Aprilia RS125 Workshop Service Repair Manual RS 125 # 1
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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: Various (implied comprehensive coverage) Codes Product Code: RS125 # 1 👋 Introduction Market Position Segment: Lightweight Supersport / Performance Motorcycle Competitive Analysis Competitors: Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125, Kawasaki Ninja 125. Key Features Design Philosophy: Race-inspired styling, sporty handling, efficient two-stroke (earlier models) or four-stroke (later models) engine, lightweight chassis. Target Audience: Beginner motorcyclists, track day enthusiasts, riders seeking a stylish and agile sportbike experience. Manual Utility Value Proposition: Empowers owners to perform a wide range of maintenance and repair tasks, saving on dealership labor costs and ensuring optimal performance. 📋 Manual Details Coverage Areas Scope: Workshop Service and Repair Page Count Estimated Pages: Likely 300+ (typical for comprehensive workshop manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English (implied by product description) Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, top-end overhaul, bottom-end overhaul, piston/ring replacement, valve adjustment, crankshaft service, cylinder head repair. Fuel System: Carburetor tuning and overhaul (likely Dell'Orto PHBH/VHST variants), fuel pump operation, fuel lines, fuel tank maintenance. Ignition System: CDI ignition system, spark plug selection and gap, ignition timing, stator and rotor service, wiring diagrams. Cooling System: Radiator service, coolant type and capacity, water pump overhaul, thermostat operation, fan operation. Exhaust System: Exhaust pipe removal and installation, mufflers, expansion chambers (if applicable to specific model variations). Transmission: Gearbox disassembly and reassembly, gear selection mechanism, clutch operation, clutch friction plate replacement, chain and sprockets. Chassis Frame: Frame inspection, headstock bearing service, swingarm service, pivot point lubrication. Suspension Front: Telescopic fork service, oil change and level, seal replacement, spring inspection, damping adjustment (if applicable). Suspension Rear: Monoshock absorber service, linkage maintenance, spring preload adjustment, damping adjustment (if applicable). Brakes Front: Brake caliper service and overhaul, brake pad replacement, disc inspection and replacement, master cylinder service, brake fluid type and bleeding procedure. Brakes Rear: Brake caliper service and overhaul, brake pad replacement, disc inspection and replacement, master cylinder service, brake fluid type and bleeding procedure. Wheels Tires: Wheel bearing service, tire inspection and replacement, wheel balancing, spoke tension adjustment (if applicable). Electrical System: Battery maintenance, starter motor, lighting system (headlight, taillight, indicators), wiring diagrams for all circuits, fuse replacement, electrical troubleshooting. Bodywork Fairings: Fairing removal and installation, graphic application, seat maintenance, fuel tank removal and installation. Procedures Included Preventative Maintenance: Routine checks, lubrication points, filter replacement, fluid changes, spark plug replacement. Troubleshooting: Diagnostic charts for common problems, fault finding procedures for engine, electrical, and mechanical systems. Repair Overhaul: Step-by-step instructions for component disassembly, repair, and reassembly. Diagnostics: Methods for diagnosing specific issues, electrical system testing, mechanical component checks. Adjustments: Carburetor adjustment, chain adjustment, brake lever adjustment, clutch lever adjustment, suspension adjustments. Torque Specifications: Detailed torque values for all critical fasteners. Wiring Diagrams: Comprehensive electrical schematics for all model variations. Technical Depth Depth: Comprehensive from basic maintenance to full engine rebuilds and detailed electrical troubleshooting. 📊 Manual Specifications File Format Format: PDF Print Quality Resolution: High-resolution, suitable for printing all pages. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, 2-stroke (early models), or 4-stroke (later models, often liquid-cooled). Displacement: Approximately 125cc Bore X Stroke: Varies by specific model year and engine version (e.g., 54 mm x 54.5 mm for some Rotax engines). Compression Ratio: Varies by engine (e.g., 12.0:1 for some 4-stroke models). Cooling System: Liquid-cooled Performance Horsepower: Typically around 15 hp (restricted for A1 license in many regions), with potential for higher output in unrestricted versions. Torque: Specific values vary, but focus on usability in the mid-range for this class. Fuel System Carburetion: Often Dell'Orto PHBH or VHST series (e.g., 28mm or 30mm), or fuel injection on later 4-stroke models. Fuel Type: Unleaded Gasoline (RON 95 or higher recommended) 🔧 Transmission Standard Type: 6-speed constant mesh sequential gearbox Optional Optional Types: N/A Features Clutch Type: Wet multi-plate clutch (cable operated) Final Drive: Chain drive 📐 Dimensions Exterior Length: Varies by model year (e.g., approx. 1950 mm). Width: Varies by model year (e.g., approx. 720 mm). Height: Varies by model year (e.g., approx. 1060 mm). Wheelbase: Varies by model year (e.g., approx. 1360 mm). Weights Dry Weight: Varies by model year (e.g., approx. 117 kg). Wet Weight: Varies by model year (e.g., approx. 130 kg). Capacities Fuel Tank Capacity: Approximately 10.5 - 11 liters 🛡️ Safety Features Ratings Safety Standard: Manufactured to meet European safety standards (e.g., Euro 3/4/5 depending on year). Active Features Braking System: Disc brakes front and rear, often with ByBre or Brembo calipers. ABS: Optional on some later models or specific market variants. Passive Features Lighting: Halogen or LED headlight, taillight, and indicators. 💡 Technology Features Infotainment Instrument Cluster: Digital/analog combination or fully digital display showing speed, RPM, fuel level, trip meters, and warning lights....
