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Aprilia RS125 Service Repair Workshop Manual 93-02

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Years Covered: 1993-2002 Codes Manual Product Code: N/A (provided as product name) Vehicle Chassis Codes: RT (early models), AP0 (later models - indicative) 👋 Introduction Market Position Category: Lightweight Sportbike / Two-Stroke Performance Target Audience: Enthusiasts, DIY mechanics, performance tuners, and owners seeking in-depth maintenance and repair knowledge. Competitive Analysis Segment: Competed with other 125cc sportbikes of its era, known for its sharp handling and potent two-stroke engine. Differentiation: Often lauded for its race-replica styling and aggressive performance characteristics for its displacement. Key Features Manual Value Proposition: Vehicle-specific, technician-level information for comprehensive DIY maintenance and repair, covering all models and repairs A-Z. Vehicle Appeal: The RS125 is a highly regarded 125cc two-stroke sportbike known for its potent engine and agile chassis, making it a popular choice for young riders and track enthusiasts. 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair Workshop Manual Model Coverage: All RS125 Models (1993-2002) Repair Scope: A-Z Repairs Page Count Estimated Page Count: 300-500 pages (typical for this era and scope) Manual Type Type: Service and Repair Workshop Manual Language Language: English Format Format: Digital Download (PDF implied) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, top-end rebuild (cylinder, piston, head), bottom-end rebuild (crankshaft, connecting rod, bearings), lubrication system, cooling system (radiator, water pump, thermostat), fuel system (carburetor tuning, jetting, fuel lines), ignition system (CDI, spark plug, coil), exhaust system. Transmission: Gearbox disassembly and reassembly, clutch inspection and replacement, gear selection mechanism, shift drum and forks, transmission bearings and seals. Chassis And Frame: Frame inspection, steering head bearing replacement, swingarm maintenance, rear shock absorber adjustment and overhaul, front fork overhaul (oil change, seal replacement). Brakes: Front and rear brake caliper overhaul, brake pad replacement, brake disc inspection, brake line bleeding, master cylinder service. Electrical System: Wiring diagrams for all models, lighting system, battery, starter motor, charging system (alternator, regulator/rectifier), instrumentation, switches, fuses. Bodywork And Fairings: Fairing removal and installation, seat, fuel tank, fenders, graphics, general bodywork repair. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, spark plug checks, coolant checks, brake fluid changes, carburetor cleaning. Diagnostics: Troubleshooting guides for common issues, fault diagnosis for engine performance, electrical problems, and braking system issues. Repair: Step-by-step repair procedures for all major components and systems, including detailed disassembly and reassembly instructions. Special Tools: Identification and usage of specific tools required for certain repairs and adjustments. Technical Depth Depth: Comprehensive (from basic maintenance to complete engine rebuilds and advanced diagnostics). Diagnostic Procedures: Detailed diagnostic trees and symptom-based troubleshooting. Specification Tables: Extensive tables of torque values, clearances, fluid capacities, and electrical resistance. 📊 Manual Specifications File Format Format: PDF (common for digital downloads) Searchability: Likely text-searchable PDF (standard for reputable manuals) Print Quality Quality: High-resolution scans or original digital files ensuring clear diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder Displacement: 124.8 cc Bore X Stroke: 54 mm x 54.5 mm (typical) Compression Ratio: Approx. 8.4:1 to 11.5:1 (depending on variant and tuning) Power Delivery: Typically features an aggressive powerband characteristic of performance two-strokes, often with a powervalve system. Performance Horsepower Output: Approx. 31-34 HP (at crankshaft, depending on market and specific tune) Torque Output: Approx. 20-22 Nm (at crankshaft) Fuel System Carburetion: Dell'Orto PHBH 28, PHBH 30, or VHSD 34 (depending on year and market) with electronic oil injection (Autolube). Fuel Type: Unleaded gasoline (95 RON recommended), premixed with 2-stroke oil (or via autolube system). Ignition System Ignition Type: Digital CDI (Capacitor Discharge Ignition) Cooling System Type: Liquid-cooled Lubrication System: Autolube (separate oil tank and pump) or pre-mix, depending on model variant and year. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Optional Optional Gearbox: N/A (standard 6-speed) Features Clutch Type: Wet, multi-plate, cable-operated Final Drive: Chain drive Gear Ratios Ratios: Specific gear ratios will be detailed in the manual, crucial for performance tuning. Fluid Specifications Transmission Oil: Refer to manual for specific API GL-4 or GL-5, SAE 80W/90 gear oil (or specific Aprilia recommendation). 📐 Dimensions Exterior Length: Approx. 1945 mm (varies slightly by year) Width: Approx. 700 mm (at handlebars) Height: Approx. 1135 mm (at handlebars) Wheelbase: Approx. 1345 mm Weights Dry Weight: Approx. 132 kg Wet Weight: Approx. 145 kg (with fluids) Fuel Tank Capacity: Approx. 12 Liters (including 2-liter reserve) Wheels And Tires Front Tire Size: 110/70-17 (common) Rear Tire Size: 150/60-17 (common) Wheel Type: Alloy wheels Wheelbase Material: Aluminum alloy 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety ratings not standardized in the same way as cars). Active Features Braking System: Hydraulic disc brakes front and rear. Typically a dual-piston caliper front and single-piston rear. Lighting: Halogen headlight, taillight, turn signals. Passive Features Chassis Design: Steel twin-spar frame, providing rigidity and handling....
