Aprilia RS125 Motorcycle Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Vehicle Type: Motorcycle Manual Product Name: Aprilia RS125 Motorcycle Workshop Service Repair Manual Download 👋 Introduction Market Position Positioning: The Aprilia RS125 is a well-regarded entry-level sportbike, known for its race-inspired styling and performance for its class, appealing to younger riders and those seeking a lightweight, agile machine. This manual supports enthusiasts and mechanics in maintaining and repairing these iconic motorcycles. Competitive Analysis Competitors: Competes with other 125cc sportbikes such as the Yamaha YZF-R125, Honda CBR125R, and KTM RC 125, offering a distinct Italian flair and often a more potent two-stroke engine in earlier generations. Key Features Features: Race-derived chassis and suspension, sharp aerodynamic styling, high-revving two-stroke engine (in most iterations), and a potent braking system for its class. Manual Value Proposition Value: Provides crucial, detailed information for owners and technicians to perform accurate maintenance, troubleshooting, and repairs, thereby preserving the performance and longevity of the Aprilia RS125. 📋 Manual Details Coverage Areas Engine: True Transmission: True Fuel System: True Ignition System: True Cooling System: True Exhaust System: True Chassis: True Suspension Front: True Suspension Rear: True Brakes Front: True Brakes Rear: True Electrical System: True Lighting System: True Instrumentation: True Bodywork And Fairings: True Troubleshooting: True Maintenance Schedule: True Page Count Estimated Pages: Comprehensive (exact number not specified, but implies extensive coverage) Manual Type Type: Workshop Service Repair Manual Language Language: English (implied by product description) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Overhaul: Complete engine disassembly, inspection, and reassembly procedures for the 125cc two-stroke engine. Carburetion: Detailed explanation of carburetor operation, adjustment, cleaning, and rebuilding for models equipped with Dell'Orto carburetors (e.g., PHBH 28, VHSB 34). Exhaust Tuning: Information on expansion chamber design principles and tuning for optimal performance. Transmission And Clutch: Procedures for clutch inspection, adjustment, and replacement, as well as gearbox disassembly and assembly. Suspension Tuning: Specifications for fork oil levels, damping adjustments, and rear shock preload settings. Electrical Diagnostics: Wiring diagrams for various model years and electrical systems, including ignition, lighting, and starting circuits. Frame And Bodywork: Instructions for fairing removal, installation, and minor bodywork repairs. Procedures Included Scheduled Maintenance: Routine service tasks such as oil changes, filter replacements, spark plug servicing, and chain adjustment. Troubleshooting Guides: Step-by-step diagnostic procedures for common starting, running, and electrical issues. Rebuild Instructions: Detailed guides for rebuilding major components like the engine, gearbox, and suspension forks. Component Replacement: Instructions for replacing wear items and common failure points like brake pads, clutch plates, and wheel bearings. Calibration And Adjustment: Procedures for adjusting the clutch, throttle, brakes, and ignition timing. Technical Depth Depth: Comprehensive: Covers basic maintenance to complete engine and chassis rebuilds, including in-depth diagnostics and specifications. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Quality: High-resolution, illustrated with clear diagrams and images. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder with reed valve induction (typical for most RS125 variants). Some later models might have variations. Displacement: 124.8 cc (approximate, varies slightly by specific model year) Bore X Stroke: Typically 54 mm x 54.5 mm (specific values may vary) Compression Ratio: Around 11.5:1 to 12.8:1 (varies by model and tuning) Power Output: Ranges from approximately 25 hp to 33 hp at the crank, depending on model year, emissions regulations, and tuning. Restricted versions for learner riders exist. Torque: Approximately 16-18 Nm (varies by model year and tuning) Performance Top Speed: Typically around 140-155 km/h (87-96 mph), depending on rider, conditions, and model variant. Acceleration: Capable of 0-100 km/h (0-62 mph) in approximately 7-9 seconds. Fuel System Fuel Delivery: Carburetor (e.g., Dell'Orto PHBH 28 AS or VHSB 34 LD on later models) Fuel Type: Unleaded gasoline, minimum 95 RON (octane rating may vary based on specific engine tuning). Oil Mixing: Automatic oil injection system for two-stroke engine oil. 🔧 Transmission Standard Type: 6-speed constant mesh sequential gearbox Features Clutch: Wet multi-plate clutch, cable-operated Final Drive: O-ring sealed chain drive 📐 Dimensions Exterior Length: Approximately 1950 mm (varies by model year) Width: Approximately 740 mm (varies by model year) Height: Approximately 1135 mm (varies by model year) Weights Dry Weight: Approximately 130-135 kg (dry weight, varies by model year) Fuel Tank Capacity: Typically 12-13 liters 🛡️ Safety Features Ratings Type: Motorcycle safety standards, not typically rated by car-centric safety organizations. Active Features Brakes: Disc brakes front and rear. Front typically a dual-piston caliper with a large diameter disc (e.g., 320mm), rear a single-piston caliper with a smaller disc (e.g., 210mm). ABS was not standard on most earlier models. Tires: Sport-biased tire fitment, crucial for grip and handling. Passive Features Frame: Aluminum twin-spar frame for rigidity and light weight. Lighting: Halogen headlights for illumination, LED taillight...
