Aprilia RS125 99-03 service repair manual full workshop

FOREWORD RS 125 FOREWORD 0 GENERAL INFORMATION 1 ROUTINE MAINTENANCE 2 LUBRICATION 3 FUEL SYSTEM 4 COOLING SYSTEM 5 ENGINE 6 CHASSIS 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING INFORMATION 9 0 - 1 http://manuals.magnamaniac.com

FOREWORD RS 125 SUMMARY 0.1. FOREWORD .................................................................................................................................... 3 0.1.1. FOREWORD ........................................................................................................................... 3 0.1.2. REFERENCE MANUALS ........................................................................................................ 4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS...................................................................... 5 0 - 2 http://manuals.magnamaniac.com

FOREWORD RS 125 0.1. FOREWORD 0.1.1. FOREWORD - This manual provides the information required for normal servicing. - This manual is intended for use by aprilia Dealers and their qualified mechanics. Certain information has been omitted intentionally, as this manual does not purport to provide a comprehensive treatise on mechanics. The persons who will use this manual must be fully conversant with the basics of mechanics and with the basic procedures of motorcycle repair. Repairing or inspecting a motorcycle when one does not possess such basic knowledge or training could result in improper servicing and make the motorcycle unsafe to ride. For the same reason, certain basic precautions have been omitted in the descriptions of repair and inspection procedures. Take special care to avoid damage to motorcycle components or injury to persons. aprilia s.p.a.'s mission is to constantly enhance the riding pleasure of final users through the on-going improvement of its products as well as of the relevant technical literature. All aprilia Points of Sale and Subsidiaries worldwide are kept updated on major engineering changes and modifications to repair procedures. Such changes and modifications are then reflected in the next release of the relevant manual. When in doubt about an inspection or repair procedure, please contact the aprilia CONSUMER SERVICE (A.C.S.) DEPARTMENT, who will be glad to provide full information on the procedure in question as well as on any updates or engineering changes affecting the motorcycle under consideration. aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual. All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted, are reserved in all countries. Any reference to products or services provided by outside suppliers is for information only and by no means binding, and implies no warranties or responsibilities as to the performance or use of any such products and/or services. For more detailed information, please read 0.1.2. Original release: november 2002 Produced and printed by: DECA s.r.l. via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy Tel. +39 - 0545 35235 Fax +39 - 0545 32844 E-mail: deca@decaweb.it www.decaweb.it for: aprilia s.p.a. via G. Galilei, 1 - 30033 Noale (VE) - Italy Tel. +39 – (0)41 58 29 111 Fax +39 – (0)41 44 10 54 www.aprilia.com www.serviceaprilia.com 0 - 3 http://manuals.magnamaniac.com

FOREWORD RS 125 0.1.2. REFERENCE MANUALS ENGINE WORKSHOP MANUALS aprilia part# (description) 8140133 (926) 8140134 (943) PARTS CATALOGUES aprilia part# (description) 340X ……… 993………… SPECIAL TOOLS CATALOGUES aprilia part# (description) 8202278 OWNER’S MANUALS aprilia part# (description) Model years 1993 8102260 Model years 1994 8102260 8102319 Model years 1995 8102476 8102530 8102543 Model years 1996 8102685 8102682 8102530 8102683 8102543 Model years 1997 8102685 8102682 8102683 8102530 8102543 8102752 8102753 Model years 1998 8102685 8102682 8102683 8102849 8102934 Model years 1999 8102821 8102937 8102938 8102939 Model years 2001 8202248 8102821 8102937 8102938 8102939 Model years 2002 8104465 8104466 8104467 8104468 0 - 4 http://manuals.magnamaniac.com

FOREWORD 0- 5 RS 125 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS # = number < = is less than > = is more than < = is less than or equal to > = is more than or equal to ~ = approximately f = infinite °C = degrees Celsius (centigrade) °F = degrees Fahrenheit ± = plus or minus a.c = alternated current A =ampere Ah =ampere per hour API = American Petroleum Institute HT = High Tension AV/DC = Anti-Vibration Double Countershaft bar = pressure measurement (1 bar =100 kPa) DC = Direct Current cu cm = cubic centimetres CO = carbon oxide CPU = Central Processing Unit DIN = German industrial standards (Deutsche Industrie Norm) DOHC = Double Overhead Camshaft ECU = Electronic Control Unit rpm = revolutions per minute HC = unburnt hydrocarbons ISC = Idle Speed Control ISO = International Standardization Organization kg = kilograms kgm = kilograms per metre (1 kgm =10 Nm) km = kilometres km/h = kilometres per hour k: = kiloOhm kPa = kiloPascal (1 kPa =0.01 bar) KS = clutch side (from the German "Kupplungseite") kW = kiloWatt l =litres LAP = racetrack lap LED = Light Emitting Diode LEFT SIDE =left side m/s = metres per second max = maximum mbar = millibar (1 mbar =0.1 kPa) mi = miles MIN = minimum MPH = miles per hour MS = flywheel side (from the German "Magnetoseite") M: = megaOhm N.A. = Not Available N.O.M.M. = Motor Octane Number N.O.R.M. = Research Octane Number Nm = Newton per metre (1 Nm =0.1 kgm) : =ohm PICK-UP BDC = Bottom Dead Centre TDC = Top Dead Centre PPC = Pneumatic Power Clutch RIGHT SIDE = right side SAE = Society of Automotive Engineers T.B.E.I. = crowned-head Allen screw T.C.E.I. = cheese-headed Allen screw http://manuals.magnamaniac.com

