APRILIA RS 125 Workshop Manual
1300 6
00/2006-03
www.serviceaprilia.com
RS 125
workshopmanual
UK
8104976
RS125
INTRODUCTION
INTRODUCTION 0
0-1
INTRODUCTION
SUMMARY
0.1. INTRODUCTION ............................................................................................................................................. 3
0.1.1. FOREWORD.......................................................................................................................................... 3
0.1.2. REFERENCE MANUALS....................................................................................................................... 4
0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..................................................................................... 5
RS125
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RS125
INTRODUCTION
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. 0545-216611
Fax 0545-216610
www.vftis.com
deca@vftis.spx.com
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
0-3
INTRODUCTION
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
RS125
0 - 4
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
Ω = kiloOhm
k
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
0-5
INTRODUCTION
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
UPSIDEDOWN = inverted fork
V = volt
W = watt
Ø = diameter
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GENERAL INFORMATION
GENERAL INFORMATION 1
1-1
GENERAL INFORMATION
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
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GENERAL INFORMATION
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:
Italy
United
Kingdom
Austria
Portugal
Finland
Belgium
Germany
France
Spain
Greece
Holland
Switzerland
Denmark
Japan
Singapore
Slovenia
Israel
South
Korea
Malaysia
Chile
Croatia
Australia
United
States of
America
Brazil
South Africa
New
Zealand
Canada
1-3
GENERAL INFORMATION
1.1.2. SAFETY WARNINGS
The following precautionary warnings are used throughout this manual in order to convey the following messages:
Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a
personal injury hazard. Non-compliance with the indications given in the messages preceded by this
symbol may result in grave risks for your and other people’s safety and for the vehicle!
DANGER
Indicates a potential hazard which may result in serious injury or even death.
WARNING
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
NOTE The word "NOTE" in this manual precedes important information or instructions.
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GENERAL INFORMATION
1.2. GENERAL RULES
1.2.1. BASIC SAFETY RULES
CARBON MONOXIDE
Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a wellaerated room.
Avoid starting the engine indoors.
In case you are working indoors, use a gas exhaust system.
DANGER
Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of
consciousness or even lead to death.
FUEL
DANGER
The fuel used in internal combustion engines is highly flammable and can become explosive under
particular conditions.
Refuelling and engine service should take place in a well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid open flames,
sparks and any element that could ignite fuel or provoke explosions.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
HIGH-TEMPERATURE COMPONENTS
The engine and the components of the exhaust system become very hot and remain hot for some time after the engine
has been stopped.
Before handling these components, wear insulating gloves or wait until the engine and the exhaust system have cooled
down.
USED GEARBOX AND FORK FLUIDS
DANGER
Wear latex gloves when servicing.
Gear fluid may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after handling gear fluid.
Take it to the filling station where you usually buy it or to an oil salvage centre.
Wear latex gloves when servicing.
DO NOT DISPOSE OF FLUID IN THE ENVIRONMENT
KEEP AWAY FROM CHILDREN.
BRAKE FLUID
WARNING
When handling the brake fluid, take care not to spill it on the plastic, rubber or painted parts, since it
can damage them. When carrying out the maintenance operations on the braking system, use a clean
cloth to cover these parts.
Always wear safety goggles when working on the braking system.
The brake fluid is highly irritant. Avoid contact with your eyes.
If the brake fluid gets in contact with your eyes, carefully wash them with fresh water and immediately
seek medical advice.
KEEP AWAY FROM CHILDREN.
COOLANT
Coolant contains ethylene glycol that is flammable, under certain conditions. When ignited, ethylene glycol produces
invisible flames that might cause burns.
1-5
GENERAL INFORMATION
DANGER
Take care not to spill coolant onto hot engine parts and exhaust system. It may ignite and produce
invisible flames.
Wear latex gloves when servicing.
Although toxic, it has a sweet taste that might attract animals. Never leave coolant in open container
or in a position easily reachable by animals.
KEEP AWAY FROM CHILDREN.
Do not remove radiator cap when engine is still hot. Coolant is under pressure and might cause burns.
HYDROGEN GAS AND BATTERY ELECTROLYTE
DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact with the skin.
Always wear tight gloves and protective clothes when handling this fluid.
In case of contact with skin, rinse with plenty of fresh water.
Always use a protection for your eyes since even a very small amount of the battery fluid can cause
blindness. In the event of contact with your eyes, carefully wash them with water for fifteen minutes
and then consult immediately an eye specialist.
Should you accidentally drink some fluid, drink abundant water or milk, then drink magnesia milk or
vegetable oil and immediately seek medical advice.
The battery gives off explosive gases and must be kept away from flames and sources of ignition or
heat; do not smoke near the battery.
KEEP AWAY FROM CHILDREN.
Battery fluid is corrosive.
Do not spill it, especially on plastic parts.
