Introduction to repair manual motorcycle Aprilia RS125 3 (RS-series, 1999-2005)

Abbreviations, symbols and 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...

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...

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 well-aerated room. Avoid starting the engine in closed or badly-ventilated rooms. In case you are working indoors, make...

Warnings concerning fuel, lubricants, cooland and other component parts
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...

Running-in recommendations
The running-in of the engine is essential to ensure its duration and correct functioning. 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...

Vehicle identification data
Serial numbers location The vehicle serial numbers are used for its homologation. NOTE Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. In particular, the alteration of the frame number...

Using spare parts
Should some parts be replaced, use aprilia Original Spare Parts only. Aprilia high-quality Original Spare Parts have been expressly designed and manufactured for Aprilia vehicles. Warning! The use of Aprilia non original spare parts can impair the...

Use of products for all operations
For all maintenance operations, use the product listed below only. The listed materials have been tested for many years and are suitable for all the applications specified by the manufacturer. Note. Consumer goods, article number, are available upon...

Use of special tools for all operations
Special and suitable tools are required to carry out the disassembly and reassembly operations as well as for a correct setting up. The use of special tools avoids any possible damage arising from the use of non-suitable tools and/or the...

General tightening torque settings
The table shows the standard tightening torque settings for ISO thread screws and bolts. Screw or bolt thread Wrench Tightening torque Nm kgm M 6 10 6 0.6 M 8 12 15 1.5 M 10 14 30 3.0 M 12 17 55 5.5 M 14 19 85 8.5 M 16 22 130 13.0 For special...

Technical data of motorcycle
Dimensions Max. length 1950 mm Max. length (with the optional rear mudguard extension). 2005 mm Max. width 720 mm Max. heigth (front part of the fairing included) 1135 mm Seat height 805 mm Wheel base 1345 mm Min. ground clearance 163 mm Weight...

Positioning the vehicle on the front service stand (OPT)
Position the vehicle on the appropriate rear service stand (OPT), see 1.7.2. Insert the two ends of the stand (1) in the two holes positioned on the lower ends of the front fork. Rest one foot on the front part of the stand. Push the stand downwards...

Positioning the vehicle on the rear service stand (OPT)
Screw and tighten the pin (1) into its proper location on the rear swingarm. Note. Have someone help you keep the vehicle in vertical position with the two wheels on the ground. At the same time introduce the two seats on the stand (2) into the two...

Lubricant chart
LUBRICANT PRODUCT Gear oil RECOMMENDED: F.C., SAE 75W - 90 or gear synth, sae 75W - 90. As an alternative to the recommended oils, it is possible to use select oils having properties in compliance with or even above A.P.I. GL-4 specifications. Mixer...

Decals instructions
Should some frame parts be removed: Note. Plastic and painted parts shall be handled with care. Do not score or damage them. Operate with care. Do not damage keys and/or keyways. When sticking decals, carefully follow the instructions listed...