Aprilia RS125 RS 125 1999 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: 1999 Model Code: External references suggest variants like AP8114530, AP8114532, etc., but specific internal codes for 1999 model year are best confirmed within the manual. 👋 Introduction Market Position Positioning: The Aprilia RS125 of this era was positioned as a premium, high-performance lightweight sportbike, often considered one of the best 125cc motorcycles available. It aimed to provide a near-superbike riding experience in a smaller displacement package. Competitive Analysis Competitors: Competed against other premium 125cc sportbikes of the late 1990s, such as the Yamaha YZF-R125 (later models), Honda RS125 GP (racing, but influenced road models), Cagiva Mito 125, and Suzuki GSX-R125. Key Features Features: DOHC, two-stroke, liquid-cooled engine; aggressive styling inspired by larger Aprilia RSV Mille; advanced chassis and suspension for its class; strong performance figures for a 125cc. 📋 Manual Details Coverage Areas Coverage Scope: Complete factory service repair Page Count Estimated Page Count: Hundreds (exact count varies by edition, but typically 300-500+ pages for this era of factory manuals) Manual Type Type: Factory Service Repair Manual Language Language: Likely English, with potential for other European languages depending on original distribution. Primary language for this listing is English. Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, internal components (piston, rings, cylinder, crankshaft, connecting rod), valve timing, compression testing, lubrication system. Engine Electrical: Ignition system, CDI unit, spark plug, charging system (alternator, stator), starter motor, wiring diagrams, sensor testing. Fuel System: Carburetor (likely Dell'Orto PHBH or similar) tuning, cleaning, rebuilding, fuel pump, fuel lines, fuel filter. Cooling System: Radiator, water pump, coolant hoses, thermostat, coolant specifications and flushing procedures. Exhaust System: Expansion chamber, muffler, catalytic converter (if applicable), gasket replacement, inspection. Transmission: Clutch operation, gear selection mechanism, gearbox disassembly and assembly, gear ratios, lubrication, clutch fluid. Brakes: Front and rear brake systems (likely hydraulic discs), caliper overhaul, brake fluid type and bleeding procedures, master cylinder, brake pad replacement, rotor inspection. Suspension: Front fork (telescopic, likely inverted) disassembly, seal replacement, oil type and level, rear shock absorber adjustment and overhaul, swingarm maintenance. Steering: Handlebar, steering head bearings inspection and adjustment, steering lock. Wheels And Tires: Tire pressure, wheel bearing inspection and replacement, rim specifications, spoke tension (if applicable). Electrical System: Lighting (headlight, taillight, turn signals), horn, battery maintenance, fuses, switches, instrument cluster troubleshooting. Bodywork And Frame: Fairing removal and installation, seat, fuel tank, body panel fasteners, frame inspection, chassis alignment. Procedures Included Routine Maintenance: Oil change, filter replacement, spark plug replacement, chain adjustment, brake inspection, tire pressure checks, air filter cleaning/replacement. Troubleshooting: Diagnostic charts for common issues, symptom-based problem solving for engine, electrical, and mechanical systems. Engine Rebuilding: Complete step-by-step instructions for engine disassembly, component inspection, repair, and reassembly. Electrical Diagnostics: Testing procedures for all electrical components, including use of multimeters and diagnostic tools. Suspension Service: Fork oil change, seal replacement, shock absorber servicing. Brake System Service: Bleeding, pad replacement, caliper and master cylinder overhaul. Carburetor Tuning: Detailed instructions for jetting, idle speed, and mixture adjustments. Wiring Diagrams: Complete and detailed electrical schematics for all factory equipment. Technical Depth Depth: Comprehensive. Covers everything from basic scheduled maintenance and routine checks to complete engine rebuilds, transmission overhauls, and detailed electrical system diagnostics. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: Downloadable PDF typically offers high resolution, ensuring clear text and diagrams. Ability to print at original quality. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) Searchability Text Searchable: Typically, factory PDF manuals are text-searchable, allowing users to quickly find specific topics. ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder Displacement: 124.8 cc (approximately) Bore X Stroke: 54 mm x 54.5 mm (typical for Rotax 122 engine) Cooling System: Liquid-cooled Valve Train: Reed valve induction, electronically controlled exhaust valve (APCS - Aprilia Power Combustion System) Performance Horsepower: Typically around 30-34 HP at the crank, depending on market restrictions (e.g., 15 HP in some European markets for learner riders). Torque: Approximately 22-25 Nm (16-18 lb-ft) at the crank. Fuel System Carburetor: Dell'Orto PHBH 28 (common fitment), or similar 28mm carb. Later models may have used different configurations. The manual will specify the exact type. Fuel Type: Unleaded gasoline, minimum 95 RON (premium) Lubrication Oil System: Premix or separate oil injection system (manual will specify and cover maintenance). 🔧 Transmission Standard Type: 6-speed sequential manual transmission Optional Optional Types: N/A (Standard for this model) Features Clutch Type: Wet multi-plate clutch Gear Ratios: Specific gear ratios are detailed in the manual, crucial for performance tuning and maintenance. Final Drive: Chain drive 📐 Dimensions Exterior Length: Approximately 1970 mm Width: Approximately 730 mm (at handlebars) Height: Approximately 1060 mm (at seat) Wheelbase: Approximately 1345 mm Weights Dry Weight: Approximately 130-135 kg (this manual will provide the precise figure) Fuel Tank Capacity: Approximately 13 liters 🛡️ Safety...