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Aprilia RS125 Service Repair Workshop Manual 93-02
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Years Covered:
1993-2002
Codes
Manual Product Code:
N/A (provided as product name)
Vehicle Chassis Codes:
RT (early models), AP0 (later models - indicative)
👋 Introduction
Market Position
Category:
Lightweight Sportbike / Two-Stroke Performance
Target Audience:
Enthusiasts, DIY mechanics, performance tuners, and owners seeking in-depth maintenance and repair knowledge.
Competitive Analysis
Segment:
Competed with other 125cc sportbikes of its era, known for its sharp handling and potent two-stroke engine.
Differentiation:
Often lauded for its race-replica styling and aggressive performance characteristics for its displacement.
Key Features
Manual Value Proposition:
Vehicle-specific, technician-level information for comprehensive DIY maintenance and repair, covering all models and repairs A-Z.
Vehicle Appeal:
The RS125 is a highly regarded 125cc two-stroke sportbike known for its potent engine and agile chassis, making it a popular choice for young riders and track enthusiasts.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service Repair Workshop Manual
Model Coverage:
All RS125 Models (1993-2002)
Repair Scope:
A-Z Repairs
Page Count
Estimated Page Count:
300-500 pages (typical for this era and scope)
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF implied)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, top-end rebuild (cylinder, piston, head), bottom-end rebuild (crankshaft, connecting rod, bearings), lubrication system, cooling system (radiator, water pump, thermostat), fuel system (carburetor tuning, jetting, fuel lines), ignition system (CDI, spark plug, coil), exhaust system.
Transmission:
Gearbox disassembly and reassembly, clutch inspection and replacement, gear selection mechanism, shift drum and forks, transmission bearings and seals.
Chassis And Frame:
Frame inspection, steering head bearing replacement, swingarm maintenance, rear shock absorber adjustment and overhaul, front fork overhaul (oil change, seal replacement).
Brakes:
Front and rear brake caliper overhaul, brake pad replacement, brake disc inspection, brake line bleeding, master cylinder service.
Electrical System:
Wiring diagrams for all models, lighting system, battery, starter motor, charging system (alternator, regulator/rectifier), instrumentation, switches, fuses.
Bodywork And Fairings:
Fairing removal and installation, seat, fuel tank, fenders, graphics, general bodywork repair.
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, spark plug checks, coolant checks, brake fluid changes, carburetor cleaning.
Diagnostics:
Troubleshooting guides for common issues, fault diagnosis for engine performance, electrical problems, and braking system issues.
Repair:
Step-by-step repair procedures for all major components and systems, including detailed disassembly and reassembly instructions.
Special Tools:
Identification and usage of specific tools required for certain repairs and adjustments.
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine rebuilds and advanced diagnostics).
Diagnostic Procedures:
Detailed diagnostic trees and symptom-based troubleshooting.
Specification Tables:
Extensive tables of torque values, clearances, fluid capacities, and electrical resistance.
📊 Manual Specifications
File Format
Format:
PDF (common for digital downloads)
Searchability:
Likely text-searchable PDF (standard for reputable manuals)
Print Quality
Quality:
High-resolution scans or original digital files ensuring clear diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, two-stroke, single-cylinder
Displacement:
124.8 cc
Bore X Stroke:
54 mm x 54.5 mm (typical)
Compression Ratio:
Approx. 8.4:1 to 11.5:1 (depending on variant and tuning)
Power Delivery:
Typically features an aggressive powerband characteristic of performance two-strokes, often with a powervalve system.
Performance
Horsepower Output:
Approx. 31-34 HP (at crankshaft, depending on market and specific tune)
Torque Output:
Approx. 20-22 Nm (at crankshaft)
Fuel System
Carburetion:
Dell'Orto PHBH 28, PHBH 30, or VHSD 34 (depending on year and market) with electronic oil injection (Autolube).
Fuel Type:
Unleaded gasoline (95 RON recommended), premixed with 2-stroke oil (or via autolube system).