Make sure that the electrolyte acid is suitable for the type of battery used.
GENERAL PRECAUTIONS AND INFORMATION
Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components.
DANGER
Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or
inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the
engine and exhaust system to cool down; where possible, lift the motorcycle using adequate
equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system
which may still be hot to the touch to avoid scalds or burns.
Do not put any vehicle parts into your mouth: vehicle components are not edible and some of them
are harmful or even toxic.
Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling
procedure. Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly
to avoid disturbing any parts unless strictly necessary. Do not polish matt-painted surfaces with
polishing paste.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean any rubber or plastic parts or the seat with alcohol, petrol or solvents. Clean with water
and mild detergent.
Always disconnect the battery negative (-) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.
BEFORE DISASSEMBLING ANY COMPONENTS
• Clean off all dirt, mud, and dust and clear any foreign objects from the vehicle before disassembling any
components.
• Use the model-specific special tools where specified.
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GENERAL INFORMATION
DISASSEMBLING THE COMPONENTS
- Never use pliers or similar tools to slacken and/or tighten nuts and bolts. Always use the suitable spanner.
- Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection
using a distinctive symbol or convention.
- Mark each part clearly to avoid confusion when refitting.
- Thoroughly clean and wash any components you have removed using a detergent with low flash point.
- Mated parts should always be refitted together. These parts will have seated themselves against one another in
service as a result of normal wear and tear and should never be mixed up with other similar parts on refitting.
- Certain components are matched-pair parts and should always be replaced as a set.
- Keep away from heat sources.
REASSEMBLING THE COMPONENTS
DANGER
Never reuse a circlip or snap ring. These parts must always be renewed once they have been
disturbed.
When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow
fitment to the shaft.
Make it a rule to check that a newly-fitted circlip or snap ring has located fully into its groove.
Never clean a bearing with compressed air.
CAUTION All bearings must rotate freely with no hard spots or noise. Replace any bearings that do not meet these
requirements.
- Use ORIGINAL aprilia SPARE PARTS only.
- Use the specified lubricants and consumables.
- Where possible, lubricate a part before assembly.
- When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten
evenly, in subsequent steps until achieving the specified torque.
- Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which
have a damaged thread.
- Lubricate the bearings abundantly before assembly.
- Make it a rule to check that all components you have fitted are correctly in place.
- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then operate
the motorcycle in a private estate area or in a safe area away from traffic.
- Clean all mating surfaces, oil seal edges and gaskets before assembly. Apply a thin layer of lithium grease along
the edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).
ELECTRICAL CONNECTORS
To disconnect the electrical connectors, follow the procedures below. Failure to comply with these procedures may lead
to irreparable damage to the connector and the wiring as well.
If present, press the special safety hooks.
WARNING
Do not pull cables to disconnect the two connectors.
• Grasp the two connectors and disconnect them by pulling them in the two opposite directions.
• In case of dirt, rust, moisture, etc.., thoroughly clean the inside of the connectors with compressed air.
• Make sure that the cables are correctly fitted inside the connector terminals.
CAUTION The two connectors have just one correct positioning. Make sure to position them in the right direction.
• Then fit the two connectors. Make sure they are correctly coupled (a click will be heard if hooks are present).
TIGHTENING TORQUE SETTINGS
DANGER
Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other
suspension parts play a fundamental role to ensure vehicle safety. Make sure that these values are
always within the specified limits.
Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a
torque wrench.
Failure to comply with these recommendations could lead to the loosening and detachment of one of
these parts with a consequent locking of the wheel or other serious troubles affecting the vehicle
manoeuvrability, and thus the risk of falls and serious injuries or death.
1-7
GENERAL INFORMATION
1.3. DANGEROUS ELEMENTS
1.3.1. WARNINGS
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
Refuelling and engine service should take place in a well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid open flames,
sparks and any element that could ignite fuel or provoke explosions.
Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts.
In the event of accidental fuel spillage, make sure the affected area is fully dry before starting the
engine. Fuel expands from heat and when left under direct sunlight.
Never fill the fuel tank up to the brim. Tighten the filler cap securely after each refuelling.
Avoid contact with skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between
different containers using a hose.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only premium grade unleaded petrol, min. O.N. 95 (RON) and 85 (MON).
LUBRICANTS
DANGER
A good lubrication ensures the vehicle safety.
Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean
type of lubricant can lead to the engine or gearbox seizure, thus causing serious accidents, personal
injury or even death.
Gear fluid may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil in the environment.
Take it to the filling station where you usually buy it or to the supplier.
WARNING
When filling the vehicle with this oil, take care not to spill it out. Immediately clean spilt oil, or it might
damage the vehicle paintwork.
In case of contact with oil, the tyres surface will become very slippery, thus becoming a serious
danger for your safety.
In case of leaks, do not use the vehicle. Check and trace the cause of leaks and proceed to repair.