Aprilia RS125 Motorcycle Workshop Service Repair Manual Download
👋 Introduction
Market Position
Positioning:
The Aprilia RS125 is a well-regarded entry-level sportbike, known for its race-inspired styling and performance for its class, appealing to younger riders and those seeking a lightweight, agile machine. This manual supports enthusiasts and mechanics in maintaining and repairing these iconic motorcycles.
Competitive Analysis
Competitors:
Competes with other 125cc sportbikes such as the Yamaha YZF-R125, Honda CBR125R, and KTM RC 125, offering a distinct Italian flair and often a more potent two-stroke engine in earlier generations.
Key Features
Features:
Race-derived chassis and suspension, sharp aerodynamic styling, high-revving two-stroke engine (in most iterations), and a potent braking system for its class.
Manual Value Proposition
Value:
Provides crucial, detailed information for owners and technicians to perform accurate maintenance, troubleshooting, and repairs, thereby preserving the performance and longevity of the Aprilia RS125.
📋 Manual Details
Coverage Areas
Engine:
True
Transmission:
True
Fuel System:
True
Ignition System:
True
Cooling System:
True
Exhaust System:
True
Chassis:
True
Suspension Front:
True
Suspension Rear:
True
Brakes Front:
True
Brakes Rear:
True
Electrical System:
True
Lighting System:
True
Instrumentation:
True
Bodywork And Fairings:
True
Troubleshooting:
True
Maintenance Schedule:
True
Page Count
Estimated Pages:
Comprehensive (exact number not specified, but implies extensive coverage)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English (implied by product description)
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Overhaul:
Complete engine disassembly, inspection, and reassembly procedures for the 125cc two-stroke engine.
Carburetion:
Detailed explanation of carburetor operation, adjustment, cleaning, and rebuilding for models equipped with Dell'Orto carburetors (e.g., PHBH 28, VHSB 34).
Exhaust Tuning:
Information on expansion chamber design principles and tuning for optimal performance.
Transmission And Clutch:
Procedures for clutch inspection, adjustment, and replacement, as well as gearbox disassembly and assembly.
Suspension Tuning:
Specifications for fork oil levels, damping adjustments, and rear shock preload settings.
Electrical Diagnostics:
Wiring diagrams for various model years and electrical systems, including ignition, lighting, and starting circuits.
Frame And Bodywork:
Instructions for fairing removal, installation, and minor bodywork repairs.
Procedures Included
Scheduled Maintenance:
Routine service tasks such as oil changes, filter replacements, spark plug servicing, and chain adjustment.
Troubleshooting Guides:
Step-by-step diagnostic procedures for common starting, running, and electrical issues.
Rebuild Instructions:
Detailed guides for rebuilding major components like the engine, gearbox, and suspension forks.
Component Replacement:
Instructions for replacing wear items and common failure points like brake pads, clutch plates, and wheel bearings.
Calibration And Adjustment:
Procedures for adjusting the clutch, throttle, brakes, and ignition timing.
Technical Depth
Depth:
Comprehensive: Covers basic maintenance to complete engine and chassis rebuilds, including in-depth diagnostics and specifications.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable PDF for efficient information retrieval.
Print Quality
Quality:
High-resolution, illustrated with clear diagrams and images.
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, two-stroke, single-cylinder with reed valve induction (typical for most RS125 variants). Some later models might have variations.
Displacement:
124.8 cc (approximate, varies slightly by specific model year)
Bore X Stroke:
Typically 54 mm x 54.5 mm (specific values may vary)
Compression Ratio:
Around 11.5:1 to 12.8:1 (varies by model and tuning)
Power Output:
Ranges from approximately 25 hp to 33 hp at the crank, depending on model year, emissions regulations, and tuning. Restricted versions for learner riders exist.
