APRILIA RS 125 Instruction manual

www.serviceaprilia.com
workshopmanual
RS 125
1300 6
00/2006-03
8104976 UK

INTRODUCTION
0-1
RS125
INTRODUCTION 0

INTRODUCTION
0 - 2
RS125
SUMMARY
0.1. INTRODUCTION ............................................................................................................................................. 3
0.1.1. FOREWORD.......................................................................................................................................... 3
0.1.2. REFERENCE MANUALS....................................................................................................................... 4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..................................................................................... 5

INTRODUCTION
0-3
RS125
0.1. INTRODUCTION
0.1.1. FOREWORD
This manual provides the information required for normal servicing.
This publication is intended for use by aprilia Dealers and their qualified mechanics; many concepts have been omitted
on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been included in
this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair procedures.
Without such familiarity, repairs and checks could be ineffective and even hazardous. Since the repair and vehicle check
instructions are not exhaustive, special care must be taken to avoid damage and injury. Piaggio & C. S.p.A. undertakes
to constantly improve the design of its products and the relevant literature to ensure maximum customer satisfaction. The
main technical modifications and changes in repair procedures are communicated to all aprilia dealers and agencies
worldwide. Such modifications will be entered in subsequent editions of the manual. Should you need assistance or
clarifications about the inspection and repair procedures, please contact the aprilia SERVICE DEPT., they will be glad to
give you any information on the matter, or supply you with any detail on updates and technical changes applied to the
vehicle.
Piaggio & C. 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.
Third parties' products are only mentioned for information purposes, and constitute no engagement.
Piaggio & C. S.p.A. is not liable in any way for the performance or use of these products.
First edition: March 2006
Produced and printed by:
VALLEY FORGE DECA
Ravenna , Modena, Torino
DECA s.r.l.
Registered Main Office
Via Vincenzo Giardini, 11
48022 Lugo (RA) - Italy -
Tel. [phone]
Fax [phone]
www.vftis.com
[email protected]
on behalf of:
Piaggio & C. S.p.A.
via G. Galilei, 1 - 30033 Noale (VE) - Italy
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 29 190
www.aprilia.com
www.serviceaprilia.com

INTRODUCTION
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RS125
0.1.2. REFERENCE MANUALS
SPARE PARTS CATALOGUE
aprilia part# (description)
3406
MANUALI ATTREZZI SPECIALI
aprilia part# (description)
8202278
CHASSIS WORKSHOP MANUAL
aprilia part# (description)
8104972
8104973
8104974
8104975
8104976
8CM0101
ENGINE TECHNICAL MANUAL
aprilia part# (description)
8140880
8140883
8140881
8140882
8140884
8CM0027
OWNER’S MANUALS
aprilia part# (description)
Model Year 1993
8102260
Model Year 1994
8102260
8102319
Model Year 1995
8102476
8102530
8102543
Model Year 1996
8102685
8102682
8102530
8102683
8102543
Model Year 1997
8102685
8102682
8102683
8102530
8102543
8102752
8102753
Model Year 1998
8102685
8102682
8102683
8102849
8102934
Model Year 1999
8102821
8102937
8102938
8102939
Model Year 2001
8202248
8102821
8102937
8102938
8102939
Model Year 2002
8104465
8104466
8104467
8104468
Model Year 2006
8104917
8104934
8104935

INTRODUCTION
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RS125
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS
# = number
< = less than
> = greater than
≤= less than or equal to
≥= more than or equal to
~ = approximately
∞= infinity
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = plus or minus
a.c = alternating current
A = Ampere
Ah = Ampere per hour
API = American Petroleum Institute
AT = high voltage
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement unit (1 bar = 100 kPa)
d.c. = direct current
cc = cubic centimetres
CO = carbon monoxide
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 Standardisation Organisation
kg = kilograms
kgm = kilograms per metre (1 kgm = 10 Nm)
km = kilometres
km/h = kilometres per hour
kΩ= kiloOhm
kPa = kiloPascal (1 kPa = 0.01 bar)
KS = clutch side (from the German "Kupplungsseite")
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")
MΩ= MegaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton metre (1 Nm = 0.1 kgm)
Ω= ohm
PICK-UP = pick-up
BDC = Bottom Dead Centre
TDC = Top Dead Centre
PPC = Pneumatic Power Clutch

INTRODUCTION
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RS125
RIGHT
SIDE = right side
SAE = Society of Automotive Engineers
TEST = diagnostic check
T.B.E.I. = crown-head Allen screw
T.C.E.I. = cheese-head Allen screw
T.E. = hexagonal head
T.P. = flat head screw
TSI = Twin Spark Ignition
UPSIDE-
DOWN = inverted fork
V = volt
W = watt
Ø = diameter

GENERAL INFORMATION
1-1
RS125
GENERAL INFORMATION 1

GENERAL INFORMATION
1 - 2
RS125
SUMMARY
1.1. GENERAL INFORMATION.............................................................................................................................. 3
1.1.1. CONVENTIONS USED IN THE MANUAL ............................................................................................. 3
1.1.2. SAFETY WARNINGS............................................................................................................................. 4
1.2. GENERAL RULES........................................................................................................................................... 5
1.2.1. BASIC SAFETY RULES......................................................................................................................... 5
1.3. DANGEROUS ELEMENTS ............................................................................................................................. 8
1.3.1. WARNINGS ........................................................................................................................................... 8
1.4. RUNNING-IN ................................................................................................................................................. 12
1.4.1. RUNNING-IN........................................................................................................................................ 12
1.5. VEHICLE IDENTIFICATION.......................................................................................................................... 13
1.5.1. POSITION OF THE SERIAL NUMBERS ............................................................................................. 13

GENERAL INFORMATION
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RS125
1.1. GENERAL INFORMATION
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.
Refer to the index of sections when consulting the manual.
•Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure.
•The terms "right" and "left" are referred to the rider seated on the vehicle in the normal riding position.
•Motorcycle operation and basic maintenance are covered in the "OWNER'S MANUAL".
In this manual any variants are identified with these symbols:
optional
catalytic version
Full Power version
- all versions
250 cc version
200 cc version
125 cc version
MP national certification
SF European certification (EURO 3 limits)
VERSION:
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Belgium Singapore Brazil
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