ENGINE OIL
DANGER
Engine oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil in the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves when servicing.
FRONT FORK FLUID
DANGER
Front suspension response can be modified to a certain extent by changing damping settings and/or
selecting a particular grade of oil. Standard oil viscosity: SAE 20 W. Different oil grades can be
selected to obtain a particular suspension response (choose SAE 5W for a softer suspension, 20W for
a stiffer suspension).
The two grades can also be mixed in varying solutions to obtain the desired response.
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GENERAL INFORMATION
BRAKE FLUID
NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic
circuit. The information provided below applies to both braking systems.
DANGER
Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts
that most ensure your safety and for this reason they must always be perfectly working. Failure to
comply with these recommendations will probably lead to a crash or an accident, with a consequent
risk of personal injury or death.
A wet surface reduces brakes efficiency.
DANGER
In case of wet ground the braking distance will be doubled, since both brakes and tyre grip on the
road surface are extremely reduced by the water present on the road surface.
Any water on brakes, after washing the vehicle or driving on a wet road surface or crossing puddles
or gips, can wet brakes so as to greatly reduce their efficiency.
Failure to comply with these recommendations may lead to serious accidents, with a consequent risk
of severe personal injuries or death.
Brakes are critical safety components. Do not ride the vehicle in case brakes are not working at their
best.
Check for brakes proper operation before every trip.
Brake fluid is irritant. Avoid contact with eyes or skin.
In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental
contact with eyes, contact an eye specialist or seek medical advice.
DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will
damage.
DANGER
Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up
level, as this will damage the braking system.
Do not use brake fluid from old containers which have been kept open or in storage for long periods.
Any sudden changes in play or hardness in the brake levers are warning signs of problems with the
hydraulic circuits.
Ensure that the brake discs and brake linings have not become contaminated with oil or grease. This
is particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Prevent accidental entering of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.
DISC BRAKES
DANGER
The brakes are the parts that most ensure your safety
and for this reason they must always be perfectly working; check them before every trip.
A dirty disc soils the pads.
Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser.
Perform the maintenance operations reducing by half the indicated frequency if the vehicle is used in
rainy or dusty areas, on uneven surfaces or for racing.
Check brake pads for wear.
When the brake pads wear out, the level of the fluid decreases to automatically compensate for their
wear.
The front brake fluid reservoir is located on the right handlebar, near the front brake lever.
The rear brake fluid reservoir is located under the right fairing.
Do not use the vehicle if the braking system leaks fluid.
1-9
GENERAL INFORMATION
COOLANT
DANGER
Coolant is toxic when ingested, contact with eyes or skin may cause irritation.
In the event of contact with your skin or eyes, rinse repeatedly with abundant water and seek medical
advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and
seek medical advice immediately.
DO NOT RELEASE INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
DANGER
Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear
latex gloves when servicing.
Do not ride when coolant is below the minimum level.
Coolant mixture is a 50% solution of water and antifreeze. This is the ideal solution for most operating temperatures and
provides good corrosion protection.
This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce the need for topups.
In addition, less water evaporation means fewer minerals salts depositing in the radiator, which helps preserve the
efficiency of the cooling system.
When the outdoor temperature drops below zero degrees centigrade, check the cooling system frequently and add more
antifreeze (up to 60% maximum) to the solution, if needed.
Use distilled water in the coolant mixture. Tap water will damage the engine.
Refer to the chart given below and add water with the quantity of antifreeze to obtain a solution with the desired freezing
point:
Freezing point C° (-°F) Coolant % of volume
-20° (-4 F°) 35
-30° (-22 F°) 45
-40° (-40 F°) 55
RS125
NOTE Coolants have different specifications. The protection degree is written on the label.
WARNING
Use only nitrite-free antifreeze and corrosion inhibitors with a freezing point of -35°C
(-31°F) as a minimum.
DRIVE CHAIN
Check drive chain operation, wear, slack and lubrication.
The vehicle is equipped with an endless chain with a joint link.
WARNING
If too slack, the chain can come off the front or rear sprockets thus leading to serious accidents and
damage to the vehicle, with consequent serious personal injury or death.
Do not use the vehicle if the chain slack has not been correctly adjusted.
To check the chain, take it with your hand where it turns on the rear sprocket and pull it as to separate
it from the sprocket itself.
If you can move the chain apart of the front sprocket for more than 3 mm (0.125 in), change chain,
front and rear sprocket.
DANGER
If not properly maintained, chain can early wear out and lead to the damage of both front and rear
sprockets.
Perform chain maintenance operations more frequently if the vehicle is used on dusty or muddy
areas.
1 - 10
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TYRES
GENERAL INFORMATION
WARNING
If tyres are excessively inflated, the vehicle will be harder, more difficult and uncomfortable to ride.
