 139 kg (with all fluids)
Max Load Capacity:
Refer to manual; typically around 180-200 kg (rider + passenger + luggage).
Cargo
Cargo Capacity:
Minimal, designed for single rider, small under-seat storage may exist.
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles typically do not receive official NCAP-style crash ratings.)
Active Features
Braking System:
Hydraulic disc brakes front and rear. Often with larger diameter front disc for enhanced stopping power.
Tires:
Sport-oriented radial tires for grip. Recommended pressures listed in manual.
Passive Features
Lighting:
Halogen headlight, taillight, turn signals.
Frame Construction:
Aluminum alloy twin-spar frame for rigidity and light weight.
💡 Technology Features
Infotainment
Dashboard:
Analog tachometer, speedometer, odometer, trip meter, coolant temperature gauge, turn signal indicators, neutral indicator.
Driver Assistance
Power Delivery System:
Aprilia Performance Tuning System (APTS) - electronically controlled exhaust power valve for improved torque at low RPM and peak power at high RPM.
Connectivity
Connectivity Features:
None (No modern electronic connectivity features like Bluetooth or Wi-Fi are present on this model).
🔧 Maintenance
Service Intervals
Oil Change Engine:
Every 3,000-5,000 km or annually (refer to manual for precise interval and oil type).
Spark Plug Inspect:
Every 5,000 km, replace as needed based on condition.
Air Filter Clean:
Every 5,000-7,000 km or as needed based on riding conditions.
Chain Lubrication Adjust:
Every 500-1,000 km, adjust slack as per manual specifications.
Brake Fluid Change:
Every 1-2 years.
Coolant Change:
Every 2-3 years.
Fluid Specifications
Engine Oil Capacity:
Approx. 1.1 Liters (for gearbox oil, separate from 2-stroke oil injection)
Coolant Type:
Ethylene glycol based, anti-freeze/anti-corrosion mixture (typically 50/50 distilled water ratio).
Brake Fluid Type:
DOT 4
Known Issues
Power Valve Sticking:
Carbon buildup can cause the exhaust power valve to stick, affecting performance. Requires regular cleaning.
Carburetor Jetting:
Can be sensitive to altitude and temperature changes; correct jetting is crucial for optimal performance and longevity.
Electrical Connections:
Older wiring harnesses can develop corroded connections, leading to intermittent electrical faults. Regular inspection and dielectric grease application is recommended.
Two Stroke Engine Wear:
Like all 2-strokes, requires diligent maintenance of oil levels and proper fuel/oil mix to prevent premature wear.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian motorcycle manufacturer with a strong racing pedigree, particularly in smaller displacement classes.
Model Evolution
Rs 125 Lineage:
The RS 125 has been a staple in Aprilia's lineup for decades, evolving through various engine and chassis updates. The 2004 model represents a refinement of a successful formula.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Market Reputation:
Highly regarded in its class for its performance, handling, and premium feel, often considered one of the best 125cc sportbikes of its era.
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