Brake caliper service and overhaul, brake pad replacement, disc inspection and replacement, master cylinder service, brake fluid type and bleeding procedure.
Brakes Rear:
Brake caliper service and overhaul, brake pad replacement, disc inspection and replacement, master cylinder service, brake fluid type and bleeding procedure.
Diagnostic charts for common problems, fault finding procedures for engine, electrical, and mechanical systems.
Repair Overhaul:
Step-by-step instructions for component disassembly, repair, and reassembly.
Diagnostics:
Methods for diagnosing specific issues, electrical system testing, mechanical component checks.
Adjustments:
Carburetor adjustment, chain adjustment, brake lever adjustment, clutch lever adjustment, suspension adjustments.
Torque Specifications:
Detailed torque values for all critical fasteners.
Wiring Diagrams:
Comprehensive electrical schematics for all model variations.
Technical Depth
Depth:
Comprehensive from basic maintenance to full engine rebuilds and detailed electrical troubleshooting.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Resolution:
High-resolution, suitable for printing all pages.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Configuration:
Single-cylinder, 2-stroke (early models), or 4-stroke (later models, often liquid-cooled).
Displacement:
Approximately 125cc
Bore X Stroke:
Varies by specific model year and engine version (e.g., 54 mm x 54.5 mm for some Rotax engines).
Compression Ratio:
Varies by engine (e.g., 12.0:1 for some 4-stroke models).
Cooling System:
Liquid-cooled
Performance
Horsepower:
Typically around 15 hp (restricted for A1 license in many regions), with potential for higher output in unrestricted versions.
Torque:
Specific values vary, but focus on usability in the mid-range for this class.
Fuel System
Carburetion:
Often Dell'Orto PHBH or VHST series (e.g., 28mm or 30mm), or fuel injection on later 4-stroke models.
Fuel Type:
Unleaded Gasoline (RON 95 or higher recommended)
🔧 Transmission
Standard
Type:
6-speed constant mesh sequential gearbox
Optional
Optional Types:
N/A
Features
Clutch Type:
Wet multi-plate clutch (cable operated)
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Varies by model year (e.g., approx. 1950 mm).
Width:
Varies by model year (e.g., approx. 720 mm).
Height:
Varies by model year (e.g., approx. 1060 mm).
Wheelbase:
Varies by model year (e.g., approx. 1360 mm).
Weights
Dry Weight:
Varies by model year (e.g., approx. 117 kg).
Wet Weight:
Varies by model year (e.g., approx. 130 kg).
Capacities
Fuel Tank Capacity:
Approximately 10.5 - 11 liters
🛡️ Safety Features
Ratings
Safety Standard:
Manufactured to meet European safety standards (e.g., Euro 3/4/5 depending on year).
Active Features
Braking System:
Disc brakes front and rear, often with ByBre or Brembo calipers.
ABS:
Optional on some later models or specific market variants.
Passive Features
Lighting:
Halogen or LED headlight, taillight, and indicators.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital/analog combination or fully digital display showing speed, RPM, fuel level, trip meters, and warning lights.
Driver Assistance
ABS:
Available on select later models as an option.
Connectivity
Connectivity Features:
Typically none, focused on core motorcycle performance.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 - 5,000 km or annually, depending on usage and oil type.
Spark Plug Replacement:
Every 5,000 - 10,000 km or as per manual recommendation.
Air Filter Cleaning Replacement:
Every 3,000 - 6,000 km, or more frequently in dusty conditions.
Valve Clearance Check:
Every 6,000 - 12,000 km for 4-stroke models (if applicable).
Fluid Specifications
Engine Oil:
10W-40 or 15W-50 Synthetic or Semi-Synthetic Motorcycle Oil (API SG or higher, JASO MA/MA2).
Coolant:
Ethylene glycol based coolant with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid:
DOT 4
2-Stroke Oil:
High-quality, JASO FD certified 2-stroke premix or injection oil (for 2-stroke models).
Known Issues
Common Problems:
Carburetor jetting sensitivity to altitude/temperature, potential for reed valve wear (2-stroke), clutch wear under heavy use, electrical connector corrosion.
Maintenance Tips:
Regular cleaning of the air filter, ensuring correct 2-stroke oil mix, checking chain tension, keeping cooling system clean.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer with a strong heritage in racing and performance motorcycles.
Model Evolution
Development:
The RS125 has been in production for several decades, evolving from a potent two-stroke to a more modern four-stroke powerplant, adapting to emissions regulations and performance enhancements.
Production
Origin:
Italy
🏆 Awards & Recognition
Recognitions
Racing Heritage:
The RS125 platform has a significant racing history, particularly in 125cc Grand Prix classes, contributing to its sporty reputation.
Ratings
User Reviews:
Generally praised for its handling, aggressive styling, and engaging ride for its class.
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