APRILIA RS125 ROTAX 122 Engine Service Repair Manual 1999-2003
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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Engine: Rotax 122 Generation Production Years Covered: 1999-2003 👋 Introduction Market Position Target Audience: Owners of Aprilia RS125 models (1999-2003) seeking to perform maintenance, repairs, and restoration themselves to save costs. Competitive Analysis Value Proposition: Provides access to professional-level repair information, empowering users to avoid costly dealership or mechanic fees. Offers the convenience of instant download and on-demand printing. Key Features Features: Highly detailed, printable diagrams, step-by-step repair procedures, troubleshooting guides, and comprehensive technical data. Instant email delivery of download link. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance, Rebuild, Refurbish, Restoration Page Count Estimated Pages: Indeterminate (Digital Download, Printable) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine assembly, disassembly, tuning, carburetor adjustment, ignition system, cooling system, lubrication system, exhaust system, fuel delivery, starter system, power valve operation Chassis Systems: Frame, suspension (front forks, rear shock absorber), steering, wheels, brakes (front and rear calipers, master cylinders, lines), swingarm Electrical Systems: Wiring diagrams, lighting, battery, charging system, ignition, starter motor, instrumentation, sensors Bodywork And Fairings: Fairing removal and installation, seat, fuel tank, minor body repairs Procedures Included Maintenance Procedures: Routine checks, oil changes, filter replacements, spark plug replacement, chain adjustment, brake fluid flush, coolant flush Repair Procedures: Engine rebuild, transmission repair, carburetor overhaul, suspension fork rebuild, brake caliper service, electrical troubleshooting Diagnostic Procedures: Troubleshooting guides for common issues, identification of fault codes (if applicable to the era), performance diagnosis Technical Depth Depth Of Coverage: Comprehensive A-Z coverage, suitable for professional technicians and DIY enthusiasts. Includes detailed diagnostics, rebuild procedures, and component specifications. 📊 Manual Specifications File Format Compatibility: PC & MAC Computers, Adobe PDF Reader required Print Quality Printability: High-quality, printable pages for convenient use at the workbench. Binding Type Binding: Digital Download (No physical binding) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke, Single Cylinder, Liquid-Cooled Bore X Stroke: 54 mm x 54.5 mm Displacement: 124.8 cc Compression Ratio: Approx. 11.5:1 to 12.5:1 (depending on specific variant/region) Performance Horsepower Peak: Approx. 30-34 hp (15 kW for restricted versions in some markets) Torque Peak: Approx. 20-22 Nm Fuel System Carburetor: Dell'Orto VHST 28/30mm (common for this era, specific model may vary) Fuel Type: Unleaded gasoline (minimum 95 RON) Fuel Mixture: Premix (2-stroke oil mixed with gasoline) or separate oil injection system (depending on specific model variant) Lubrication Engine Oil Type: High-quality 2-stroke synthetic oil for racing applications (e.g., Motul 800, Castrol TTS) Ignition Ignition System: Electronic ignition (CDI) Cooling System Cooling Type: Liquid-cooled Coolant Type: Ethylene glycol based coolant with anti-corrosion additives (e.g., Motul Motocool Expert) Power Valve Power Valve System: Rotax "Power Jet" or 'APCS' (Aprilia Controlled Power System) exhaust port power valve. 🔧 Transmission Standard Transmission Type: 6-speed sequential manual gearbox Optional Optional Transmissions: N/A (Standard for RS125) Features Clutch Type: Wet, multi-plate clutch Final Drive: Chain drive Gear Ratios Gear Ratios: Specific ratios documented within the manual (e.g., 1st: 2.5, 2nd: 1.8, 3rd: 1.4, 4th: 1.14, 5th: 1, 6th: 0.86 - *example, actual ratios provided in manual*) Transmission Fluid Transmission Oil Type: Specific gearbox oil as per Aprilia recommendations (typically SAE 75W/90 or similar, but check manual for exact specification) 📐 Dimensions Exterior Length: Approx. 