FOREWORD RS 125 T.E. =hexagonal head TEST = diagnostic check T.P. =flat head screw TSI = Twin Spark Ignition UPSIDE- DOWN = inverted fork V =volt W =watt Ø = Diameter 0 - 6 http://manuals.magnamaniac.com

GENERAL INFORMATION RS 125 GENERAL INFORMATION 1 1 - 1 http://manuals.magnamaniac.com

GENERAL INFORMATION RS 125 SUMMARY 1.1. MANUAL LAYOUT ........................................................................................................................... 3 1.1.1. CONVENTIONS USED IN THE MANUAL .............................................................................. 3 1.1.2. SAFETY INFORMATION......................................................................................................... 4 1.2. GENERAL RULES ........................................................................................................................... 5 1.2.1. BASIC SAFETY RULES .......................................................................................................... 5 1.3. DANGEROUS ELEMENTS .............................................................................................................. 8 1.3.1. WARNINGS CONCERNING FUEL, LUBRICANTS, COOLAND AND OTHER COMPONENT PARTS............................................................................................................. 8 1.4. RUNNING-IN .................................................................................................................................. 11 1.4.1. RUNNING-IN RECOMMENDATIONS................................................................................... 11 1.5. VEHICLE IDENTIFICATION DATA................................................................................................ 12 1.5.1. SERIAL NUMBERS LOCATION ........................................................................................... 12 1.6. USING TOOLS AND SPARE PARTS ............................................................................................ 13 1.6.1. SPARE PARTS...................................................................................................................... 13 1.6.2. USE OF PRODUCTS ............................................................................................................ 14 1.6.3. SPECIAL TOOLS .................................................................................................................. 15 1.6.4. GENERAL TIGHTENING TORQUE SETTINGS................................................................... 16 1.6.5. TECHNICAL DATA ................................................................................................................ 17 1.7. STANDS ......................................................................................................................................... 19 1.7.1. POSITIONING THE VEHICLE ON THE FRONT SERVICE STAND (OPT) ........................ 19 1.7.2. POSITIONING THE VEHICLE ON THE REAR SERVICE STAND (OPT)........................... 20 1.8. PRODUCTS ................................................................................................................................... 21 1.8.1. LUBRICANT CHART ............................................................................................................. 21 1.8.2. DECALS INSTRUCTIONS .................................................................................................... 22 1 - 2 http://manuals.magnamaniac.com

GENERAL INFORMATION RS 125 1.1. MANUAL LAYOUT 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. For quick reference, see the sections index. • Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure. • The terms “left” and “right” are referred to the motorcycle when viewed from the riding position. • Motorcycle operation and basic maintenance are covered in the “OWNER’S MANUAL”. In this manual any variants are identified with these symbols: frame # ZD4DW...........(starting from Model Year 2001) option Catalysed version - All versions 11Kw 11 Kw derated version 80Km 80Km/h speed f.p Full-power version MP National homologation SF European homologations (EURO 1 limits) VERSION: Italy Greece Malaysia United Kingdom Netherlands Chile Austria Switzerland Croatia Portugal Denmark Australia Finland Japan United States of America Belgium Singapore Brazil Germany Slovenia Republic of South Africa France Israel New Zealand Spain South Korea Canada 1 - 3 http://manuals.magnamaniac.com

GENERAL INFORMATION RS 125 1.1.2. SAFETY INFORMATION The following conventions are used to identify safety information throughout the manual: This symbol identifies safety-related information. Whenever you see this symbol in the manual or attached to the motorcycle, use utmost care to avoid the risk of injury. Disregarding the instructions identified by this symbol may put your safety, as well as that of other persons or of the motorcycle at risk! DANGER Disregarding these indications may lead to severe injury or death WARNING Disregarding these indications may lead to minor injury or motorcycle damage. NOTE The term "NOTE" in this manual precedes important information or instructions. 1 - 4 http://manuals.magnamaniac.com

Aprilia RS125 99-03 service repair manual full workshop

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