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Aprilia RS125 RS 125 1999 Factory Service Repair Manual

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$133.00
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$133.00
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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...
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Aprilia RS125 RS 125 1999 Factory Service Repair Manual
🏷️ 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 Features
Ratings
Crash Test Ratings:
N/A (Motorcycles typically do not receive standardized crash test ratings like cars).
Active Features
Brake System:
Dual hydraulic disc brakes (front and rear) for strong stopping power, essential for performance riding.
Lighting:
Full lighting system including headlight, taillight, brake light, and turn signals for visibility.
Passive Features
Chassis Design:
Aluminum alloy twin-spar frame for rigidity and stability, contributing to predictable handling.
Ergonomics:
Sportbike riding position, designed for control and rider connection to the machine. Manual will cover adjustments.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle instrumentation: speedometer, tachometer, odometer, turn signal indicators, engine warning light).
Driver Assistance
Rider Aids:
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.
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