🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: 2002 Codes Product Name: 2002 Aprilia RS125 Factory Service Repair Manual 👋 Introduction Market Position Target Audience: Owners of the 2002 Aprilia RS125 looking to perform maintenance, repairs, and diagnostics themselves or understand dealer procedures. Key Features Authenticity: Complete factory service manual, identical to what authorized dealers use. Accessibility: Instant download with no shipping costs. Competitive Analysis Advantage: Provides in-depth technical information not found in owner's manuals or generic repair guides. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English File Format: PDF/ZIP Compatibility: WIN/MAC/LINUX Page Count: Estimated 300-500 pages (typical for comprehensive factory service manuals of this era, exact count not provided) 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, inspection, repair, tuning, and component testing. Fuel System: Carburetor (likely Dell'Orto PHBH or similar), fuel pump, fuel lines, fuel tank, fuel filter maintenance and repair. Cooling System: Radiator, coolant hoses, water pump, thermostat, coolant specifications and flush procedures. Lubrication System: Oil pump, oil specifications, oil change intervals, lubrication points. Electric System: Wiring diagrams, battery, starter, ignition system (CDI, spark plug), lighting system, indicators, charging system (stator, regulator/rectifier). Chassis Systems: Frame inspection and repair, front fork (suspension, seals, oil), rear shock absorber, steering head bearings, swingarm, wheel bearings. Brake System: Front and rear brake calipers, master cylinders, brake lines, brake fluid specifications, pad replacement, bleeding procedures. Wheel And Tire: Tire types, pressure specifications, wheel balancing, rim specifications. Bodywork: Fairing removal and installation, seat, fuel tank cover, body panel fasteners. Procedures Included Routine Maintenance: Pre-ride checks, oil changes, filter replacements, chain adjustment, spark plug replacement, brake checks. Troubleshooting: Diagnostic procedures for common issues, symptom-based troubleshooting guides. Engine Repair: Top-end rebuild (piston, cylinder, rings), crankshaft inspection and replacement, clutch service, gearbox inspection and repair. Fuel System Repair: Carburetor cleaning, jetting, float adjustment, fuel line replacement. Cooling System Repair: Coolant flush and refill, water pump seal replacement, radiator leak repair. Electric System Repair: Component testing (e.g., ignition coil resistance), wiring harness repair, bulb replacement. Suspension Service: Front fork oil change and seal replacement, rear shock absorber inspection and adjustment. Brake System Service: Brake caliper overhaul, master cylinder service, brake line replacement, brake bleeding. Torque Specifications: Crucial torque values for critical fasteners across all systems (engine, chassis, brakes). Technical Depth Depth: Comprehensive factory-level repair and diagnostic procedures, suitable for DIY enthusiasts and professional mechanics. 📊 Manual Specifications File Specifications File Type: PDF Searchability: Likely text-searchable PDF, allowing for quick access to specific topics. Printability: Printable pages, allowing for easy referencing during work. Archiving: ZIP format for efficient download and storage. ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder, liquid-cooled (typical for RS125) Displacement: 125cc (exact designation may vary by market, e.g., Rotax 122) Bore X Stroke: Typically around 54 mm x 54.5 mm (verify specific model variant) Power Output: Approximately 30-34 HP at ~12,000 RPM (restricted versions may be lower) Torque: Typically around 20-22 Nm at ~11,000 RPM (verify specific model variant) Performance Ignition System: Electronic CDI ignition Starting System: Kick-start Fuel System Carburetor: Dell'Orto PHBH 28 (common, but check specific regional variant) Fuel Delivery: Premixed fuel/oil or separate oil injection system (check specific model variant) 🔧 Transmission Standard Type: 6-speed constant mesh gearbox Features Clutch: Wet multi-plate clutch Final Drive: Chain drive 📐 Dimensions Exterior Wheelbase: Approximately 1375 mm (verify specific model variant) Seat Height: Approximately 810 mm (verify specific model variant) Weights Dry Weight: Approximately 132 kg (verify specific model variant) Fuel Capacity: Approximately 11 liters (verify specific model variant) 🛡️ Safety Features Passive Features Lighting: Halogen headlight, LED tail light, turn signals 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, speedometer, odometer, coolant temperature gauge, indicator lights. Driver Assistance Aids: Not applicable for this model year (basic sportbike design). 🔧 Maintenance Service Intervals Oil Change: Typical interval: every 3,000-5,000 km or annually (refer to manual for exact) Spark Plug Replacement: Typical interval: every 5,000-8,000 km (refer to manual for exact) Air Filter Cleaning: Frequent checks, cleaning/replacement every 3,000-6,000 km (depending on conditions) Fluid Specifications Engine Oil 2Stroke: High-quality 2-stroke synthetic or semi-synthetic oil (e.g., Motul 710, Castrol TTS - refer to manual for specific recommendation) Coolant: Ethylene glycol-based antifreeze/coolant mixture (e.g., 50/50 water/coolant - refer to manual for specific type and capacity) Brake Fluid: DOT 4 brake fluid (refer to manual for specific type and capacity) Known Issues Engine Wear: High-mileage two-strokes can experience wear in the cylinder, piston rings, and crankshaft bearings. Regular maintenance is key. Carburetor Issues: Clogging or maladjustment of the carburetor can lead to poor running conditions. Ignition System: CDI units or stator failures can lead to no-spark conditions. 📚 Vehicle History Brand Heritage Manufacturer: Aprilia is an Italian manufacturer known for its sport motorcycles. Model Evolution Rs125 Legacy: The RS125 has a long-standing reputation as a potent 125cc two-stroke sportbike,...