🏷️ Basic Information Identification Make: Aprilia Model: RS125 Model Variant: RS 125 (Rotax 122) Codes Chassis Code Range: AP000000 - AP049999 (approximate, may vary by region/specific model year) 👋 Introduction Market Position Market Position: The Aprilia RS125 was a highly regarded lightweight sportbike, popular for its aggressive styling, race-inspired performance, and handling. It competed in the 125cc sportbike segment against rivals like the Yamaha YZF-R125 (later models), Honda RS125GP (though the RS125 was a street-legal variant), and Cagiva Mito. Competitive Analysis Competition: The RS125's key selling points were its potent Rotax 2-stroke engine, capable of performance exceeding many contemporary 4-stroke 250cc bikes, and its chassis derived from Aprilia's racing experience. This manual is crucial for owners seeking to maintain or restore these performance characteristics. Key Features Key Features: Lightweight, agile handling, strong performance for its class, race-replica styling, and the distinctive 2-stroke engine note. The availability of a detailed parts list is essential for keeping this performance-oriented machine operational. 📋 Manual Details Coverage Areas Coverage: Comprehensive coverage for the Aprilia RS125 motorcycle, spanning model years 1999 through 2003. Includes all major mechanical, electrical, and bodywork components. Page Count Page Count: Estimated 300-500 pages (typical for a detailed parts list and technical manual for this era and complexity). Manual Type Manual Type: Parts List / Technical Manual Language Language: English (primary). May contain diagrams with component labels in multiple languages. Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Systems: Engine (Rotax 122 2-stroke, including top-end, bottom-end, cooling, lubrication), Fuel System (carburetor, fuel tank, lines), Ignition System, Exhaust System, Transmission (gearbox, clutch, shifting mechanism), Chassis (frame, subframe, suspension, steering), Brakes (front and rear calipers, master cylinders, lines, discs), Electrical System (wiring harness, lights, battery, charging system, indicators), Wheels and Tires, Bodywork (fairings, seat, tank covers), Controls (throttle, clutch lever, brake lever, footpegs). Procedures Included Procedures: Component identification, part number cross-referencing, assembly/disassembly procedures for major components, torque specifications, fluid capacities, basic troubleshooting based on component identification, exploded diagrams for visual guidance on assembly. Technical Depth Depth: Detailed parts listing with OEM part numbers, allowing for accurate sourcing of spares. Includes technical specifications relevant to parts installation and maintenance. Focuses on identification and procurement of correct components, with some procedural guidance for installation and basic maintenance. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High-resolution scans of original documentation, ensuring clarity of text and diagrams for printing specific pages. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download - Printable) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, single-cylinder Engine Family: Rotax 122 Displacement: 124.8 cc (7.6 cu in) Bore X Stroke: 54 mm x 54.5 mm (2.13 in x 2.15 in) Compression Ratio: 12.5:1 (approximate, can vary with specific engine tuning) Performance Horsepower: Approx. 30-34 HP at 11,000 RPM (depending on market and tuning restrictions) Torque: Approx. 20 Nm (15 lb-ft) at 10,000 RPM Fuel System Carburetor: Dell'Orto VHSB 34 (typically 34mm) or similar high-performance carburetor Fuel Type: Unleaded gasoline, minimum 95 RON (91 AKI) Oil Mixture: Pre-mix or Automatic Oil Injection System (check specific model variant). For premix, typically 2-stroke engine oil at 2-3% ratio. Intake: Reed valve induction Cooling Cooling System: Liquid-cooled Lubrication Lubrication System: Crankshaft and connecting rod bearings lubricated by fuel-oil mixture or automatic injection system. Gearbox lubricated by transmission oil. 🔧 Transmission Standard Transmission Type: 6-speed manual gearbox Features Clutch Type: Wet multi-plate, cable-actuated Gear Ratios: Specific ratios vary slightly by year and market but are optimized for sporty performance (e.g., 1st: ~2.6, 2nd: ~1.9, 3rd: ~1.5, 4th: ~1.2, 5th: ~1.0, 6th: ~0.85). Final Drive: Chain drive (typically 520 pitch chain, 16T front sprocket, 47T rear sprocket - check manual for exact ratios) 📐 Dimensions Exterior Length: Approx. 1970 mm (77.6 in) Width: Approx. 720 mm (28.3 in) (at handlebars) Height: Approx. 1145 mm (45.1 in) (at seat) Wheelbase: Approx. 1370 mm (53.9 in) Weights Dry Weight: Approx. 131 kg (289 lbs) Fuel Tank Capacity: Approx. 12 liters (3.17 US gal) Wheels Tires Front Tire Size: 110/70-17 Rear Tire Size: 150/60-17 Wheel Type: Cast aluminum alloy 🛡️ Safety Features Passive Features Frame Construction: Aluminum alloy perimeter frame, derived from racing technology. Braking System: Dual disc front brakes with 4-piston calipers (e.g., Brembo or similar high-performance), single disc rear brake with 2-piston caliper. Suspension Front: Upside-down telescopic fork (e.g., Marzocchi or Paioli), with adjustable preload and compression/rebound damping. Suspension Rear: Monoshock absorber with adjustable preload, compression, and rebound damping (e.g., Sachs or similar). Active Features Lighting: Dual halogen headlamps, LED tail light, front and rear turn signals. 💡 Technology Features Infotainment Infotainment Features: Basic analog instrumentation: speedometer, tachometer, engine temperature gauge, odometer, trip meter. No advanced infotainment systems present. Driver Assistance Driver Assistance Features: None. Focus is on rider control and mechanical feedback. Connectivity...
