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APRILIA RS125 RS 125 1993-2006 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year Range: 1993-2006 👋 Introduction Market Position Target Audience: Owners and technicians seeking detailed repair and maintenance information for the Aprilia RS125. Competitive Analysis Value Proposition: Provides professional-level technical data and procedures, mirroring what is used in local service repair shops, enabling cost savings and self-sufficiency for owners. Key Features Diagrams Illustrations: High-quality exploded pictures and diagrams for clear procedural understanding. Delivery Method: Instant Download - no shipping, no waiting. Usability: Easy-to-read text sections, step-by-step instructions, designed for both novice and experienced users. 📋 Manual Details Coverage Areas Applicable Years: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Page Count: Extensive (specific count not provided, but described as comprehensive) Manual Type Type: Full Service & Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, tuning, carburetion, ignition, cooling system, exhaust system Transmission: Gearbox overhaul, clutch operation, shift mechanism, lubrication Chassis: Frame inspection, suspension (front and rear), steering system, wheel bearings Brakes: Hydraulic system, caliper service, master cylinder overhaul, disc and pad replacement, bleeding procedures Electrical System: Wiring diagrams, battery, lighting, charging system, ignition system components, starter, fuses, relays Fuel System: Carburetor (likely Dell'Orto PHBH/VHST based on era and model), fuel tank, fuel lines, fuel pump (if applicable) Bodywork: Fairing removal and installation, seat, fuel tank, fenders, trim components Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning/replacement Troubleshooting: Diagnostic charts, common problems and solutions, fault finding for engine, electrical, and mechanical issues Repair: Step-by-step repair procedures for all major components, detailed disassembly and reassembly instructions Rebuilds: Engine rebuilds (piston, cylinder, crankshaft), gearbox rebuilds, suspension overhaul Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and chassis overhauls) User Level: Suitable for both DIY enthusiasts and professional mechanics 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Full Printable Zoom Functionality Zoom Capability: Zoom IN/OUT enabled for detailed viewing Binding Type Binding: Digital Download (PDF) Paper Type Paper Type: N/A (Digital PDF) Requirements Software Requirements: Adobe PDF Reader, WinZip (for potential archive extraction) Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder (Rotax 122) Displacement: 124.8 cc Bore X Stroke: 54 mm x 54.5 mm Cooling System: Liquid-cooled Power Output: Approx. 30-34 HP (depending on year and market restrictions) Torque: Approx. 20-22 Nm (depending on year and market restrictions) Fuel System Carburetor Type: Dell'Orto PHBH 28/VHST 28 (common fitments, manual will specify exact models) Fuel Type: Unleaded gasoline (RON 95 or higher recommended) Engine Management Ignition System: Electronic CDI (Capacitor Discharge Ignition) Reed Valve System: Rotax design with specific reed block specifications 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch Type: Wet, multi-plate, cable-operated Final Drive: Chain drive (specific sprocket sizes will be detailed) Fluid Type Transmission Oil Spec: Specific gearbox oil (e.g., SAE 75W/80 or equivalent two-stroke gearbox oil, manual to confirm exact specification) 📐 Dimensions Exterior Length: Approx. 1975 mm (may vary slightly by year) Width: Approx. 700 mm (at handlebars, may vary) Height: Approx. 1060 mm (at seat, may vary) Weights Dry Weight: Approx. 130-135 kg (depending on year and equipment) Wet Weight: Approx. 140-145 kg (with all fluids) 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycle safety primarily relies on rider skill and protective gear, but chassis integrity and braking performance are covered) Active Features Braking System: Hydraulic disc brakes front and rear (dual piston front caliper, single piston rear caliper common) Suspension Damping: Adjustable front forks (pre-load, compression/rebound damping on some models) and rear shock absorber Passive Features Lighting: Halogen headlamp, LED tail light (later models), turn signals 💡 Technology Features Infotainment Dashboard: Analog tachometer, speedometer, odometer, trip meter, and essential warning lights (coolant temp, oil level, neutral). Driver Assistance ABS: Anti-lock Braking System (ABS) was not a standard feature on most RS125 models of this era; some later or specific market variants might have offered it as an option. Manual will confirm. Connectivity Connectivity Features: N/A (No modern connectivity features like Bluetooth or smartphone integration). 🔧 Maintenance Service Intervals Oil Change Engine: Refer to manual for 2-stroke premix or oil injection system; gearbox oil change every 6,000-10,000 km or annually. Spark Plug Replacement: Typically every 3,000-5,000 km (specific plug type and gap crucial) Chain Lubrication Adjustment: Every 500 km or after riding in wet conditions; adjustment as per manual specifications. Fluid Specifications Coolant Type: Ethylene glycol based antifreeze/coolant (50/50 mix with distilled water recommended) Brake Fluid Type: DOT 4 or DOT 5.1 hydraulic brake fluid (check manual for precise recommendation) Two Stroke Oil: High-quality synthetic two-stroke engine oil specifically designed for high-performance, liquid-cooled engines (manual will specify grades). Known Issues Cylinder Wear: Common in high-performance two-strokes, requiring timely piston...
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APRILIA RS125 RS 125 1993-2006 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Year Range:
1993-2006
👋 Introduction
Market Position
Target Audience:
Owners and technicians seeking detailed repair and maintenance information for the Aprilia RS125.
Competitive Analysis
Value Proposition:
Provides professional-level technical data and procedures, mirroring what is used in local service repair shops, enabling cost savings and self-sufficiency for owners.
Key Features
Diagrams Illustrations:
High-quality exploded pictures and diagrams for clear procedural understanding.
Delivery Method:
Instant Download - no shipping, no waiting.
Usability:
Easy-to-read text sections, step-by-step instructions, designed for both novice and experienced users.