In addition, the roadworthiness, mainly on wet surfaces and during cornering, will be impaired.
Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle.
In this case too, both vehicle roadworthiness, manoeuvrability and brake efficiency will be impaired.
Tyres changing, repair, maintenance and balancing must be carried out by specialised technicians
using suitable equipment.
When new, tyres can have a thin slippery protective coating. Drive carefully for the first kilometres
(miles).
Never use rubber treating substances on tyres.
In particular, avoid contact with fluid fuels, leading to a rapid wear.
In case of contact with oil or fuel, do not clean but change the tyres.
DANGER
Some of the factory-assembled tyres of this vehicle are provided with wear indicators.
There are several kinds of wear indicators.
For more information on how to check the wear, contact your Dealer.
Visually check if the tyres are worn and in this case have them changed.
If a tyre deflates while driving, stop immediately.
Avoid hard brakings or moves and do not close throttles too abruptly.
Slowly close the throttle grip, move to the edge of the road and use the engine brake to slow down
until coming to a halt.
Failure to comply with these recommendations may lead to accidents, with a consequent risk of
personal injuries or death.
Do not install tyres with air tube on rims for tubeless tyres and vice versa.
1-11
GENERAL INFORMATION
RS125
1.4. RUNNING-IN
1.4.1. RUNNING-IN
Correct engine running-is essential to ensuring proper performance and durability.
If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes
undergo a more effective running-in.
During running-in, change speed.
In this way the components are first "loaded" and then "relieved" and the engine parts can thus cool down.
Even if it is important to stress the engine components during running-in, take care not to exceed.
WARNING
Top acceleration performance is obtained only after covering the first 1500 km (932 mi).
Keep to the following indications:
• Do not open the throttle completely if the speed is low, both during and after running-in.
• Apply the brakes gently and avoid hard, prolonged braking until covering the first 100 km (62 mi). This will allow the
brake pad lining to break in properly rubbing on the brake disks.
• During the first 800 km (497 mi), never exceed 5000 rpm (see table).
DANGER
After the first 1000 km (621 mi), have the checking operations indicated in the column "After runningin" carried out by an aprilia Authorised Dealer, see REGULAR SERVICE INTERVALS CHART, in order
to avoid hurting yourself or other people and/or damaging the vehicle.
• After the first 800 km (497 mi) and until covering 1600 km (994 mi), drive more briskly, varying speed and using
maximum acceleration for just a few seconds, in order to ensure better coupling of the components; never exceed
9000 rpm (see table).
• After the first 1600 km (994 mi), you can expect higher performance from your engine. However, never exceed the
maximum rpm allowed (11000 rpm).
Recommended maximum rpm
Mileage Km (mi) rpm
0÷800 (497) 6000
800-1600 (497-994) 9000
Over 1600 (994) 11000
1 - 12
RS125
1.5. VEHICLE IDENTIFICATION
1.5.1. POSITION OF THE SERIAL NUMBERS
These numbers are necessary for vehicle registration.
NOTE Altering the vehicle identification numbers is a legal
offence. Altering the frame number invalidates the warranty.
FRAME NUMBER
The frame number is stamped on the right side of the
steering column.
GENERAL INFORMATION
ENGINE NUMBER
The engine number is stamped on the rear end, near the
shock absorber.
1-13
RS125
TECHNICAL INFORMATION
TECHNICAL INFORMATION 2
2-1
TECHNICAL INFORMATION
SUMMARY
2.1. TECHNICAL INFORMATION .......................................................................................................................... 3
2.1.1. TECHNICAL DATA ................................................................................................................................ 3
2.1.2. SCHEDULED MAINTENANCE CHART................................................................................................. 5
2.1.3. LUBRICANT CHART.............................................................................................................................. 6
2.1.4. TIGHTENING TORQUE SETTINGS......................................................................................................7
2.1.5. SPECIAL TOOLS................................................................................................................................. 11
2.1.6. LOCATION OF KEY COMPONENTS .................................................................................................. 12
2.1.7. LOCATION OF INSTRUMENTS / CONTROLS ................................................................................... 14
2.1.8. INSTRUMENT PANEL OPERATION................................................................................................... 16
2.1.9. GEARBOX FLUID ................................................................................................................................ 20
2.1.10. CHANGING GEARBOX FLUID............................................................................................................ 21
2.1.11. CLUTCH ADJUSTMENT...................................................................................................................... 22
2.2. SCHEDULED MAINTENANCE...................................................................................................................... 23
2.2.1. BRAKE FLUID...................................................................................................................................... 23
2.2.2. BRAKE PADS ...................................................................................................................................... 28
2.2.3. LIFTING THE FUEL TANK................................................................................................................... 29
2.2.4. CLEANING THE AIR FILTER .............................................................................................................. 30
2.2.5. COOLANT............................................................................................................................................ 31
2.2.6. REMOVING THE BATTERY ................................................................................................................ 32
2.2.7. IDLING SPEED ADJUSTMENT ........................................................................................................... 33
2.2.8. CHOKE ADJUSTMENT ....................................................................................................................... 34
2.2.9. DRIVE CHAIN ADJUSTMENT ............................................................................................................. 35
2.2.10. INSPECTING THE DRIVE CHAIN SLIDER ......................................................................................... 37
RS125
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RS125
2.1. TECHNICAL INFORMATION
2.1.1. TECHNICAL DATA
DIMENSIONS
Max. length 1955 mm (76.97 in.)