Torque:
Approximately 16-18 Nm (varies by model year and tuning)
Performance
Top Speed:
Typically around 140-155 km/h (87-96 mph), depending on rider, conditions, and model variant.
Acceleration:
Capable of 0-100 km/h (0-62 mph) in approximately 7-9 seconds.
Fuel System
Fuel Delivery:
Carburetor (e.g., Dell'Orto PHBH 28 AS or VHSB 34 LD on later models)
Fuel Type:
Unleaded gasoline, minimum 95 RON (octane rating may vary based on specific engine tuning).
Oil Mixing:
Automatic oil injection system for two-stroke engine oil.
🔧 Transmission
Standard
Type:
6-speed constant mesh sequential gearbox
Features
Clutch:
Wet multi-plate clutch, cable-operated
Final Drive:
O-ring sealed chain drive
📐 Dimensions
Exterior
Length:
Approximately 1950 mm (varies by model year)
Width:
Approximately 740 mm (varies by model year)
Height:
Approximately 1135 mm (varies by model year)
Weights
Dry Weight:
Approximately 130-135 kg (dry weight, varies by model year)
Fuel Tank Capacity:
Typically 12-13 liters
🛡️ Safety Features
Ratings
Type:
Motorcycle safety standards, not typically rated by car-centric safety organizations.
Active Features
Brakes:
Disc brakes front and rear. Front typically a dual-piston caliper with a large diameter disc (e.g., 320mm), rear a single-piston caliper with a smaller disc (e.g., 210mm). ABS was not standard on most earlier models.
Tires:
Sport-biased tire fitment, crucial for grip and handling.
Passive Features
Frame:
Aluminum twin-spar frame for rigidity and light weight.
Lighting:
Halogen headlights for illumination, LED taillight on later models.
💡 Technology Features
Infotainment
System:
Basic analog or digital instrument cluster displaying speedometer, tachometer, odometer, trip meter, and warning lights. No advanced infotainment system.
Driver Assistance
Features:
No advanced driver-assistance systems (ADAS) typical of modern cars. Focus is on rider feedback and control.
Connectivity
Features:
No Bluetooth or smartphone connectivity. Basic electrical system for ignition, lights, and instrumentation.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 km or annually, depending on usage. Two-stroke oil reservoir top-up as needed.
Spark Plug:
Inspection every 3,000-4,000 km, replacement as needed.
Air Filter:
Inspection and cleaning every 3,000-5,000 km, replacement as needed.
Chain Cleaning Lubrication:
Every 500-1,000 km and after riding in wet conditions.
Brake Fluid Flush:
Every 2 years or as per manual recommendations.
Coolant Flush:
Every 2-3 years or as per manual recommendations.
Fluid Specifications
Engine Oil Type:
N/A (Two-stroke engine, uses pre-mix or automatic injection of two-stroke oil)
Two Stroke Oil:
High-quality JASO FD or API TC certified two-stroke motorcycle oil (specific grade recommended by Aprilia).
Coolant:
Ethylene glycol-based antifreeze with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 4 brake fluid.
Fork Oil:
Specific viscosity and quantity (e.g., SAE 5W or 7.5W, specified volume per fork leg).
Known Issues
Common Issues:
Carburetor jetting sensitivity to altitude and temperature, reed valve wear, exhaust port carbon buildup, clutch wear, and potential electrical gremlins common in older motorcycles.
Two Stroke Maintenance:
Requires regular decarbonization of the exhaust port and head, and diligent attention to the oil injection system.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia has a rich history in motorsport, particularly in Grand Prix racing, often focusing on performance-oriented motorcycles. The RS line embodies this racing heritage.
Model Evolution
Evolution:
The RS125 has undergone several iterations since its introduction in the early 1990s, with styling updates, engine modifications (including stricter emissions compliance and potential electronic fuel injection in very late or specific markets), and suspension improvements to maintain its competitiveness and appeal.
Production
Manufacturing Origin:
Italy
Production Years:
Produced from approximately 1994 to the present, with significant updates and variations across different markets and model years.
🏆 Awards & Recognition
Recognitions
Awards:
While specific awards for the RS125 itself may not be widely documented, the model has consistently been praised by motorcycle publications for its class-leading performance, handling, and race-inspired styling, especially during its peak production years.
Ratings
Owner Satisfaction:
Generally high owner satisfaction for those who appreciate its sporty nature and two-stroke character, with a dedicated enthusiast following.