📋 Manual Details
Coverage Areas
Applicable Years:
1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Page Count
Estimated Page Count:
Extensive (specific count not provided, but described as comprehensive)
Manual Type
Type:
Full Service & Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, tuning, carburetion, ignition, cooling system, exhaust system
Transmission:
Gearbox overhaul, clutch operation, shift mechanism, lubrication
Chassis:
Frame inspection, suspension (front and rear), steering system, wheel bearings
Brakes:
Hydraulic system, caliper service, master cylinder overhaul, disc and pad replacement, bleeding procedures
Electrical System:
Wiring diagrams, battery, lighting, charging system, ignition system components, starter, fuses, relays
Fuel System:
Carburetor (likely Dell'Orto PHBH/VHST based on era and model), fuel tank, fuel lines, fuel pump (if applicable)
Bodywork:
Fairing removal and installation, seat, fuel tank, fenders, trim components
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning/replacement
Troubleshooting:
Diagnostic charts, common problems and solutions, fault finding for engine, electrical, and mechanical issues
Repair:
Step-by-step repair procedures for all major components, detailed disassembly and reassembly instructions
Rebuilds:
Engine rebuilds (piston, cylinder, crankshaft), gearbox rebuilds, suspension overhaul
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and chassis overhauls)
User Level:
Suitable for both DIY enthusiasts and professional mechanics
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Full Printable
Zoom Functionality
Zoom Capability:
Zoom IN/OUT enabled for detailed viewing
Binding Type
Binding:
Digital Download (PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Requirements
Software Requirements:
Adobe PDF Reader, WinZip (for potential archive extraction)
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
Two-stroke, single-cylinder (Rotax 122)
Displacement:
124.8 cc
Bore X Stroke:
54 mm x 54.5 mm
Cooling System:
Liquid-cooled
Power Output:
Approx. 30-34 HP (depending on year and market restrictions)
Torque:
Approx. 20-22 Nm (depending on year and market restrictions)
Fuel System
Carburetor Type:
Dell'Orto PHBH 28/VHST 28 (common fitments, manual will specify exact models)
Fuel Type:
Unleaded gasoline (RON 95 or higher recommended)
Engine Management
Ignition System:
Electronic CDI (Capacitor Discharge Ignition)
Reed Valve System:
Rotax design with specific reed block specifications
🔧 Transmission
Standard
Type:
6-speed constant mesh
Features
Clutch Type:
Wet, multi-plate, cable-operated
Final Drive:
Chain drive (specific sprocket sizes will be detailed)
Fluid Type
Transmission Oil Spec:
Specific gearbox oil (e.g., SAE 75W/80 or equivalent two-stroke gearbox oil, manual to confirm exact specification)
📐 Dimensions
Exterior
Length:
Approx. 1975 mm (may vary slightly by year)
Width:
Approx. 700 mm (at handlebars, may vary)
Height:
Approx. 1060 mm (at seat, may vary)
Weights
Dry Weight:
Approx. 130-135 kg (depending on year and equipment)
Wet Weight:
Approx. 140-145 kg (with all fluids)
🛡️ Safety Features
Ratings
Crash Safety:
N/A (Motorcycle safety primarily relies on rider skill and protective gear, but chassis integrity and braking performance are covered)
Active Features
Braking System:
Hydraulic disc brakes front and rear (dual piston front caliper, single piston rear caliper common)
Suspension Damping:
Adjustable front forks (pre-load, compression/rebound damping on some models) and rear shock absorber
Passive Features
Lighting:
Halogen headlamp, LED tail light (later models), turn signals
💡 Technology Features
Infotainment
Dashboard:
Analog tachometer, speedometer, odometer, trip meter, and essential warning lights (coolant temp, oil level, neutral).
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was not a standard feature on most RS125 models of this era; some later or specific market variants might have offered it as an option. Manual will confirm.
Connectivity
Connectivity Features:
N/A (No modern connectivity features like Bluetooth or smartphone integration).
🔧 Maintenance
Service Intervals
Oil Change Engine:
Refer to manual for 2-stroke premix or oil injection system; gearbox oil change every 6,000-10,000 km or annually.
Spark Plug Replacement:
Typically every 3,000-5,000 km (specific plug type and gap crucial)
Chain Lubrication Adjustment:
Every 500 km or after riding in wet conditions; adjustment as per manual specifications.
Fluid Specifications
Coolant Type:
Ethylene glycol based antifreeze/coolant (50/50 mix with distilled water recommended)
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (check manual for precise recommendation)
Two Stroke Oil:
High-quality synthetic two-stroke engine oil specifically designed for high-performance, liquid-cooled engines (manual will specify grades).
Known Issues
Cylinder Wear:
Common in high-performance two-strokes, requiring timely piston and ring replacement. Manual provides clearances and tolerances.
Carburetor Tuning:
Can be sensitive to altitude, temperature, and fuel quality. Manual details jetting and adjustment procedures.
Rotax Power Valve:
The electronically controlled exhaust power valve system can accumulate carbon and require cleaning/service for optimal performance. Manual covers its maintenance.
Electrical Connections:
Corrosion and loose connections can cause intermittent issues, particularly on older bikes. Manual's wiring diagrams are essential.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer renowned for its sporty motorcycles, particularly in the small-displacement categories.
Model Evolution
Development:
The RS125 is a long-standing model that evolved from earlier Aprilia 125cc sports bikes, consistently offering high performance for its class.
Production
Manufacturing Location:
Italy
Market Segment:
Lightweight sportbike (supersport)
🏆 Awards & Recognition
Recognitions
Performance Accolades:
The Aprilia RS125 has historically been a highly regarded motorcycle in its class, winning numerous awards and accolades in motorcycle journalism for its handling, performance, and race-derived styling. Specific awards vary by year and publication.
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