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Aprilia RS 125 1996 All Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 1996 Generation Generation Code: First Generation (Rotax 122) Codes Vin Prefix: ZAPG VLA 👋 Introduction Market Position Segment: Lightweight sportbike segment Target Audience: Enthusiast riders, track day participants, DIY mechanics Competitive Analysis Competitors: Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125 (though some models post-date this manual) Key Features Vehicle Philosophy: Performance-oriented, race-inspired styling, lightweight handling Manual Benefit: Empowers owners to perform maintenance and repairs confidently, preserving performance and resale value 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for Aprilia RS 125 (1996 model year) Secondary Coverage: Includes maintenance, diagnostics, troubleshooting, and component replacement Page Count Estimated Pages: 300-400 Manual Type Type: Service/Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Two-stroke, single-cylinder Rotax 122 engine: Top-end rebuild, bottom-end service, cooling system, lubrication system, ignition system (CDI), carburetor tuning (Dell'Orto PHBH 28) Transmission: Six-speed gearbox: Clutch operation and adjustment, gear shifting mechanism, transmission oil change and specifications Chassis: Frame inspection and repair, suspension (front telescopic forks, rear monoshock absorber) servicing and adjustments, steering head bearing replacement Brakes: Front and rear disc brake systems: Hydraulic system bleeding, pad replacement, caliper servicing, master cylinder inspection Electrical: Wiring diagrams, lighting system, battery maintenance, starter system, charging system (alternator), instrument cluster troubleshooting Fuel System: Fuel tank, fuel lines, fuel filter, carburetor reassembly and jetting Cooling System: Liquid cooling system: Radiator inspection and cleaning, coolant type and capacity, thermostat operation Bodywork: Fairing removal and installation, seat assembly, fuel tank mounting, body panel repair and alignment Procedures Included Routine Maintenance: Oil change, spark plug replacement, air filter cleaning, chain adjustment, brake fluid flush, coolant flush Troubleshooting: Diagnostic charts for common engine, electrical, and mechanical issues, symptom-based troubleshooting Rebuilds: Engine top-end and bottom-end rebuild procedures, carburetor overhaul, brake caliper rebuild Diagnostics: Electrical system testing, ignition timing checks, compression testing Adjustments: Carburetor idle speed and mixture adjustment, clutch cable free play, brake lever reach Replacement: Component replacement for all major mechanical and electrical parts Technical Depth Depth Level: Comprehensive, suitable for home mechanics and professional technicians Detail Level: Includes torque specifications, clearance measurements, and step-by-step instructions with diagrams 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Likely text-searchable if digitally generated Print Quality Resolution: High resolution for clear diagrams and text Binding Type Binding For Download: N/A (Digital Download) Paper Type Paper For Download: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Rotax 122 Liquid-Cooled, Two-Stroke, Single-Cylinder Displacement: 124.8 cc (7.6 cubic inches) Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 12.5:1 Ignition: Electronic CDI (Capacitor Discharge Ignition) Cooling System: Liquid-cooled, pressurized with thermostat Performance Horsepower: Approx. 30-34 hp (depending on market and restrictions) Torque: Approx. 20-22 Nm Fuel System Carburetor: Dell'Orto PHBH 28 FD (or similar) Fuel Type: Unleaded Gasoline (95 RON recommended) Fuel Mixture: Automatic oil injection (separate oil reservoir) 🔧 Transmission Standard Transmission Type: Constant Mesh, 6-Speed Sequential Manual Clutch: Wet Multi-Plate Clutch, Cable Operated Features Gear Ratios: Refer to manual for specific gear ratios (e.g., 1st: 2.5, 2nd: 1.78, 3rd: 1.38, 4th: 1.14, 5th: 0.95, 6th: 0.84) Final Drive: Chain Drive (520 pitch) Transmission Oil: API GL-3/GL-4, SAE 75W-90 or SAE 10W-40 (check manual for exact spec) 📐 Dimensions Exterior Length: Approx. 1990 mm (78.3 in) Width: Approx. 710 mm (28.0 in) Height: Approx. 1080 mm (42.5 in) Wheelbase: Approx. 1375 mm (54.1 in) Weights Dry Weight: Approx. 126 kg (277.8 lbs) Gross Vehicle Weight Rating: Refer to manual Fuel Tank Capacity: Approx. 