AP000000 - AP049999 (approximate, may vary by region/specific model year)
👋 Introduction
Market Position
Market Position:
The Aprilia RS125 was a highly regarded lightweight sportbike, popular for its aggressive styling, race-inspired performance, and handling. It competed in the 125cc sportbike segment against rivals like the Yamaha YZF-R125 (later models), Honda RS125GP (though the RS125 was a street-legal variant), and Cagiva Mito.
Competitive Analysis
Competition:
The RS125's key selling points were its potent Rotax 2-stroke engine, capable of performance exceeding many contemporary 4-stroke 250cc bikes, and its chassis derived from Aprilia's racing experience. This manual is crucial for owners seeking to maintain or restore these performance characteristics.
Key Features
Key Features:
Lightweight, agile handling, strong performance for its class, race-replica styling, and the distinctive 2-stroke engine note. The availability of a detailed parts list is essential for keeping this performance-oriented machine operational.
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive coverage for the Aprilia RS125 motorcycle, spanning model years 1999 through 2003. Includes all major mechanical, electrical, and bodywork components.
Page Count
Page Count:
Estimated 300-500 pages (typical for a detailed parts list and technical manual for this era and complexity).
Manual Type
Manual Type:
Parts List / Technical Manual
Language
Language:
English (primary). May contain diagrams with component labels in multiple languages.
Component identification, part number cross-referencing, assembly/disassembly procedures for major components, torque specifications, fluid capacities, basic troubleshooting based on component identification, exploded diagrams for visual guidance on assembly.
Technical Depth
Depth:
Detailed parts listing with OEM part numbers, allowing for accurate sourcing of spares. Includes technical specifications relevant to parts installation and maintenance. Focuses on identification and procurement of correct components, with some procedural guidance for installation and basic maintenance.
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality:
High-resolution scans of original documentation, ensuring clarity of text and diagrams for printing specific pages.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download - Printable)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, liquid-cooled, single-cylinder
Engine Family:
Rotax 122
Displacement:
124.8 cc (7.6 cu in)
Bore X Stroke:
54 mm x 54.5 mm (2.13 in x 2.15 in)
Compression Ratio:
12.5:1 (approximate, can vary with specific engine tuning)
Performance
Horsepower:
Approx. 30-34 HP at 11,000 RPM (depending on market and tuning restrictions)
Torque:
Approx. 20 Nm (15 lb-ft) at 10,000 RPM
Fuel System
Carburetor:
Dell'Orto VHSB 34 (typically 34mm) or similar high-performance carburetor
Fuel Type:
Unleaded gasoline, minimum 95 RON (91 AKI)
Oil Mixture:
Pre-mix or Automatic Oil Injection System (check specific model variant). For premix, typically 2-stroke engine oil at 2-3% ratio.
Intake:
Reed valve induction
Cooling
Cooling System:
Liquid-cooled
Lubrication
Lubrication System:
Crankshaft and connecting rod bearings lubricated by fuel-oil mixture or automatic injection system. Gearbox lubricated by transmission oil.
🔧 Transmission
Standard
Transmission Type:
6-speed manual gearbox
Features
Clutch Type:
Wet multi-plate, cable-actuated
Gear Ratios:
Specific ratios vary slightly by year and market but are optimized for sporty performance (e.g., 1st: ~2.6, 2nd: ~1.9, 3rd: ~1.5, 4th: ~1.2, 5th: ~1.0, 6th: ~0.85).