Max. width 720 mm (28.34 ) in.
Max. height (at headlight fairing) 1100 mm (43.31 in.)
Seat height 805 mm (31.69 in.)
Wheelbase 1345 mm (52.95 in.)
Minimum ground clearance 163 mm (6.42 in.)
Weight in running order (including fluids and fuel) 137 kg (302.03 lb.)
ENGINE
Type Single-cylinder 2-stroke with reed intake. Separate
lubrication with automatic variable mixer ( 1.0 - 3.0 %).
Number of cylinders 1
Total displacement 124.82 cu cm (7.62 cu. in.)
Bore/stroke 54 mm /54.5 mm (2.12 in. /2.14 in.).
Compression ratio 12.5 ± 0.5 : 1
Squish clearance 1.5 mm (0.06 in.)
Engine idling speed 1250 ± 100 rpm
Engine maximum rpm 11000 ± 100 rpm
Ignition CDI ignition system with electronic spark timing
Starting Electric starter
Clutch Multiplate wet clutch, with control lever on left handlebar
Gearbox mechanical, 6-speed, with control pedal on left side of
engine
Gearbox lubrication Splash lubrication
Lubricating system Separate lubrication with automatic variable mixer ( 1.0 -
1.3 %)
CAPACITIES
Fuel (including reserve) 14 l ± 0.5 l (3.70 USgal ± 0.13 USgal) (3.08 gal ± 0.11 gal)
Fuel reserve 3.5 l (0.92 USgal) (0.77 gal)
Gearbox fluid 600 cu cm (36.61 cu. in.)
Gearbox fluid 600 cu cm (36.61 cu. in.)
Coolant 0.8 l (50% water + 50% antifreeze with ethylene glycol)
(0.21 USgal) (0.17 gal)
Mixer oil (reserve included) 1,7 l (0.45 USgal) (0.37 gal)
Mixer oil reserve 0.6 l (0.16 USgal) (0.16 gal)
Front fork oil/air 440 ± 2,5 cm³ (26.85 ± 0.15 cuin)
Seat 2
Vehicle max. load (rider + passenger + luggage) 180 kg (396.83 lb.)
TRANSMISSION SYSTEM
TECHNICAL INFORMATION
GEAR RATIOS Ratio
1st
2nd
3rd
4th
5th
6th
FUEL SYSTEM
Type Carbureted
Model DELL’ORTO PHBH 28
FUEL SYSTEM
Fuel Premium-grade unleaded petrol, minimum octane rating
Primary
19/63 = 1: 3.316
Final
10/30 = 1: 3.000
14/29 = 1: 2.071
17/27 = 1: 1.588
19/25 = 1: 1.316
21/24 = 1: 1.143
22/23 = 1: 1.045
95 (RON) and 85 (MON), as per DIN 51 607.
Final ratio
17/40 = 1: 2.353
Total ratio
1 : 23.406
1 : 16.161
1 : 12.391
1 : 10.266
1 : 8.916
1 : 8.156
2-3
TECHNICAL INFORMATION
FRAME
Type Twin-spar frame with cast and stamped frame sections
Steering head angle 25° 30’
Trail 102 mm (4.01 in.)
SUSPENSIONS
Front hydraulically operated telescopic fork
Travel 120 mm (4.72 in.)
Rear Adjustable hydraulic mono-shock absorber
Wheel stroke 44.5 mm (1.75 in.)
BRAKES
Front Disc - Ø 320 mm (12.60 in.) - with hydraulic transmission
Rear Disc - Ø 220 mm (8.66 in.) - with hydraulic transmission
WHEEL RIMS
Type in light alloy
Front 3.00 x 17"
Rear 4.00 x 17"
TYRES
Wheel Size
Front
Rear 150/60 R 17’’ 66 H
IGNITION
Type CDI
Spark advance 12°±2° at 2000 rpm
SPARK PLUG
Standard NGK R BR10EG
Standard NGK BR8ES
Spark plug gap 0.7 - 0.8 mm (0.028 – 0.031 in.)