1940 mm Width: Approx. 750 mm Height: Approx. 1135 mm Wheelbase: Approx. 1360 mm Weights Dry Weight: Approx. 122 kg Wet Weight: Approx. 137 kg (fully fueled, ready to ride) Fuel Capacity Fuel Tank Capacity: Approx. 13 Liters (including a reserve) Wheels And Tires Front Tire Size: 110/70-17 Rear Tire Size: 150/60-17 Wheel Type: Alloy wheels Suspension Front Suspension Type: Telescopic front forks (upside-down or conventional depending on specific variant, e.g., Marzocchi or Showa) Rear Suspension Type: Monoshock swingarm with adjustable preload and rebound damping 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety is typically assessed via component performance and design, not crash ratings like cars) Active Features Braking System: Front: Single or dual hydraulic disc brake (e.g., 320mm disc with 4-piston caliper); Rear: Hydraulic disc brake (e.g., 220mm disc with 2-piston caliper). ABS was not a common feature on this model. Passive Features Lighting: Halogen headlight, LED taillight, turn signals. 💡 Technology Features Infotainment Infotainment System: N/A (Basic instrumentation: speedometer, tachometer, odometer, engine temperature warning light, neutral indicator, turn signal indicators) Driver Assistance Driver Assistance Features: N/A (No electronic driver assistance systems typically found on this model) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km or annually (for gearbox oil, check manual for exact recommendation). 2-stroke oil level needs constant monitoring if not using automatic injection. Spark Plug Replacement: Every 5,000-8,000 km, depending on plug type and usage (check manual for specific recommendation). Chain Lubrication Adjustment: Every 500-1000 km, or more frequently in adverse conditions. Air Filter Cleaning Replacement:...
Owners of Aprilia RS125 models (1999-2003) seeking to perform maintenance, repairs, and restoration themselves to save costs.
Competitive Analysis
Value Proposition:
Provides access to professional-level repair information, empowering users to avoid costly dealership or mechanic fees. Offers the convenience of instant download and on-demand printing.
Key Features
Features:
Highly detailed, printable diagrams, step-by-step repair procedures, troubleshooting guides, and comprehensive technical data. Instant email delivery of download link.
Troubleshooting guides for common issues, identification of fault codes (if applicable to the era), performance diagnosis
Technical Depth
Depth Of Coverage:
Comprehensive A-Z coverage, suitable for professional technicians and DIY enthusiasts. Includes detailed diagnostics, rebuild procedures, and component specifications.
📊 Manual Specifications
File Format
Compatibility:
PC & MAC Computers, Adobe PDF Reader required
Print Quality
Printability:
High-quality, printable pages for convenient use at the workbench.
Binding Type
Binding:
Digital Download (No physical binding)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-Stroke, Single Cylinder, Liquid-Cooled
Bore X Stroke:
54 mm x 54.5 mm
Displacement:
124.8 cc
Compression Ratio:
Approx. 11.5:1 to 12.5:1 (depending on specific variant/region)
Performance
Horsepower Peak:
Approx. 30-34 hp (15 kW for restricted versions in some markets)
Torque Peak:
Approx. 20-22 Nm
Fuel System
Carburetor:
Dell'Orto VHST 28/30mm (common for this era, specific model may vary)
Fuel Type:
Unleaded gasoline (minimum 95 RON)
Fuel Mixture:
Premix (2-stroke oil mixed with gasoline) or separate oil injection system (depending on specific model variant)
Lubrication
Engine Oil Type:
High-quality 2-stroke synthetic oil for racing applications (e.g., Motul 800, Castrol TTS)
Ignition
Ignition System:
Electronic ignition (CDI)
Cooling System
Cooling Type:
Liquid-cooled
Coolant Type:
Ethylene glycol based coolant with anti-corrosion additives (e.g., Motul Motocool Expert)
Power Valve
Power Valve System:
Rotax "Power Jet" or 'APCS' (Aprilia Controlled Power System) exhaust port power valve.
