Aprilia RS125 RS125 1996 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: 1996 Vehicle Type: Sport Motorcycle Codes Manual Product Code: RS125_1996_SVM 👋 Introduction Market Position Target Audience: Aprilia RS125 owners, independent motorcycle repair shops, performance tuners Value Proposition: Empowers owners and technicians with the knowledge to maintain, repair, and optimize the performance of the 1996 Aprilia RS125. Competitive Analysis Uniqueness: A dedicated and comprehensive resource for a popular, performance-oriented 125cc sportbike, essential for proper upkeep. Key Features Documentation Quality: Utilizes clear language and detailed diagrams, mirroring professional workshop manuals. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and workshop procedures Secondary Coverage: Maintenance, troubleshooting, diagnostics, specifications, diagrams Page Count Estimated Page Count: 300-500 (estimated based on typical workshop manuals for this era) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English (assumed based on market and common usage) Format Format: Digital (likely PDF, given common distribution for this product) 📖 Manual Coverage Systems Covered Engine: Engine assembly, disassembly, tuning, cooling system, lubrication, fuel delivery (carburetor), ignition system, exhaust system, engine management (if applicable) Transmission: Gearbox disassembly, inspection, reassembly, clutch operation, gear shift mechanism, lubrication Chassis: Frame inspection and repair, suspension (front forks, rear shock absorber), steering system, wheel bearings, spoke maintenance Brakes: Front and rear brake systems (hydraulic), caliper maintenance, master cylinder, brake fluid specifications, bleeding procedures, pad replacement Electrical: Wiring diagrams, lighting system, battery, starter motor, charging system (alternator/stator), fuses, ignition switch, control switches, instrument cluster Fuel System: Carburetor identification, dismantling, cleaning, adjustment (jetting), fuel tank, fuel lines, fuel petcock Cooling System: Radiator, coolant type and mixture, water pump, thermostat, hoses, fan (if equipped) Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug servicing, brake checks, tire pressure Troubleshooting: Diagnostic charts for common issues, symptom-based problem solving Repair Procedures: Step-by-step instructions for component removal, installation, and overhaul Rebuilding: Engine, carburetor, brake caliper, and suspension component rebuilding Adjustments: Carburetor jetting, ignition timing, valve clearance (if applicable for 2-stroke), clutch and throttle cables Technical Depth Depth Of Coverage: Comprehensive, covering all aspects from routine maintenance to major engine overhauls and electrical system diagnostics. Diagnostic Capabilities: Detailed troubleshooting guides, electrical schematics, and component testing procedures. 📊 Manual Specifications File Format Digital Format Details: Likely searchable PDF with high-resolution diagrams and text, optimized for printing. Print Quality Print Quality Suitability: Designed for clear printing of diagrams, schematics, and detailed text. Binding Type Binding Type Recommendation: Spiral bound for ease of use on a workbench, allowing pages to lay flat. Paper Type Paper Type Suitability: Glossy or semi-gloss paper recommended for durability and clarity of printed diagrams. ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder Displacement: 125cc Bore X Stroke: 54 mm x 54.5 mm (typical for this model, verify in manual) Cooling Method: Liquid-cooled Carburetor Model: Dell'Orto PHBH 28 (typical, may vary) Ignition System: Electronic CDI Performance Horsepower Output: Approx. 30-35 hp (depending on market restrictions and tuning) Torque Output: Approx. 20-23 Nm (depending on market restrictions and tuning) Fuel System Fuel Type: Unleaded gasoline (95 RON or higher recommended) Oil Mixture: Pre-mix or separate oil injection system (manual will specify details) 🔧 Transmission Standard Transmission Type: Constant mesh, 6-speed sequential Optional Optional Transmission: N/A (standard for this model) Features Clutch Type: Wet multi-plate, cable-actuated Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1950 mm (typical, verify in manual) Width: Approx. 720 mm (typical, verify in manual) Height: Approx. 1130 mm (typical, verify in manual) Weights Dry Weight: Approx. 131 kg (typical, verify in manual) Fuel Tank Capacity: Approx. 13 liters (typical, verify in manual) Wheels Tires Front Wheel Size: 17 inch Rear Wheel Size: 17 inch Front Tire Size: 110/70-17 (typical, verify in manual) Rear Tire Size: 150/60-17 (typical, verify in manual) 🛡️ Safety Features Ratings Safety Ratings: Motorcycle safety standards apply; no formal automotive-style crash test ratings. Active Features Braking System: Dual hydraulic disc brakes (front), single hydraulic disc brake (rear). Suspension Performance: USD (Upright Down) forks front, adjustable monoshock rear for stability. Passive Features Lighting: Halogen headlight, LED taillight (typical). 💡 Technology Features Infotainment Infotainment System: Basic instrument cluster: speedometer, tachometer, odometer, temperature gauge, warning lights. Driver Assistance Driver Assistance Features: None (typical for a 1996 sportbike). Connectivity Connectivity Features: None (typical for a 1996 sportbike). 🔧 Maintenance Service Intervals Engine Oil Change: Every 3,000-5,000 km or annually (specific interval in manual). Spark Plug Check: Every 6,000-10,000 km (verify in manual). Chain Cleaning Lubrication: Every 500-1,000 km, or after riding in wet conditions. Air Filter Cleaning: Every 6,000-10,000 km or as needed based on operating conditions. Fluid Specifications Engine Oil Type: 2-stroke synthetic or semi-synthetic oil meeting JASO FD or ISO-L-EGD standards (manual will specify exact grade). Coolant Type: Ethylene glycol-based antifreeze with corrosion inhibitors, mixed 50/50 with distilled water. Brake Fluid Type: DOT 4 hydraulic brake fluid (verify in manual). Transmission Oil...