External references suggest variants like AP8114530, AP8114532, etc., but specific internal codes for 1999 model year are best confirmed within the manual.
👋 Introduction
Market Position
Positioning:
The Aprilia RS125 of this era was positioned as a premium, high-performance lightweight sportbike, often considered one of the best 125cc motorcycles available. It aimed to provide a near-superbike riding experience in a smaller displacement package.
Competitive Analysis
Competitors:
Competed against other premium 125cc sportbikes of the late 1990s, such as the Yamaha YZF-R125 (later models), Honda RS125 GP (racing, but influenced road models), Cagiva Mito 125, and Suzuki GSX-R125.
Key Features
Features:
DOHC, two-stroke, liquid-cooled engine; aggressive styling inspired by larger Aprilia RSV Mille; advanced chassis and suspension for its class; strong performance figures for a 125cc.
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete factory service repair
Page Count
Estimated Page Count:
Hundreds (exact count varies by edition, but typically 300-500+ pages for this era of factory manuals)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
Likely English, with potential for other European languages depending on original distribution. Primary language for this listing is English.
Front and rear brake systems (likely hydraulic discs), caliper overhaul, brake fluid type and bleeding procedures, master cylinder, brake pad replacement, rotor inspection.
Suspension:
Front fork (telescopic, likely inverted) disassembly, seal replacement, oil type and level, rear shock absorber adjustment and overhaul, swingarm maintenance.
Steering:
Handlebar, steering head bearings inspection and adjustment, steering lock.
Wheels And Tires:
Tire pressure, wheel bearing inspection and replacement, rim specifications, spoke tension (if applicable).
Diagnostic charts for common issues, symptom-based problem solving for engine, electrical, and mechanical systems.
Engine Rebuilding:
Complete step-by-step instructions for engine disassembly, component inspection, repair, and reassembly.
Electrical Diagnostics:
Testing procedures for all electrical components, including use of multimeters and diagnostic tools.
Suspension Service:
Fork oil change, seal replacement, shock absorber servicing.
Brake System Service:
Bleeding, pad replacement, caliper and master cylinder overhaul.
Carburetor Tuning:
Detailed instructions for jetting, idle speed, and mixture adjustments.
Wiring Diagrams:
Complete and detailed electrical schematics for all factory equipment.
Technical Depth
Depth:
Comprehensive. Covers everything from basic scheduled maintenance and routine checks to complete engine rebuilds, transmission overhauls, and detailed electrical system diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
Downloadable PDF typically offers high resolution, ensuring clear text and diagrams. Ability to print at original quality.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
Searchability
Text Searchable:
Typically, factory PDF manuals are text-searchable, allowing users to quickly find specific topics.
N/A (No electronic rider aids like ABS or traction control common on modern bikes).
Engine Management
Engine Control Unit:
CDI (Capacitor Discharge Ignition) unit controlling ignition timing, potentially with an integrated electronic powervalve controller.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Recommended every 2,000-3,000 km or annually, with specific details provided in the manual.
Spark Plug Replacement:
Typically recommended every 3,000-5,000 km, or based on plug condition. Manual specifies type and gap.
Chain Lubrication And Adjustment:
Frequent checks and lubrication recommended (e.g., every 500 km or after riding in wet conditions), with adjustment intervals specified.
Fork Oil Change:
Recommended every 10,000-15,000 km or as needed based on performance degradation. Manual specifies oil type and level.
Brake Fluid Change:
Recommended every 1-2 years to maintain system performance and prevent corrosion. Manual specifies DOT fluid type.
Fluid Specifications
Engine Oil:
For the gearbox and clutch (if separate from engine oil), typically a specific gearbox oil or premium motorcycle-specific lubricant is required. For 2-stroke engines with oil injection, the manual will specify the 2-stroke oil type (e.g., fully synthetic).
Coolant:
Mixture of distilled water and ethylene glycol-based antifreeze (typically 50/50 ratio). Manual specifies the recommended type and capacity.
Brake Fluid:
DOT 4 is a common specification for this era of sportbikes.
Fork Oil:
Manual will specify viscosity (e.g., SAE 5W, SAE 10W) and fill level. Common aftermarket choices exist, but using the specified type is recommended for optimal performance.
Known Issues
Common Problems:
Potential issues include wear on the powervalve mechanism (requiring cleaning/servicing), carburetor jetting sensitivity to altitude/temperature, clutch wear, and general maintenance needs common to high-performance two-strokes. The manual addresses diagnostics and repair for these.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia has a strong heritage in racing, particularly in Grand Prix motorcycle racing, which heavily influenced the development and design of their road-going sportbikes like the RS125. This racing pedigree is evident in the RS125's performance and handling characteristics.
Model Evolution
Evolution:
The RS125 model has undergone several updates and revisions over its production run. The 1999 model represents a mature iteration of this successful platform, incorporating refinements from earlier versions and building upon its reputation.
Production
Manufacturing Location:
Aprilia motorcycles are typically manufactured in Italy.