Frame and attachments of motorcycle Aprilia RS125/3 (1998-2005)

Main elements of chassis
1. Headlight; 2. Left rearview mirror; 3. Clutch control; 4. Ignition switch / steering lock / parking lights; 5. Fuse carrier; 6. Fuel tank; 7. Seat lock; 8. Left-hand seat subframe cover; 9. Passenger seat; 10. Tail section; 11. Tail light; 12....

Rider seat — removal and installation
Removal Insert the key (1) into the lock (2) and turn counter clockwise. Lift and remove the seat. Remove the lid (3). Installation Locate the tabs (4) at the seat rear end into the suitable recesses. Locate the anchor point (5) into its seat. Lower...

Removing the side fairings
Torque wrench settings: Screws (1-3-7-9): 3 Nm (0.3 Kgm) Screws (12): 2 Nm (0.2 Kgm) Right-hand side fairing Release and remove the six screws (1). Withdraw the pin (2). Release and remove the two screws (3) at the front end. Disconnect the two...

Air dam removal
Torque wrench settings: Screws (1-2-3): 3 Nm (0.3 Kgm) Release and remove the two side screws (1) on either side. Release and remove the two screws (2). Release and remove the two screws (3). Remove the air dam.

Front fairing removal
Torque wrench settings: Screws (1-3): 3 Nm (0.3 Kgm) Repeat these three steps on either side: Release and remove the two screws (1). Remove the rearview mirror (2). Release and remove the three screws on the side fairing (3). Release and remove the...

Windscreen removal
Working from inside the front fairing, remove the seven washers (1) and collect the seals (2). Remove the seven retaining pins (3). Remove the windscreen. Note. Fit new washers (1) on assembly.

Fuel tank filler cap removal
Torque wrench settings: Screws (1): 5 Nm (0.5 kg·m) Screws (3): 3 Nm (0.3 kg·m) Put the motorcycle on the stand. Release and remove the three screws (1). Note. The other three screws are there for aesthetic purposes only and can be left in place....

Fuel tank fairing removal
Torque wrench settings: Fuel tank fairing screws (1): 3 Nm (0.3 Kgm). Remove the fuel tank and place it on a work bench; see 4.1.2. Release and remove the two screws (1). Collect the washers and the rubber spacer (2). Note. Fit the rubber spacer (2)...

Seat subframe cover removal
Torque wrench settings: Front screws (1): 3 Nm (0.3 Kgm). Rear screws (2): 2 Nm (0.2 Kgm). Inner screw (3): 3 Nm (0.3 Kgm). Nut (4): 5 Nm (0.5 Kgm). Remove the seat; see 7.1.1. Release and remove the two front screws (1). Release and remove the two...

Tail section removal
Torque wrench settings: Inner nuts (1): 5 Nm (0.5 Kgm). Screws (2): 2 Nm (0.2 Kgm). Screws (3): 2 Nm (0.2 Kgm). Remove both seat subframe covers; see 7.1.8. Undo and remove the two inner nuts (1) and collect the screws. Release and remove the two...

Removing the front mudguard
Torque wrench settings: Screws (1): 2 Nm (0.2 Kgm). Release and remove the two screws (1) on both sides. Remove the front mudguard.

Removing the rear mudguard
Release and remove the screw (1) on both sides. Remove the rear mudguard.

Removing the seat end cover
Torque wrench settings: Screws (1): 2 Nm (0.2 Kgm). Screws (2): 3 Nm (0.3 Kgm). Screws (4): 3 Nm (0.3 Kgm). Remove the seat; see 7.1.1. Release and remove the two screws (1) on both sides. Release and remove the four screws (2). Lower the seat end...

Removing the number plate bracket
Read 1.2.1 carefully. Torque wrench settings: Screws (1): 3 Nm (0.3 kg·m) Nut (2): 3 Nm (0.3 kg·m) Release and remove the two screws (1). Undo and remove the nut (2). Disconnect the four connectors of the rear direction indicators (3). Disconnect...

Chain guard removal
Torque wrench settings: Screws (1): 2 Nm (0.2 kg·m) Release and remove the two screws (1). Remove the chain guard (2).

Upper chain slider removal
Torque wrench settings: Screw (1): 2 Nm (0.2 kg·m) Screw (3): 2 Nm (0.2 kg·m) Note. The chain slider is best accessed after splitting the drive chain; see 7.13.1. Release and remove the screw (1) and collect the nut (2). Release and remove the screw...

Lower chain slider removal
Torque wrench settings: Screws (1): 2 Nm (0.2 kg·m) Note. The chain slider is best accessed after splitting the drive chain; see 7.13.1. Release and remove the two screws (1). Remove the lower chain slider (2).

Air scoop removal
Remove the front fairing; see 7.1.4. Remove the air scoop (1).

Removing the throttle control
Read 1.2.1 carefully. Torque wrench settings: Screws (1): 3 Nm (0.3 kg·m) Screws (3): 10 Nm (1.0 kg·m) Release and remove the two screws (1) securing the two shells from the bottom. Separate the two shells. Warning! On refitting, position the bottom...

Removing the throttle cable from intermediate pulley to oil pump
Torque wrench settings: Screw (2): 5 Nm (0.5 Kgm) Lift the fuel tank, see 2.9.1. Remove the left fairing, see 7.1.2. Loosen and remove the three screws (1) and remove oil pump cover. Slide out the throttle cable. Loosen and remove screw (2) from...