ELECTRIC SYSTEM
Battery 12 V - B9 - B
Fuses 20 - 15 - 7.5 A
Generator 12 V – 180 W
BULBS
Low beam (halogen) 12 V - 55 W H11
High beam (halogen) 12 V - 55 W H11
Parking light 12 V - 5 W
Turn indicator light Mini lamps (cannot be replaced)
Rear parking light / number plate light / stoplight 12 V – 5 / 21 W
Revolution counter LED
Speedometer light LED
Multifunction display light LED
WARNING LIGHTS
Neutral LED
Direction indicators LED
High beam lights LED
General alarm LED
Fuel oil reserve LED
110/70 R 17’’ 54H
100/70 ZR 17’’ 54W
150/60 ZR 17’’/ 66W
Pressure kPa (bar)
Rider only Rider and passenger
180 (1.8) 180 (1.8)
200 (2.0) 230 (2.3)
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RS125
2.1.2. SCHEDULED MAINTENANCE CHART
After running-
Component
Rear shock absorber - - 1
Battery - Clamp tightening 1 1 Spark plug 1 1 3
Carburettor 1 2 Transmission and control cables 1 1 RAVE control unit 1 - 4
Wheel truing - 1 Steering bearings and steering clearance 1 1 Wheel bearings - 1 Brake discs 1 1 Air filter - 2 3
Vehicle operation 1 1 Clutch clearance 4 4 Braking systems 1 1 Cooling system 1 1 Light system 1 1 Brake fluid 1 1 Brake fluid every year: 3
Coolant every 2 years: 3
Coolant Every 1500 km (935 mi): 1
Mixer oil level Every 500 km (310 mi): 1
Gearbox fluid 3 1
Fork fluid and oil seal Every 12000 km (7456 mi): 3
Headlight beam direction - operation - 1 -
Piston and piston rings
Engine idling speed 4 4 Odometer drive - - 1
Wheels/Tyres and inflation pressure 1 1 Wheels/Tyres and inflation pressure Every 1000 km (621 mi): 1
Tightening of nuts and bolts 1 1 Exhaust silencer (except catalytic version) 2 2 Front suspension 1
Mixer oil reserve LED light 1 1 Drive chain tension and lubrication Every 500 km (310 mi): 1
Final transmission (chain, rear sprocket and front
sprocket)
Fuel hose - 1 every 4 years: 3
Braking system lines - 1 every 4 years: 3
Mixer oil pipe - 1 every 4 years: 3
Clutch wear - 1 Front and rear brake wear 1 Every 2000 km (1242 mi): 1
Exhaust valve 1 2 + 4 -
1 = check and clean, adjust, lubricate or change, if necessary; 2 = clean; 3 = change; 4 = adjust.
Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas, on uneven ground
or for racing.
) = OPERATIONS THAT CAN BE CARRIED OUT BY THE USER
(
(**) = Check every two weeks or at the specified intervals.
in
[1000 km
(621 mi)]
- 1 -
Every 4000 km
(2485 mi) or
12 months
Every 8000 km (4970 mi): 1
Every 16000 km (9941 mi): 3
Every 8000 km
(4970 mi) or
Every 12000 km
24 months
(7456 mi): 3
TECHNICAL INFORMATION
2-5
TECHNICAL INFORMATION
2.1.3. LUBRICANT CHART
LUBRICANT PRODUCT
Gearbox fluid
Mixer oil
Fork fluid
Bearings and other
lubrication points
Battery terminals
Aerosol lubricant for chains
Brake fluid
Engine coolant
RECOMMENDED:
As an alternative to recommended oils, top brand oils meeting or exceeding
A.P.I. GL-4 specifications can be used.
RECOMMENDED:
As an alternative to recommended oil, top brand oils meeting or exceeding
ISO-L-ETC ++,A.P.I. TC ++ specifications can be used.
RECOMMENDED: Fork fluid
When you wish to obtain an intermediate response between those offered
by
F.A. 5W and F.A. 20W oils, you may mix the different products as
follows:
SAE 10W =
SAE 15W =
RECOMMENDED:
As an alternative to recommended grease, use top brand rolling bearing
grease that will resist a temperature range of -30 °C to +140 °C (-22 °F to
+284 °F), with dripping point 150 °C to 230 °C (302 °F to 446 °F), high
corrosion protection, good resistance to water and oxidisation.
Use neutral grease or Vaseline.
RECOMMENDED:
RECOMMENDED:
CAUTION Use new brake fluid only. Do not mix different makes or types of
oil without having checked bases compatibility.
RECOMMENDED:
NOTE Use only nitrite-free antifreeze and corrosion inhibitors with a
freezing point of - 35°C (- 31°F) as a minimum.
RS125
F.C., SAE 75W - 90.
MAX 2T COMPETITION.
F.A. 5W or F.A. 20W.
F.A. 5W 67% of volume, + F.A. 20W 33% of volume.
F.A. 5W 33% of volume, + F.A. 20W 67% of volume.
AUTOGREASE MP
CHAIN SPRAY.
