Aprilia RS125 99-04 Service Manual ENG By Mosue.pdf

RS 125

FOREWORD

GENERAL INFORMATION

ROUTINE MAINTENANCE

LUBRICATION

FUEL SYSTEM

COOLING SYSTEM

ENGINE

CHASSIS

ELECTRICAL SYSTEM

TROUBLESHOOTING INFORMATION

0 - 1

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

RS 125

FOREWORD

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

FOREWORD

RS 125

0.1.2. REFERENCE MANUALS

ENGINE WORKSHOP MANUALS

aprilia part# (description)

8140133 (926)

OWNER’S MANUALS

aprilia part# (description)

Model years 1993

8102260

8140134 (943)

PARTS CATALOGUES

aprilia part# (description)

340X ………

8102319

Model years 1995

8102476

993…………

SPECIAL TOOLS CATALOGUES

aprilia part# (description)

8202278

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

Model years 1994

8102260

RS 125

FOREWORD

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

=ampere

=ampere per hour

API

= American Petroleum Institute

= High Tension

AV/DC

= Anti-Vibration Double Countershaft

bar

= pressure measurement (1 bar =100 kPa)

= Direct Current

cu cm

= cubic centimetres

= 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

= unburnt hydrocarbons

ISC

= Idle Speed Control

ISO

= International Standardization Organization

= kilograms

kgm

= kilograms per metre (1 kgm =10 Nm)

= kilometres

km/h

= kilometres per hour

k Ω

= kiloOhm

kPa

= kiloPascal (1 kPa =0.01 bar)

= clutch side (from the German "Kupplungseite")

= kiloWatt

=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)

= miles

MIN

= minimum

MPH

= miles per hour

= flywheel side (from the German "Magnetoseite")

M Ω

= megaOhm

N.A.

= Not Available

N.O.M.M.

= Motor Octane Number

N.O.R.M.

= Research Octane Number

= 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

0- 5

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