APRILIA RS 125 User manual

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
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SI QUIERE CONSEGUIR MAS INFORMACIÓN DE MOTOS Y MANUALES
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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
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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: [e-mail]
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
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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


 






 
  
 
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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
∞= 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
kΩ= 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")
MΩ= 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)
Ω=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

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
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GENERAL INFORMATION
RS 125
GENERAL INFORMATION 1
1 - 1

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
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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

 
 
  
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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.
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