Ignition System
Ignition Type:
Digital CDI (Capacitor Discharge Ignition)
Cooling System
Type:
Liquid-cooled
Lubrication
System:
Autolube (separate oil tank and pump) or pre-mix, depending on model variant and year.
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Optional
Optional Gearbox:
N/A (standard 6-speed)
Features
Clutch Type:
Wet, multi-plate, cable-operated
Final Drive:
Chain drive
Gear Ratios
Ratios:
Specific gear ratios will be detailed in the manual, crucial for performance tuning.
Fluid Specifications
Transmission Oil:
Refer to manual for specific API GL-4 or GL-5, SAE 80W/90 gear oil (or specific Aprilia recommendation).
📐 Dimensions
Exterior
Length:
Approx. 1945 mm (varies slightly by year)
Width:
Approx. 700 mm (at handlebars)
Height:
Approx. 1135 mm (at handlebars)
Wheelbase:
Approx. 1345 mm
Weights
Dry Weight:
Approx. 132 kg
Wet Weight:
Approx. 145 kg (with fluids)
Fuel Tank Capacity:
Approx. 12 Liters (including 2-liter reserve)
Wheels And Tires
Front Tire Size:
110/70-17 (common)
Rear Tire Size:
150/60-17 (common)
Wheel Type:
Alloy wheels
Wheelbase Material:
Aluminum alloy
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety ratings not standardized in the same way as cars).
Active Features
Braking System:
Hydraulic disc brakes front and rear. Typically a dual-piston caliper front and single-piston rear.
Lighting:
Halogen headlight, taillight, turn signals.
Passive Features
Chassis Design:
Steel twin-spar frame, providing rigidity and handling.
Suspension:
Upside-down (USD) telescopic front forks, monoshock rear suspension (Pro-Lever or similar linkage).
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer, speedometer, odometer, trip meter, coolant temperature warning light, neutral indicator light, oil level warning light.
Driver Assistance
ABS:
N/A (ABS was not a common feature on 125cc sportbikes of this era).
Connectivity
Bluetooth:
N/A
Performance Enhancing Tech
Powervalve:
The Rotax engine typically features an exhaust powervalve system (like the RAVE system) to improve torque at lower RPMs and power at higher RPMs. Manual will cover its operation and maintenance.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual (typically every 3,000-5,000 km or annually for engine oil/autolube system).
Spark Plug Replacement:
Refer to manual (typical interval: 5,000-10,000 km, depending on plug type).
Coolant Flush:
Refer to manual (typically every 2 years).
Brake Fluid Change:
Refer to manual (typically every 1-2 years).
Fluid Specifications
Engine Oil:
Refer to manual for specific 2-stroke oil (e.g., for autolube or premix - high quality synthetic recommended).
Coolant:
Ethylene glycol-based antifreeze, mixed 50/50 with distilled water. Refer to manual for specific type.
Brake Fluid:
DOT 4 (or DOT 3 if specified for older models) hydraulic brake fluid.
Known Issues
Common Wear Items:
Piston rings, exhaust power valve mechanisms, clutch plates, fork seals, wheel bearings, carburetor jets.
Performance Degradation:
Two-stroke engines require regular decarbonization of the exhaust and cylinder head to maintain optimal performance. Carburetor jets can clog if fuel is not fresh or if oil is of poor quality.
Electrical Gremlins:
Wiring harness connections, regulator/rectifier failure, and CDI unit issues can occur with age and vibration. Manual's wiring diagrams are critical.
Technical Specs In Manual
Torque Values:
Detailed torque specifications for all critical fasteners (engine, chassis, brakes) are essential for correct assembly.
Clearances:
Piston ring gap, valve clearances (if applicable for 4-stroke variants, though RS125 is 2-stroke), chain slack, steering head bearing adjustment.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer with a strong racing heritage, particularly in smaller displacement categories.
Racing Influence:
The RS125 has a direct lineage from Aprilia's successful Grand Prix racing machines, embodying their sportbike philosophy.
Model Evolution
Development:
The RS125 was developed as a performance-oriented 125cc sportbike, aiming to offer a close-to-race experience for road use.
Updates Within Range:
Models from 1993 to 2002 saw incremental updates, including carburetor changes, styling revisions, and potential improvements to the Rotax engine's tuning and power delivery.
Production
Manufacturing Location:
Italy
Production Period:
The RS125 platform has a long production run, with the 1993-2002 period representing a significant phase of its development and popularity.
🏆 Awards & Recognition
Recognitions
Class Awards:
The RS125 was a highly popular and critically acclaimed model in its class during its production run, often praised for its performance and handling.
Ratings
Owner Satisfaction:
High owner satisfaction for those who appreciated its potent 2-stroke character and sharp dynamics.
Certifications
Emissions Compliance:
Models from this era would have been subject to the emissions standards of their respective markets at the time of sale, covered by the manual's technical data.
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