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Aprilia RS 125 2001 Repair Service Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 2001 Vehicle Type: Sportbike Motorcycle Codes Engine Code Prefix: Rotax 122 Vin Code Letter: Z 👋 Introduction Market Position Historical Significance: The Aprilia RS 125 was a highly regarded lightweight sportbike, known for its aggressive styling, nimble handling, and potent two-stroke performance, often considered a gateway to supersport riding. Target Market: Primarily aimed at younger riders, enthusiasts seeking track-day performance in a smaller displacement package, and those appreciating Italian design and engineering. Competitive Analysis Key Competitors: Honda CBR125R, Yamaha YZF-R125, Suzuki GSX-R125 (in later years), Cagiva Mito 125 Key Features Design Philosophy: Emphasizes lightweight construction, aerodynamic efficiency, and a sporty riding posture characteristic of larger sportbikes. Performance Focus: High-revving two-stroke engine coupled with a capable chassis and suspension for exhilarating performance. Manual Utility: Provides in-depth technical guidance crucial for maintaining the performance and longevity of this high-strung two-stroke motorcycle. 📋 Manual Details Coverage Areas Manual Type: Repair Service Manual Language: English Format: PDF Download Target Audience: Professional Technicians, Advanced DIYers Availability: Instant Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, top-end rebuild, bottom-end assembly, carburetor tuning, cooling system, lubrication system, exhaust system Transmission: Gearbox disassembly, clutch service, shift mechanism, gear ratio identification Fuel System: Carburetor (Dell'Orto PHBH 28 VD) overhaul and adjustment, fuel pump, fuel lines, fuel tank maintenance Electrical System: Wiring diagrams, ignition system (CDI, spark plug), lighting, charging system (stator, regulator/rectifier), battery service, starter motor Brakes: Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, brake fluid bleeding, rotor inspection Suspension: Front telescopic forks (Marzocchi) service, rear shock absorber (Monoshock) service, spring rates, damping adjustments Chassis: Frame inspection, steering head bearing service, swingarm service, wheel bearing replacement Bodywork: Fairing removal and installation, seat, fuel tank, fender service Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, chain adjustment, spark plug inspection/replacement Troubleshooting: Diagnostic charts for common performance issues, starting problems, electrical faults Repair: Step-by-step repair instructions for all major systems, component replacement procedures Rebuild: Complete engine and gearbox rebuild procedures, including torque specifications and clearances Adjustment: Carburetor jetting, idle speed, ignition timing (if applicable), suspension settings Technical Depth Diagnostic Capabilities: Detailed symptom-to-cause analysis, electrical troubleshooting flowcharts Component Specifications: Dimensional tolerances, wear limits, material specifications for critical engine components Torque Specifications: Comprehensive list of torque values for all fasteners, including critical engine and chassis bolts Wiring Diagrams: Full-color, detailed electrical schematics for all circuits 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Fully searchable text for quick information retrieval Print Quality Resolution: High-resolution, suitable for printing Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Completeness Completeness: Comprehensive coverage for the specified model year ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder Engine Displacement: 124.8 cc (7.6 cu in) Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 8.1:1 (for common configurations, subject to tuning) Valvetrain: Rotary disc valve induction Power Output: Approximately 31 hp (23 kW) at 11,000 rpm (may vary by market and specific tuning) Torque: Approximately 1.9 kgf·m (18.6 Nm; 13.7 lb·ft) at 10,000 rpm (may vary) Performance Top Speed: Approximately 160 km/h (99 mph) 0-60 Mph: Approximately 6-7 seconds Fuel System Carburetor Model: Dell'Orto PHBH 28 VD Fuel Type: Unleaded gasoline, minimum 95 RON (recommended) Fuel Delivery: Gravity feed with a small fuel pump Lubrication Oil System: Automatic oil injection (separate oil tank) Oil Type Recommendation: High-quality 2-stroke synthetic oil (e.g., Motul 710 2T, Castrol TTS) Cooling System Cooling Medium: Water/Glycol mixture Coolant Capacity: Approx. 1.2 Liters 🔧 Transmission Standard Transmission Type: 6-speed constant mesh, sequential manual Features Clutch Type: Wet multi-plate clutch, cable operated Gear Ratios: Specific ratios documented within the manual (e.g., 1st: 11/34, 2nd: 13/28, 3rd: 15/26, 4th: 17/24, 5th: 19/23, 6th: 21/22) Final Drive: Chain drive (e.g., 16T front, 42T rear sprocket) Transmission Oil Type: SAE 75W/90 or SAE 10W/40 motorcycle gear oil (refer to manual for exact specification and API rating) Transmission Oil Capacity: Approx. 0.8 Liters 📐 Dimensions Exterior Length: Approx. 1950 mm Width: Approx. 710 mm (at handlebars) Height: Approx. 1060 mm (at seat) Wheelbase: Approx. 1345 mm Ground Clearance: Approx. 130 mm Weights Dry Weight: Approx. 131 kg Wet Weight: Approx. 145 kg (fully fueled and with fluids) Fuel Capacity: Approx. 13 Liters (including 3-liter reserve) Seat Height: Approx. 810 mm 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety ratings differ from automotive; focus is on mechanical integrity and rider input) Active Features Braking System: Front: 320mm single disc with 4-piston caliper; Rear: 220mm single disc with 2-piston caliper Suspension Features: Adjustable front forks (preload) and rear monoshock (preload, rebound damping) for optimized handling and stability. Passive Features Lighting: Halogen headlamp, LED tail light, turn signals Frame Construction: Aluminum twin-spar perimeter frame, offering high rigidity and low weight. Tires: Front:...
