Aprilia RS 125 1993-2006 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Years Covered: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Chassis Codes: RP, RW 👋 Introduction Market Position Segment: Lightweight sportbike, popular for track days, commuting, and beginner riders. Competitive Analysis Rivals: Yamaha YZF-R125 (later models), Honda CBR125R, Suzuki GSX-R125 (later models). Key Features Design: Aggressive styling inspired by larger Aprilia sportbikes, sharp lines, dual headlights. Performance Focus: High-revving 2-stroke engine, capable chassis, sporty ergonomics. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for all Aprilia RS 125 models from 1993 to 2006. Page Count Estimated Pages: 500+ Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF), potentially Printable 📖 Manual Coverage Systems Covered Engine: 2-stroke Rotax 122, 123 engine systems: disassembly, assembly, tuning, diagnostics, lubrication, cooling. Fuel System: Carburetor (Dell'Orto PHBH, VHSA/B), fuel injection (later models), fuel pump, fuel lines, oil injection system. Ignition System: CDI, electronic ignition, spark plugs, stator, rotor, wiring. Transmission: 6-speed sequential gearbox: clutch, gear selector, gearbox components, lubrication, troubleshooting. Chassis: Frame, swingarm, rear suspension (monoshock, linkage), front suspension (telescopic forks, e.g., Marzocchi, Paioli), steering head bearings. Brakes: Hydraulic disc brakes: front and rear calipers, master cylinders, brake lines, fluid specifications, bleeding procedures, rotor specifications. Electrical System: Wiring diagrams, lighting, starting system, charging system (alternator, battery), fuses, relays, instruments, sensors. Bodywork: Fairings, seat, fuel tank, fenders, mounting points, disassembly, reassembly. Wheels And Tires: Wheel types, bearing maintenance, tire fitment, pressures, balancing. Procedures Included Maintenance: Regular servicing, oil changes, filter replacements, chain adjustment, bolt torquing, battery care. Troubleshooting: Diagnostic charts for common issues, electrical faults, engine performance problems, starting difficulties. Engine Rebuild: Piston ring replacement, cylinder head work, crankshaft assembly, seals, gaskets. Suspension Service: Fork oil replacement, seal replacement, shock absorber adjustments. Brake System Overhaul: Caliper rebuild, master cylinder service, hose replacement. Carburetor Adjustment: Jetting, idle speed, mixture screw settings. Technical Depth Depth: Factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts. Diagnostics: In-depth diagnostic procedures, fault code interpretation (if applicable), resistance and voltage checks. Torque Specifications: Precise torque values for all critical fasteners across all systems. Schematics: Detailed electrical wiring diagrams and system schematics. 📊 Manual Specifications File Format Digital Quality: High-resolution, searchable PDF for easy navigation and information retrieval. Print Quality Print Readability: Designed for clear printing of all text, diagrams, and images. Binding Type Digital Format Advantage: Instant download, accessible on multiple devices, easily searchable. Paper Type Original Format Assumption: Likely printed on durable, high-quality paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 2-stroke, single-cylinder Displacement: 124.8 cc (approx.) Bore X Stroke: 54 mm x 54.5 mm (typical) Power Output: Approx. 30-35 HP (depending on market restrictions and specific year) Torque Output: Approx. 20-23 Nm (depending on market restrictions and specific year) Performance Redline: Approx. 10,000-11,000 RPM Fuel System Carburetor Standard: Dell'Orto PHBH 28 or VHSA/B 28 (variable by year/market) Fuel Type: Unleaded gasoline (95 RON recommended), 2-stroke oil for premix or oil injection system. Oil Type: High-quality 2-stroke synthetic engine oil meeting JASO FD or API TC specifications. 🔧 Transmission Standard Type: 6-speed manual, constant mesh Clutch Type: Wet multi-plate clutch Features Gear Ratios: Specific ratios detailed within the manual. Transmission Oil Type: API GL-4 or GL-5, SAE 75W/90 or 10W/40 (check manual for specific recommendation). 📐 Dimensions Exterior Length: Approx. 1940-1990 mm Width: Approx. 720-740 mm Height: Approx. 1050-1110 mm Weights Dry Weight: Approx. 130-140 kg Fuel Tank Capacity: Approx. 11-13 Liters Wheelbase: Approx. 1360-1370 mm 🛡️ Safety Features Ratings Crash Test Info: As a motorcycle, official crash test ratings like those for cars are not applicable. Safety relies on rider skill and adherence to road rules. Active Features Braking System: Dual disc front brake, single disc rear brake providing strong stopping power for its class. Lighting: Halogen headlamp for visibility, brake lights, turn signals. Passive Features Frame Construction: Sturdy perimeter frame designed for rigidity and rider feedback. 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, speedometer, odometer, trip meter, coolant temperature gauge, basic indicator lights. Driver Assistance ABS: ABS was generally not a standard feature on this model during its production run; available on some later specific versions perhaps. Connectivity Integrated Tech: Focus is on mechanical and electrical systems; no digital connectivity or advanced rider aids. 🔧 Maintenance Service Intervals Oil Change Engine: Recommended every 3,000-5,000 km or annually, refer to manual for specifics. Spark Plug Replacement: Recommended every 5,000-7,500 km, or as per manual's spark plug chart. Air Filter Cleaning: Check every 2,500 km, clean or replace as needed. Chain Lubrication: Lubricate every 500 km or after riding in wet conditions. Brake Fluid Flush: Recommended every 1-2 years. Fluid Specifications Coolant: Ethylene glycol based antifreeze coolant mixture (50% water, 50% coolant) – specific Aprilia or equivalent recommended. Fork Oil: Typically...