🔧 Transmission
Standard
Transmission Type:
6-speed sequential manual gearbox
Optional
Optional Transmissions:
N/A (Standard for RS125)
Features
Clutch Type:
Wet, multi-plate clutch
Final Drive:
Chain drive
Gear Ratios
Gear Ratios:
Specific ratios documented within the manual (e.g., 1st: 2.5, 2nd: 1.8, 3rd: 1.4, 4th: 1.14, 5th: 1, 6th: 0.86 - *example, actual ratios provided in manual*)
Transmission Fluid
Transmission Oil Type:
Specific gearbox oil as per Aprilia recommendations (typically SAE 75W/90 or similar, but check manual for exact specification)
📐 Dimensions
Exterior
Length:
Approx. 1940 mm
Width:
Approx. 750 mm
Height:
Approx. 1135 mm
Wheelbase:
Approx. 1360 mm
Weights
Dry Weight:
Approx. 122 kg
Wet Weight:
Approx. 137 kg (fully fueled, ready to ride)
Fuel Capacity
Fuel Tank Capacity:
Approx. 13 Liters (including a reserve)
Wheels And Tires
Front Tire Size:
110/70-17
Rear Tire Size:
150/60-17
Wheel Type:
Alloy wheels
Suspension
Front Suspension Type:
Telescopic front forks (upside-down or conventional depending on specific variant, e.g., Marzocchi or Showa)
Rear Suspension Type:
Monoshock swingarm with adjustable preload and rebound damping
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety is typically assessed via component performance and design, not crash ratings like cars)
Active Features
Braking System:
Front: Single or dual hydraulic disc brake (e.g., 320mm disc with 4-piston caliper); Rear: Hydraulic disc brake (e.g., 220mm disc with 2-piston caliper). ABS was not a common feature on this model.
Passive Features
Lighting:
Halogen headlight, LED taillight, turn signals.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic instrumentation: speedometer, tachometer, odometer, engine temperature warning light, neutral indicator, turn signal indicators)
Driver Assistance
Driver Assistance Features:
N/A (No electronic driver assistance systems typically found on this model)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or annually (for gearbox oil, check manual for exact recommendation). 2-stroke oil level needs constant monitoring if not using automatic injection.
Spark Plug Replacement:
Every 5,000-8,000 km, depending on plug type and usage (check manual for specific recommendation).
Chain Lubrication Adjustment:
Every 500-1000 km, or more frequently in adverse conditions.
Air Filter Cleaning Replacement:
Every 5,000-10,000 km, or more frequently if ridden in dusty environments.
Fluid Specifications
Brake Fluid Type:
DOT 4 (High-performance synthetic brake fluid)
Coolant Capacity:
Approx. 1.5 Liters (check manual for exact capacity)
Known Issues
Common Issues:
Carburetor jetting issues, power valve sticking or malfunctioning due to carbon buildup, wear on clutch plates, fork seal leaks, electrical connection corrosion.
Technical Specifications
Valve Clearance:
N/A (2-stroke engine does not have valve clearance in the traditional sense; the power valve requires specific adjustment/cleaning).
Spark Plug Gap:
Typically 0.6 - 0.8 mm (refer to manual for exact specification and plug type like NGK BR9EG or similar)
📚 Vehicle History
Brand Heritage
Aprilia Heritage:
Aprilia is an Italian motorcycle manufacturer with a strong racing heritage, particularly in smaller displacement classes. Known for performance-oriented sportbikes.
Model Evolution
Rs125 Evolution:
The RS125 has a long production history, evolving through various chassis and engine updates. The Rotax 122 engine was a potent and well-regarded unit for its time, making the RS125 a popular choice for track days and spirited street riding. This 1999-2003 range often saw refinements in styling and performance.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Model Recognition:
The Aprilia RS125 is widely recognized as a benchmark 125cc sportbike of its era, praised for its handling, performance, and premium feel, often considered a step above its Japanese competitors in terms of chassis and styling.