F.F., DOT 5 (DOT 4 compatible).
ECOBLU – 40°C (- 40 °F).
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RS125
2.1.4. TIGHTENING TORQUE SETTINGS
Check and tighten as required after the first 1000 km (621 mi) and every 4000 km (2485 mi) or 12 months afterwards.
WARNING
The fasteners listed in the chart must be tightened to the specified torque using a torque wrench and
applying LOCTITE
Safety-related items are in brackets (
Notes:
L243 = secure with Loctite
Lub= lubricate
DESCRIPTION Q.ty Screw / nut Nm Kgm Note
FRAME
Head to frame 4 Socket-head screw M8x20 22 2.2
Seat frame to frame fastener 4 Socket-head screw M8x25 22 2.2
Instrument panel subframe to
frame
Filter box fastener onto seat frame 2 Hex flange screw M6x20 5 0.5
Splitter to frame 2 Hex flange screw M6x20 10 1.0
FOOTRESTS
Rider footrest bracket 4 Socket-head screw M8x30 22 2.2
Passenger footrest bracket 4 Socket-head screw M8x20 22 2.2
Rider footrest guard 2
Upper rider footrest bracket 2 Socket-head screw M8x35 22 2.2
STAND
Stand connection 2 Hex flange screw M8x35 22 2.2
Side stand pin 1 M10X1.25 10 1.0
Side stand pin short nut 1 M10X1.25 25 2.5
Stand switch fixing screw 1 Hex flange screw M6x16 10 1.0 L243
SWINGING ARM
Brake line / chain slider clamp 5
Rear lower mudguard 2 Hex flange screw M6x16 5 0.5
Swinging arm pivot fastener 1 100 10.0
Ring nut adjusting bush 1 12 1.2 lub
Chain slider 1
Swinging arm pivot adjustment 1 35 3.5
FRONT SUSPENSION
Stanchion tubes onto fork yoke 4 Socket-head screw M8x30 25 2.5
Stanchion tubes onto top yoke 2 Socket-head screw M8x30 25 2.5
Steering column nut 1 80 8.1
Ring nut 1 7 0.7
REAR SUSPENSION
Shock absorber to frame fastener 1 Socket-head screw M10x80 50 5.1 lub
Single connecting rod to frame 1 Socket-head screw M10x120 50 5.1 lub
Double connecting rod to single
connecting rod
Double connecting rod to swinging arm 1
Shock absorber to double connecting
rod
®
where specified.
®
243
).
2 Hex flange screw M6x45 10 1.0
Allen crowned-head screw
M5x12
Allen crowned-head screw
M5x12
Allen crowned-head screw
M5x16
3 0.3
2 0.2
2 0.2
1 Hex flange screw M10x75 50 5.1 lub
Socket-head screw
M12X78.5
80 8.1 lub
1 Hex flange screw M8x40 25 2.5 lub
TECHNICAL INFORMATION
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TECHNICAL INFORMATION
DESCRIPTION Q.ty Screw / nut Nm Kgm Note
ENGINE
Head to frame screw 4 Socket-head screw M8x20 22 2.2
Upper front engine mount 1 Socket-head screw M10x120 50 5.1
Lower front engine mount 1 Hex flange screw M10x205 50 5.1
Rear engine mount 1 Socket-head screw M8x85 22 2.2
Gearbox connecting rod 1 Hex flange screw M6x20 10 1.0
Lower rear fastener 1 Hex flange screw M8x70 22 2.2
Sprocket cover fastener 2 Socket-head screw M6x20 5 0.5
FILTER BOX
Filter box 2 Hex flange screw M6x25 5 0.5
EXHAUST SYSTEM
Muffler central section
(bracket)
Muffler to bracket 1 Socket-head screw M8x50 22 2.2
Clamp onto silent block 1 Socket-head screw M8x12 22 2.2
Silent blocks to supports 3 Nut M8 22 2.2
COOLING SYSTEM
Water bleed valve
FRONT WHEEL
Front wheel shaft fastener 1 Wheel shaft 80 8.1
Stanchion tubes to wheel shaft 4 Socket-head screw M6x30 10 1.0
REAR WHEEL
Rear wheel shaft fastener 1 Shaft nut 100 10.0
FRONT BRAKE
Oil tank mount to pump 1 Hex flange screw M6x12 7 0.7
Oil tank to mount 1 Hex flange screw M6x25 7 0.7
Oil tank to mount 1 Nut M6 7 0.7
Front brake disc 6 Hex flange screw M8x20 22 2.2
Brake calliper
Brake line to calliper 1 Special screw 20 2.0
REAR BRAKE
Hose clamp to swinging arm 2 Hex flange screw M5x12 2 0.2
Rear brake oil tank 1 Hex flange screw M6x16 7 0.7
Rear brake disc 6 Hex flange screw M6x20 10 1.0