Diagnostic charts for common issues, symptom-based problem solving
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul
Rebuilding:
Engine, carburetor, brake caliper, and suspension component rebuilding
Adjustments:
Carburetor jetting, ignition timing, valve clearance (if applicable for 2-stroke), clutch and throttle cables
Technical Depth
Depth Of Coverage:
Comprehensive, covering all aspects from routine maintenance to major engine overhauls and electrical system diagnostics.
Diagnostic Capabilities:
Detailed troubleshooting guides, electrical schematics, and component testing procedures.
📊 Manual Specifications
File Format
Digital Format Details:
Likely searchable PDF with high-resolution diagrams and text, optimized for printing.
Print Quality
Print Quality Suitability:
Designed for clear printing of diagrams, schematics, and detailed text.
Binding Type
Binding Type Recommendation:
Spiral bound for ease of use on a workbench, allowing pages to lay flat.
Paper Type
Paper Type Suitability:
Glossy or semi-gloss paper recommended for durability and clarity of printed diagrams.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Two-stroke, single-cylinder
Displacement:
125cc
Bore X Stroke:
54 mm x 54.5 mm (typical for this model, verify in manual)
Cooling Method:
Liquid-cooled
Carburetor Model:
Dell'Orto PHBH 28 (typical, may vary)
Ignition System:
Electronic CDI
Performance
Horsepower Output:
Approx. 30-35 hp (depending on market restrictions and tuning)
Torque Output:
Approx. 20-23 Nm (depending on market restrictions and tuning)
Fuel System
Fuel Type:
Unleaded gasoline (95 RON or higher recommended)
Oil Mixture:
Pre-mix or separate oil injection system (manual will specify details)
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed sequential
Optional
Optional Transmission:
N/A (standard for this model)
Features
Clutch Type:
Wet multi-plate, cable-actuated
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 1950 mm (typical, verify in manual)
Width:
Approx. 720 mm (typical, verify in manual)
Height:
Approx. 1130 mm (typical, verify in manual)
Weights
Dry Weight:
Approx. 131 kg (typical, verify in manual)
Fuel Tank Capacity:
Approx. 13 liters (typical, verify in manual)
Wheels Tires
Front Wheel Size:
17 inch
Rear Wheel Size:
17 inch
Front Tire Size:
110/70-17 (typical, verify in manual)
Rear Tire Size:
150/60-17 (typical, verify in manual)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycle safety standards apply; no formal automotive-style crash test ratings.
Active Features
Braking System:
Dual hydraulic disc brakes (front), single hydraulic disc brake (rear).
Suspension Performance:
USD (Upright Down) forks front, adjustable monoshock rear for stability.
Passive Features
Lighting:
Halogen headlight, LED taillight (typical).
💡 Technology Features
Infotainment
Infotainment System:
Basic instrument cluster: speedometer, tachometer, odometer, temperature gauge, warning lights.
Driver Assistance
Driver Assistance Features:
None (typical for a 1996 sportbike).
Connectivity
Connectivity Features:
None (typical for a 1996 sportbike).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000-5,000 km or annually (specific interval in manual).
Spark Plug Check:
Every 6,000-10,000 km (verify in manual).
Chain Cleaning Lubrication:
Every 500-1,000 km, or after riding in wet conditions.
Air Filter Cleaning:
Every 6,000-10,000 km or as needed based on operating conditions.
Fluid Specifications
Engine Oil Type:
2-stroke synthetic or semi-synthetic oil meeting JASO FD or ISO-L-EGD standards (manual will specify exact grade).
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 hydraulic brake fluid (verify in manual).
Transmission Oil Type:
Hypoid gear oil, API GL-4 or GL-5 (manual will specify viscosity and grade).
Known Issues
Common Wear Items:
Piston rings, cylinder wear (due to 2-stroke nature), clutch plates, chain and sprockets, stator failure, power valve issues.
Common Issues
Carburetor Tuning:
Sensitivity to altitude and temperature, requiring periodic re-jetting for optimal performance.
Cooling System Leaks:
Potential leaks from hoses or radiator due to age and heat cycles.
📚 Vehicle History
Brand Heritage
Aprilia Heritage:
Italian manufacturer with a strong heritage in racing and sport motorcycles, known for performance and innovative design.
Model Evolution
Rs125 Lineage:
The RS125 has a long history as a benchmark 125cc sportbike, evolving through several generations with performance enhancements and styling updates. The 1996 model represents a key phase in its development.
Production
Production Period:
The RS125 was in production from the early 1990s until 2012, with various updates.
🏆 Awards & Recognition
Recognitions
Awards And Recognition:
The Aprilia RS125 itself garnered significant recognition in its class for performance, handling, and styling, often considered a benchmark for 125cc sportbikes of its era.
Ratings
Performance Ratings:
Highly rated by motorcycle publications for its track-day capability and sporty feel.
Certifications
Certifications:
Compliant with relevant emissions and safety standards for its production year and market.
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