🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: 1994 Product Name: Aprilia RS125 RS 125 1994 Factory Service Repair Manual Download PDF 👋 Introduction Market Position Segment: Lightweight Sportbike Target Audience: Enthusiasts, mechanics, owners seeking in-depth maintenance information Competitive Analysis Competitors 1994: Yamaha TZR125, Suzuki RGV125, Cagiva Mito 125 Key Features Design: Aggressive styling, race-inspired ergonomics Performance Focus: High-revving two-stroke engine, agile handling 📋 Manual Details Coverage Areas All Systems: Yes Page Count Estimated Pages: Hundreds Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, troubleshooting, diagnosis Cooling System: Radiator, water pump, hoses, thermostat Fuel System: Carburetor (Dell'Orto PHBH 28 AS), fuel pump, fuel lines, tank Ignition System: CDI, spark plug, ignition coil, wiring Exhaust System: Expansion chamber, muffler, gaskets Transmission: Clutch, gearbox, lubrication, troubleshooting Chassis Frame: Frame inspection, welding, repairs Front Suspension: Telescopic forks (Marzocchi), seals, oil, springs, adjustments Rear Suspension: Monoshock (Monolever), linkage, shock absorber, adjustments Brakes Front: Caliper (2-piston), disc, master cylinder, hydraulic lines, bleeding Brakes Rear: Caliper (single-piston), disc, master cylinder, hydraulic lines, bleeding Wheels Tires: Rim inspection, bearing replacement, tire mounting, pressure Electrical System: Wiring diagrams, battery, charging system, lighting, horn, switches Bodywork Fairings: Fairing removal, installation, repair, decal placement Controls: Throttle, clutch, brake levers, footpegs, handlebar adjustments Torque Specifications: All critical fasteners listed Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, chain adjustment Troubleshooting: Diagnostic guides for common and uncommon issues Engine Rebuild: Piston, cylinder, crankshaft, seals, gaskets replacement Carburetor Tuning: Jetting, float height, idle adjustment Suspension Servicing: Fork seal replacement, shock absorber rebuild Brake System Maintenance: Pad replacement, caliper service, fluid bleeding Electrical Diagnostics: Fault finding using wiring diagrams Wheel Bearing Replacement: Front and rear wheel bearings Gearbox Overhaul: Gear removal, inspection, reassembly Technical Depth Depth: Comprehensive factory-level repair and maintenance 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Printable, allows for printing specific pages or the entire document Binding Type Binding Recommendation: N/A (Digital Download) Paper Type Paper Recommendation: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder, liquid-cooled, reed valve induction Displacement: 125 cc (124.8 cc) Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 12.5:1 (approx.) Performance Horsepower: Approximately 30-32 hp (variant dependent) Torque: Not readily specified, but designed for peak power delivery Fuel System Carburetor Model: Dell'Orto PHBH 28 AS Fuel Type: Unleaded gasoline (RON 95 or higher recommended) Oil Mixture: Automatic premix system (separate oil reservoir) Lubrication Engine Oil Type: API TC or JASO FD certified two-stroke motorcycle oil Gearbox Oil Type: API GL-4 SAE 75W-90 or 80W-90 transmission oil 🔧 Transmission Standard Transmission Type: 6-speed sequential manual Features Clutch Type: Wet, multi-plate Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1970 mm Width: Approx. 750 mm Height: Approx. 1140 mm Wheelbase: Approx. 1360 mm Weights Dry Weight: Approx. 120 kg Fuel Tank Capacity: Approx. 13 liters 🛡️ Safety Features Ratings Safety Certification: Not applicable (motorcycle) Active Features Braking System: Hydraulic disc brakes front and rear Passive Features Frame Construction: Aluminum twin-spar frame 💡 Technology Features Infotainment Infotainment System: None (Analog instrumentation: speedometer, tachometer, temperature gauge, indicator lights) 🔧 Maintenance Service Intervals Engine Oil Change: Check level frequently, top-up as needed. Change oil in gearbox every 6,000-10,000 km. Spark Plug Check: Every 3,000-5,000 km Air Filter Cleaning: Every 3,000-5,000 km (depending on conditions) Chain Lubrication Adjustment: Lubricate every 500-800 km, adjust slack as needed (typically 20-30mm) Brake Fluid Flush: Every 2 years Coolant Change: Every 2-3 years Fluid Specifications Engine Oil Capacity: N/A (Premix) Gearbox Oil Capacity: Approx. 0.75 liters Coolant Type: Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio) Known Issues Power Valve Sticking: Common on two-strokes, requires regular cleaning and lubrication. Carburetor Icing: Can occur in cold, humid conditions due to fuel vaporization. Rear Shock Wear: Original shocks can lose damping over time; rebuild or replacement may be necessary. Reed Valve Wear: Can lead to decreased performance; periodic inspection and replacement recommended. 📚 Vehicle History Brand Heritage Manufacturer: Aprilia is an Italian manufacturer of motorcycles, scooters, and mopeds, known for its racing pedigree. Model Evolution Rs125 Legacy: The RS125 model has a long and successful history, evolving from earlier models like the AF1. It became a staple in the 125cc sportbike class for decades. Production Production Era: The first generation of the RS125 began production in the early 1990s, with this 1994 model being part of its initial introduction. Manufacturing Location: Italy 🏆 Awards & Recognition Recognitions Awards: The Aprilia RS125, as a model line, has received numerous accolades in racing classes and is widely regarded as a benchmark for 125cc sportbikes.