12 liters (3.2 gal) 🛡️ Safety Features Ratings Safety Standards: CE compliant (European standards) Active Features Braking System: Dual Disc Front Brake (e.g., 290mm disc, 4-piston caliper), Single Disc Rear Brake (e.g., 240mm disc, 2-piston caliper) Suspension Features: Adjustable front forks (pre-load), adjustable rear monoshock absorber (pre-load, rebound damping) Passive Features Lighting: Halogen Headlight, LED Taillight Tires: Front: 110/70-17, Rear: 150/60-17 (typical sizes) 💡 Technology Features Infotainment Instrument Cluster: Analog Tachometer, Speedometer, Odometer, Trip Meter, Coolant Temperature Gauge, Warning Lights (Oil, Neutral, Turn Signals, High Beam) Driver Assistance ABS: Not available on this model Connectivity Connectivity Features: None (analog system) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km (or as per manual, check clutch wear) Spark Plug Replacement: Every 5,000-8,000 km (use correct heat range) Air Filter Cleaning: Every 2,000-3,000 km, replace every 10,000 km Chain Lubrication Adjustment: Every 500-1000 km Coolant Flush: Every 2 years Brake Fluid Flush: Every 2 years Fluid Specifications Engine Oil: 2-stroke pre-mix oil, specifically for high-performance racing applications (e.g., Motul 800, Castrol TTS) Cooling System Coolant: Ethylene Glycol based coolant, 50/50 mix with distilled water Brake Fluid: DOT 4 Transmission Oil: API GL-3/GL-4, SAE 75W-90 or SAE 10W-40 (refer to manual) Known Issues Engine Wear: Potential for piston and cylinder wear due to high-revving nature; regular top-end...
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Aprilia RS 125 1996 All Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Year:
1996
Generation
Generation Code:
First Generation (Rotax 122)
Codes
Vin Prefix:
ZAPG VLA
👋 Introduction
Market Position
Segment:
Lightweight sportbike segment
Target Audience:
Enthusiast riders, track day participants, DIY mechanics
Competitive Analysis
Competitors:
Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125 (though some models post-date this manual)
Key Features
Vehicle Philosophy:
Performance-oriented, race-inspired styling, lightweight handling
Manual Benefit:
Empowers owners to perform maintenance and repairs confidently, preserving performance and resale value
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service and repair for Aprilia RS 125 (1996 model year)
Secondary Coverage:
Includes maintenance, diagnostics, troubleshooting, and component replacement
Page Count
Estimated Pages:
300-400
Manual Type
Type:
Service/Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Two-stroke, single-cylinder Rotax 122 engine: Top-end rebuild, bottom-end service, cooling system, lubrication system, ignition system (CDI), carburetor tuning (Dell'Orto PHBH 28)
Transmission:
Six-speed gearbox: Clutch operation and adjustment, gear shifting mechanism, transmission oil change and specifications
Chassis:
Frame inspection and repair, suspension (front telescopic forks, rear monoshock absorber) servicing and adjustments, steering head bearing replacement
Brakes:
Front and rear disc brake systems: Hydraulic system bleeding, pad replacement, caliper servicing, master cylinder inspection
Electrical:
Wiring diagrams, lighting system, battery maintenance, starter system, charging system (alternator), instrument cluster troubleshooting
Fuel System:
Fuel tank, fuel lines, fuel filter, carburetor reassembly and jetting
Cooling System:
Liquid cooling system: Radiator inspection and cleaning, coolant type and capacity, thermostat operation
Bodywork:
Fairing removal and installation, seat assembly, fuel tank mounting, body panel repair and alignment
Procedures Included
Routine Maintenance:
Oil change, spark plug replacement, air filter cleaning, chain adjustment, brake fluid flush, coolant flush
Troubleshooting:
Diagnostic charts for common engine, electrical, and mechanical issues, symptom-based troubleshooting
Rebuilds:
Engine top-end and bottom-end rebuild procedures, carburetor overhaul, brake caliper rebuild
Diagnostics:
Electrical system testing, ignition timing checks, compression testing
Adjustments:
Carburetor idle speed and mixture adjustment, clutch cable free play, brake lever reach
Replacement:
Component replacement for all major mechanical and electrical parts
Technical Depth
Depth Level:
Comprehensive, suitable for home mechanics and professional technicians
