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Aprilia Rs 125 Gearbox Oil Problem

12K views 25 replies 8 participants last post by  Koyo 
#1 ·
Hello Everyone, its my first time creating a topic so be gentle pls :) Anyway getting to the point, I need your help/advice as I have an Aprilia Rs125 2006 New Shape, had the bike for 3 weeks now and already spotted a problem with the clutch as I found it hard to go uphill from stand still and it is making weird noises. Also after about 10 mins of riding the bike sort of stinks like some plastic has been melting and there was also a rattling sound when in neutral :/ At this point I decided to change the gearbox oil and see what will happen. Then I found something very strange as there was no oil in the gearbox at all!!! I was not sure why it was empty, but I decided to fill it in with new oil and then a real trouble came up when I started the bike up as it started to smoke a lot and you could not see anything behind the bike apart from the very thick white/grey...ish smoke. I checked the level of the gearbox oil and it seemed like it was taking the gearbox oil as there was much less oil than before. I have also checked whether there was not leaks anywhere but everything is fine. My question is whether anyone knows what is happening to the bike? I'll try and put a video up tomorrow to show what is exactly happening.
 
#4 ·
Thanks very much for fast replies, so even if I will replace the crank seals and the clutch and put everything back the noise would still be there? What do I have to do to make a full bottom end rebuild. Sorry kinda new to repairing things in the engine :)
 
#6 ·
you'll find that the plastic gears in clutch cover are obliterated. They cost about £40 iirc. You'll probably need to change the oil and water pump gears in there too. Dead easy job to just do that. Obviously the crank seal needs doing aswell, that's a big job that will require engine removal. The rest of your bottom end may have survived although your gearbox may be buggered
 
#7 · (Edited by Moderator)
i had this problem before and like every one says its the seal but i did not rebuild the engine all i did was get a screw and screw it in the seal pop it out and taped a new one in with a long socket and worked a treat
what ever you do dont screw in the metal casing !! haha good luck

oh yea when you screw it in get a hammer and just pull it out you may find the screw pops out some times so just keep trying and after a while the seal comes with it :)
 
#8 ·
Ok thanks for all help, I'll probably start to work on it tomorrow. Looks like there is gonna be a lot of work waiting for me :) but at least its the winter season so will have time to repair it hopefully :) Just last question for people that have done this thing, how long does it take to get to the crankshaft seal? Is it possible to do it within a day? or am I being too optimistic? :) Again Thanks for all the info :D
 
#9 ·
seal can be replaced without the engine split and while its in the frame
clutch cover off

remove gear selector fork

remove clutch

remove balance gears ( if theres anything left of yours lol )

pull old seal out

replace old seal

fit balance gears and time up correctly

refit clutch

refit gear selctor fork

refit clutch cover with new gasket

job done

but
the noise your hearing suggests there something amiss in the gear box i.e broken bearing or pinion on the shafts

running with no oil in the box results in heat and no lube to bearings

which ends up doing this





 
#10 ·
Those pictures look serious and I hope mine does not look like this, otherwise the repair will cost much more :/ but if I would be looking at the worst case scenario and this would actually happen to me, then is it worth repairing it? or just buy a new engine?
 
#11 ·
if you know what your doing or feel confident then its worth doing yourself
if you dont

then 2 options

buy a second hand engine with no idea when its been rebuilt with no history etc only the owners word to go off *could go boom a week after fitting )

or get it rebuilt yourself by a reputable company like these

http://www.pjme.co.uk/acatalog/Engine_Rebuilding.html
 
#15 ·
I didnt even know that, I thought it would be from the thrashing when cold, at least thats what the previous owner I assume did (b*st*rd!!) I know the bike has had better days from the service history provided to it and also because of that I thought that the bike had been maintained at least appropriately :/
 
#17 ·
Ok, I have taken out the crankshaft oil seal and I am going to put new one on monday, but I have found that there is only this one plastic sprocket with a mark on to be positioned correctly according to the dot on the metal "thing" that holds it. Am I right or is there any other marks that have to be positioned correctly?
 

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#19 ·
Thanks for the link will definitely use it to put it back together, this time properly :) Also one of the yellow plastic sprockets (left one) is worn out pretty heavily because of the crankshaft seal being not seated correctly, is there any way of buying just this sprocket or do I have to buy the whole set?
 
#21 ·
Ok thanks for the link again :) so when I put the bike up together, will the screw/wrench icon show up on my dashboard? and whats the recommended mileage the bike should be serviced at, because mine right now has nearly 12000 miles and the last service was done when had 5000 miles (not by me by previous owner). I know it has been a long time ago since it has been serviced, but its not my fault :)
 
#23 · (Edited by Moderator)
I meant like those annual servicing things :D I have receipts for the piston, rings and the barrel that they have been replaced and when looking at the date they were issued the parts are there for 8 months (fitted).
But anyway if it would be running 7000 miles on same piston and rings, it would not be able to reach the top speed right? and it would also not accelerate as well right?
 
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