Removing the front brake control
Read 1.2.1 carefully. Torque wrench settings: Reservoir retaining screw (1): 7 Nm (0.7 kg·m) Partial removal Release and remove the reservoir retaining screw (1). Release and remove the two screws (2) securing the front brake control. Note. Mark...

Removing the clutch cable
Slacken the lockring (1) fully. Tighten the adjuster (2) fully. Detach the clutch cable (3) from the lever. Remove the left fairing; see 7.1.2. Undo and remove the gearbox oil filler cap (4). With a small flat screwdriver, prise off the clutch cable...

Complete removal of the gear shift lever
Torque wrench settings: Nut (1): 5 Nm (0.5 Kgm) Screw (4): 10 Nm (1.0 Kgm) Partial removal Undo and release the nut (1). Slide the actuating rod off the lever. Undo and remove the nut (2). Remove the gear shift lever and collect spindle (3) and...

Removing the rear brake lever
Torque wrench settings: Lever adjuster screw: 10 Nm (1.0 Kgm) Unhook the spring (1). Release and remove the pivot bolt (2) and collect the washer. Remove the rear brake lever.

Removing the handlebars
Read 1.2.1 carefully. Torque wrench settings: Screw (1): 10 Nm (1.0 kg·m) Left handlebar Slacken the screw (1) and remove the counterweight (2). Fit the nozzle of an air gun between twistgrip (3) and handlebar. Blow while twisting the nozzle tip. At...

Removing the instrument panel subframe
Read 1.2.1 carefully. Torque wrench settings: Nuts (1): 10Nm (1.0 kg·m) Remove the instrument panel; see 7.2.7. Release the tie securing the wiring to the instrument panel subframe. Release and remove the two nuts (1) and collect the washers. Remove...

Removing the seat latch
Torque wrench settings: Screws (1): 10 Nm (1.0 kg·m) Remove the seat; see 7.1.1. Remove the left cover of the seat subframe; see 7.1.8. Release and remove the two bolts (1) and collect the two nuts. Release and remove the two screws (2). Remove the...

Removing the right-hand rider footpeg bracket
Torque wrench settings: Screw (1): 3 Nm (0.3 Kgm) Screws (2): 10 Nm (1.0 Kgm) Screws (3): 22 Nm (2.2 Kgm) Screw (5): 2 Nm (0.2 Kgm) Release and remove the screw (1). Release and remove the two screws (2) and collect nuts, bushes, washers and guard...

Removing the left-hand rider footpeg bracket
Torque wrench settings: Nut (1): 5 Nm (0.5 Kgm) Screws (2): 22 Nm (2.2 Kgm) Screws (3): 3 Nm (0.3 Kgm) Undo and remove the nut (1). Release and remove the two screws (2). Remove the rider footpeg bracket complete with gear shift lever and footpeg....

Removing the rider footpeg
Read 1.2.1 carefully. Remove the retaining ring (1). Withdraw the spindle (2). Collect footpeg (3) and spring (4). Note. Repeat the process to remove the other rider footpeg if needed.

Removing the passenger footpeg brackets
Torque wrench settings: Screws (1): 13 Nm (1.3 Kgm) Note. The following procedure applies to both footpeg brackets. Remove the side body panel; see 7.1.8. Release and remove the two screws (1) and collect the nuts. Remove the passenger footpeg...

Passenger footpeg removal
Remove the retaining ring (1). Withdraw the spindle (2). Warning! The ball (3) sits on a spring (4) and might be thrown out due to spring action on disassembly. Proceed carefully and make sure to collect the ball. Remove the footpeg and collect the...

Side stand removal
Torque wrench settings: Screws (1): 2 Nm (0.2 Kgm) Screw (2): 3 Nm (0.3 Kgm) Stand bracket bolts (3): 22 Nm (2.2 Kgm) Stand switch screw: 10 Nm (1.0 Kgm) Stand pivot bolt: 10 Nm (1.0 Kgm) Place the motorcycle on the rear wheel stand (OPT); see...

Seat subframe removal
Torque wrench settings: Screw (1): 7 Nm (0.7 Kgm) Screws (2): 22 Nm (2.2 Kgm) Remove the voltage regulator; see 7.2.3. Remove the seat subframe lower moulded cover; see 7.1.12. Remove the airbox; see 4.2.2. Remove the oil tank; see 3.1.1. Remove...

Frame removal
Read 1.2.1 carefully. Torque wrench settings: Shock absorber to frame (1): 50 Nm (5.0 kg·m) Linkages to frame (2): 50 Nm (5.0 kg·m) Footpeg bracket screws (3): 22 Nm (2.2 Kgm) Upper screws (5): 22 Nm (2.2 Kgm) Note. Each procedure is cross-referred...

Frame installation
Read 1.2.1 carefully. Torque wrench settings: Upper screws (1): 22 Nm (2.2 Kgm) Footpeg bracket screws (3): 22 Nm (2.2 Kgm) Shock absorber to frame (4): 50 Nm (5.0 kg·m) Linkages to frame (5): 50 Nm (5.0 kg·m) Note. Each procedure is cross-referred...

Routing and connections of wiring, cables and hoses
Front brake hoses Rear brake hoses Fuel system hoses Oil tubes Clutch cable Cold-start cable Throttle cable Cooling system