Detail Level:
Includes torque specifications, clearance measurements, and step-by-step instructions with diagrams
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable if digitally generated
Print Quality
Resolution:
High resolution for clear diagrams and text
Binding Type
Binding For Download:
N/A (Digital Download)
Paper Type
Paper For Download:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotax 122 Liquid-Cooled, Two-Stroke, Single-Cylinder
Displacement:
124.8 cc (7.6 cubic inches)
Bore X Stroke:
54 mm x 54.5 mm
Compression Ratio:
12.5:1
Ignition:
Electronic CDI (Capacitor Discharge Ignition)
Cooling System:
Liquid-cooled, pressurized with thermostat
Performance
Horsepower:
Approx. 30-34 hp (depending on market and restrictions)
Torque:
Approx. 20-22 Nm
Fuel System
Carburetor:
Dell'Orto PHBH 28 FD (or similar)
Fuel Type:
Unleaded Gasoline (95 RON recommended)
Fuel Mixture:
Automatic oil injection (separate oil reservoir)
🔧 Transmission
Standard
Transmission Type:
Constant Mesh, 6-Speed Sequential Manual
Clutch:
Wet Multi-Plate Clutch, Cable Operated
Features
Gear Ratios:
Refer to manual for specific gear ratios (e.g., 1st: 2.5, 2nd: 1.78, 3rd: 1.38, 4th: 1.14, 5th: 0.95, 6th: 0.84)
Final Drive:
Chain Drive (520 pitch)
Transmission Oil:
API GL-3/GL-4, SAE 75W-90 or SAE 10W-40 (check manual for exact spec)
📐 Dimensions
Exterior
Length:
Approx. 1990 mm (78.3 in)
Width:
Approx. 710 mm (28.0 in)
Height:
Approx. 1080 mm (42.5 in)
Wheelbase:
Approx. 1375 mm (54.1 in)
Weights
Dry Weight:
Approx. 126 kg (277.8 lbs)
Gross Vehicle Weight Rating:
Refer to manual
Fuel Tank Capacity:
Approx. 12 liters (3.2 gal)
🛡️ Safety Features
Ratings
Safety Standards:
CE compliant (European standards)
Active Features
Braking System:
Dual Disc Front Brake (e.g., 290mm disc, 4-piston caliper), Single Disc Rear Brake (e.g., 240mm disc, 2-piston caliper)
Suspension Features:
Adjustable front forks (pre-load), adjustable rear monoshock absorber (pre-load, rebound damping)
Passive Features
Lighting:
Halogen Headlight, LED Taillight
Tires:
Front: 110/70-17, Rear: 150/60-17 (typical sizes)
💡 Technology Features
Infotainment
Instrument Cluster:
Analog Tachometer, Speedometer, Odometer, Trip Meter, Coolant Temperature Gauge, Warning Lights (Oil, Neutral, Turn Signals, High Beam)
Driver Assistance
ABS:
Not available on this model
Connectivity
Connectivity Features:
None (analog system)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km (or as per manual, check clutch wear)
Spark Plug Replacement:
Every 5,000-8,000 km (use correct heat range)
Air Filter Cleaning:
Every 2,000-3,000 km, replace every 10,000 km
Chain Lubrication Adjustment:
Every 500-1000 km
Coolant Flush:
Every 2 years
Brake Fluid Flush:
Every 2 years
Fluid Specifications
Engine Oil:
2-stroke pre-mix oil, specifically for high-performance racing applications (e.g., Motul 800, Castrol TTS)
Cooling System Coolant:
Ethylene Glycol based coolant, 50/50 mix with distilled water
Brake Fluid:
DOT 4
Transmission Oil:
API GL-3/GL-4, SAE 75W-90 or SAE 10W-40 (refer to manual)
Known Issues
Engine Wear:
Potential for piston and cylinder wear due to high-revving nature; regular top-end rebuilds are crucial.
Carburetor Tuning:
Sensitivity to altitude and temperature; requires proper jetting and adjustment.
Electrical Reliability:
Older wiring can degrade; inspection of connections and grounds is recommended.
Exhaust Valve Operation:
Power valve (A.E.S. - Aprilia Exhaust System) can carbon up, affecting performance; requires periodic cleaning and inspection.
📚 Vehicle History
Brand Heritage
Company Origin:
Aprilia is an Italian motorcycle manufacturer founded in 1945, known for its racing heritage and sportbikes.
Model Evolution
Rs 125 Lineage:
The RS 125 has been a flagship model for Aprilia in the lightweight supersport class for decades, evolving through various engine and chassis updates.
1996 Updates:
This generation featured advanced chassis design and a potent Rotax engine, setting benchmarks for performance in its class.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Class Leader:
Consistently praised for performance and handling in the 125cc sportbike class during its production era.
Ratings
User Reviews:
Highly regarded by owners for its spirited performance, sharp looks, and track capability, often considered a step above its competitors.
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