Brake line to calliper 1 Special screw 20 2.0
Adjuster screw on brake lever 1 Hex flange screw M6x25 10 1.0
Rear brake pump and
guard
Brake calliper 2 Hex flange screw M6x30 22 2.2
HANDLEBAR AND CONTROLS
Anti-vibration weights 2 Socket-head screw M6x50 10 1.0
Control casings to handlebar 4 Socket-head screw M6 3 0.3
1 Socket-head screw M8x70 22 2.2
1 Allen crowned-head screw
5.5x15.9
2 Allen crowned-head screw
M10x55
2 Hex flange screw M6x35 10 1.0
2 0.2
50 5.1
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RS125
DESCRIPTION Q.ty Screw / nut Nm Kgm Note
ELECTRICAL COMPONENTS
Battery box mount
bracket
Expansion tanks to battery 1 Hex flange screw M6x16 5 0.5
Horn fastener 1 Hex flange screw M8x16 22 2.2
Battery box mount to frame 4 Socket-head screw M8x30 22 2.2
Undertail and oil tank fastener 5 Hex flange screw M5x16 2 0.2
Fuse box to frame 2 Hex flange screw M8x20 5 0.5
Fitment to headlight
Coil to holder 2 Hex flange screw M6x45 10 1.0
Voltage regulator fastener 2 Hex flange screw M6x25 10 1.0
Tail light fastener
Battery box mount 2 Hex flange screw M6x12 5 0.5
TANKS
Tank front fastener 2 Socket-head screw M6x50 7 0.7
Tank rear fastener 2 Socket-head screw M6x70 7 0.7
Tank filler plug fastener 2 Socket-head screw M5x30 5 0.5
Tank filler plug / spacer 2 Socket-head screw M5x16 3 0.3
Fuel cock to fuel tank 2 Tie 16 - 25 2 0.2
SEAT
Passenger seat fastener
Passenger grab strap
Passenger grab strap 2 Nut M6 5 0.5
COMPLEMENTARY ACCESSORIES
Number plate extension 6 Self-tapping screw 3.9x14 5 0.5
Turn indicators 2 Nut M8 8 0.8
Number plate holder 3
CHAIN
Chain tensioner wheel to footrest bracket 1 Socket-head screw M8x70 25 2.5
FRONT BODYWORK
RH-LH deflector to upper side fairing 5 PLSTC S/TAP screw 3.9x14 1 0.1
Windscreen to fairing front piece 3 Allen crowned-head screw
Mudguard to fork 5 Allen crowned-head screw
4 Hex flange screw M5x25 5 0.5
4 Crowned cheese-headed screw
M4x16
2 Allen crowned-head screw
M5x16
2 Allen crowned-head screw
M6x16
2 Allen crowned-head screw
M6x20
Allen crowned-head screw
M5x16
M4x16
M5x16
1.5 0.15
2 0.2
7 0.7
5 0.5
9 0.9
3 0.3
5 0.5
TECHNICAL INFORMATION
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TECHNICAL INFORMATION
DESCRIPTION Q.ty Screw / nut Nm Kgm Note
CENTRE BODYWORK
Upper RH-LH fairing to frame 2 Allen crowned-head screw M5x16 2 0.2
Upper RH-LH fairing to front piece 2 S/TAP crowned cheese-hd screw 4.2X16 1 0.1
RH-LH fairing to upper side fairing 8 Allen crowned-head screw M5x16 2 2 0.2
RH-LH fairing to lwr fastening plate 2 Allen crowned-head screw M5x16 2 2 0.2
RH-LH inner fairing to upper side fairing
Lower cowl to frame (radiator
connection plate)
REAR BODYWORK
RH-LH seat frame cover to seat frame 8 Allen crowned-head screw M5x16 10 1
RH-LH tail guard to tail light 4 Allen crowned-head screw M5x16 2 0.2
RH-LH tail guard to seat frame cover 2 Allen crowned-head screw M5x16 2 0.2
Seat frame lower cover to seat frame 2 Allen crowned-head screw M5x16 2 0.2
Seat frame lower cover to tail guard 10 S/TAP crownedcheese-hd screw 4.2X16 1 0.1
Number plate holder to seat frame lower
cover
Number plate holder to seat frame lower
cover
Splashguard to number plate holder 6 S/TAP crowned cheese-hd screw 4.2X14 10 1
8 PLSTC S/TAP crowned chesse-hd screw
4.2X16
2 Allen crowned-head screw M5x16
3 S/TAP crownedcheese-hd screw 4.2X14
2 Allen crowned-head screw M5x16
1 0.1
2 0.2
2 0.2
10 1
RS125
Steel / aluminium fixing screws with similar elastic moduli
Screw Nm Kgm
M4 3 0.3
M5 6 0.6
M6 12 1.2
M8 25 2.5
M10 50 5.0
M12 80 8.0
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