Final Drive:
Chain drive (typically 520 pitch chain, 16T front sprocket, 47T rear sprocket - check manual for exact ratios)
📐 Dimensions
Exterior
Length:
Approx. 1970 mm (77.6 in)
Width:
Approx. 720 mm (28.3 in) (at handlebars)
Height:
Approx. 1145 mm (45.1 in) (at seat)
Wheelbase:
Approx. 1370 mm (53.9 in)
Weights
Dry Weight:
Approx. 131 kg (289 lbs)
Fuel Tank Capacity:
Approx. 12 liters (3.17 US gal)
Wheels Tires
Front Tire Size:
110/70-17
Rear Tire Size:
150/60-17
Wheel Type:
Cast aluminum alloy
🛡️ Safety Features
Passive Features
Frame Construction:
Aluminum alloy perimeter frame, derived from racing technology.
Braking System:
Dual disc front brakes with 4-piston calipers (e.g., Brembo or similar high-performance), single disc rear brake with 2-piston caliper.
Suspension Front:
Upside-down telescopic fork (e.g., Marzocchi or Paioli), with adjustable preload and compression/rebound damping.
Suspension Rear:
Monoshock absorber with adjustable preload, compression, and rebound damping (e.g., Sachs or similar).
Active Features
Lighting:
Dual halogen headlamps, LED tail light, front and rear turn signals.
💡 Technology Features
Infotainment
Infotainment Features:
Basic analog instrumentation: speedometer, tachometer, engine temperature gauge, odometer, trip meter. No advanced infotainment systems present.
Driver Assistance
Driver Assistance Features:
None. Focus is on rider control and mechanical feedback.
Connectivity
Connectivity Features:
None. Basic electrical system for lighting and ignition.
🔧 Maintenance
Service Intervals
Oil Change Transmission:
Every 5,000 - 8,000 km (3,000 - 5,000 miles) or annually. Consult manual for specific interval.
Spark Plug Replacement:
Every 6,000 - 10,000 km (4,000 - 6,000 miles). Use recommended spark plug type (e.g., NGK BR9EG or equivalent).
Air Filter Cleaning:
Every 3,000 - 5,000 km (2,000 - 3,000 miles) or as needed depending on riding conditions. Clean and re-oil if necessary.
Top End Rebuild:
Recommended every 15,000 - 25,000 km (9,000 - 15,000 miles) for optimal 2-stroke performance. This includes piston, rings, and cylinder inspection/replacement.
Fluid Specifications
Transmission Oil:
API GL-4 or GL-5, SAE 75W/90 or 80W/90 gear oil. Capacity: approx. 0.7 - 0.8 liters. Use high-quality motorcycle-specific gear oil.
Coolant:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Total capacity: approx. 1.2 liters.
Brake Fluid:
DOT 4 or DOT 5.1 (check manual for exact specification), a high-temperature glycol-based brake fluid.
Fork Oil:
Approx. 450-500 ml per leg. Viscosity typically SAE 5W or 10W, depending on desired damping. Consult manual for specific fork model and oil level.
Known Issues
Common Issues:
Carburetor tuning sensitivity, wear on the power valve mechanism (if equipped), potential for seized piston if lubrication is inadequate or overheating occurs, wear in the clutch plates, aging electrical connectors.
Typical Repairs:
Piston/ring replacement, clutch refurbishment, carburetor cleaning and jetting, power valve cleaning/adjustment, fork seal replacement, chain and sprocket replacement.
📚 Vehicle History
Brand Heritage
Aprilia Heritage:
Aprilia has a strong racing pedigree, particularly in the smaller displacement classes (125cc and 250cc), where they have achieved numerous world championships. This racing DNA is clearly reflected in the design and performance of the RS125.
Model Evolution
Rs125 Evolution:
The RS125 lineage began in the early 1990s and evolved significantly over the years. The 1999-2003 models represent a mature iteration of the Rotax 122-powered RS125, often considered one of the peak performance versions before later iterations with different engine configurations or emission controls.
Production
Production Years:
1995 - 2012 (with various updates and engine types, including Rotax 122 and later 4-stroke engines).
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Performance Recognition:
The RS125 has consistently been praised by motorcycle publications and riders for its exceptional handling and potent 2-stroke performance, often regarded as one of the best 125cc sportbikes of its era.
Ratings
Rider Reviews:
Highly rated for its track-day capability and spirited street performance, often recommended for riders looking for a pure, engaging riding experience.
Certifications
Emissions Standards:
Compliant with European emissions standards for its model years (e.g., Euro 1 or Euro 2, depending on specific year and market regulations). This manual will help maintain proper function to meet these standards.
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