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Aprilia RS 125 2001 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Year:
2001
Vehicle Type:
Sportbike Motorcycle
Codes
Engine Code Prefix:
Rotax 122
Vin Code Letter:
Z
👋 Introduction
Market Position
Historical Significance:
The Aprilia RS 125 was a highly regarded lightweight sportbike, known for its aggressive styling, nimble handling, and potent two-stroke performance, often considered a gateway to supersport riding.
Target Market:
Primarily aimed at younger riders, enthusiasts seeking track-day performance in a smaller displacement package, and those appreciating Italian design and engineering.
Competitive Analysis
Key Competitors:
Honda CBR125R, Yamaha YZF-R125, Suzuki GSX-R125 (in later years), Cagiva Mito 125
Key Features
Design Philosophy:
Emphasizes lightweight construction, aerodynamic efficiency, and a sporty riding posture characteristic of larger sportbikes.
Performance Focus:
High-revving two-stroke engine coupled with a capable chassis and suspension for exhilarating performance.
Manual Utility:
Provides in-depth technical guidance crucial for maintaining the performance and longevity of this high-strung two-stroke motorcycle.
📋 Manual Details
Coverage Areas
Manual Type:
Repair Service Manual
Language:
English
Format:
PDF Download
Target Audience:
Professional Technicians, Advanced DIYers
Availability:
Instant Download
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, top-end rebuild, bottom-end assembly, carburetor tuning, cooling system, lubrication system, exhaust system
Transmission:
Gearbox disassembly, clutch service, shift mechanism, gear ratio identification
Fuel System:
Carburetor (Dell'Orto PHBH 28 VD) overhaul and adjustment, fuel pump, fuel lines, fuel tank maintenance
Electrical System:
Wiring diagrams, ignition system (CDI, spark plug), lighting, charging system (stator, regulator/rectifier), battery service, starter motor
Brakes:
Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, brake fluid bleeding, rotor inspection
Suspension:
Front telescopic forks (Marzocchi) service, rear shock absorber (Monoshock) service, spring rates, damping adjustments
Chassis:
Frame inspection, steering head bearing service, swingarm service, wheel bearing replacement
Bodywork:
Fairing removal and installation, seat, fuel tank, fender service
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, chain adjustment, spark plug inspection/replacement
Troubleshooting:
Diagnostic charts for common performance issues, starting problems, electrical faults
Repair:
Step-by-step repair instructions for all major systems, component replacement procedures
Rebuild:
Complete engine and gearbox rebuild procedures, including torque specifications and clearances
Adjustment:
Carburetor jetting, idle speed, ignition timing (if applicable), suspension settings
Technical Depth
Diagnostic Capabilities:
Detailed symptom-to-cause analysis, electrical troubleshooting flowcharts
Component Specifications:
Dimensional tolerances, wear limits, material specifications for critical engine components
Torque Specifications:
Comprehensive list of torque values for all fasteners, including critical engine and chassis bolts
Wiring Diagrams:
Full-color, detailed electrical schematics for all circuits
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Fully searchable text for quick information retrieval
Print Quality
Resolution:
High-resolution, suitable for printing
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Completeness
Completeness:
Comprehensive coverage for the specified model year
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, two-stroke, single-cylinder
Engine Displacement:
124.8 cc (7.6 cu in)
Bore X Stroke:
54 mm x 54.5 mm
Compression Ratio:
8.1:1 (for common configurations, subject to tuning)
Valvetrain:
Rotary disc valve induction
Power Output:
Approximately 31 hp (23 kW) at 11,000 rpm (may vary by market and specific tuning)
Torque:
Approximately 1.9 kgf·m (18.6 Nm; 13.7 lb·ft) at 10,000 rpm (may vary)
Performance
Top Speed:
Approximately 160 km/h (99 mph)
0-60 Mph:
Approximately 6-7 seconds
Fuel System
Carburetor Model:
Dell'Orto PHBH 28 VD
Fuel Type:
Unleaded gasoline, minimum 95 RON (recommended)
Fuel Delivery:
Gravity feed with a small fuel pump
Lubrication
Oil System:
Automatic oil injection (separate oil tank)
Oil Type Recommendation:
High-quality 2-stroke synthetic oil (e.g., Motul 710 2T, Castrol TTS)
Cooling System
Cooling Medium:
Water/Glycol mixture
Coolant Capacity:
Approx. 1.2 Liters
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh, sequential manual
Features
Clutch Type:
Wet multi-plate clutch, cable operated
Gear Ratios:
Specific ratios documented within the manual (e.g., 1st: 11/34, 2nd: 13/28, 3rd: 15/26, 4th: 17/24, 5th: 19/23, 6th: 21/22)
Final Drive:
Chain drive (e.g., 16T front, 42T rear sprocket)
Transmission Oil Type:
SAE 75W/90 or SAE 10W/40 motorcycle gear oil (refer to manual for exact specification and API rating)
Transmission Oil Capacity:
Approx. 0.8 Liters
📐 Dimensions
Exterior
Length:
Approx. 1950 mm
Width:
Approx. 710 mm (at handlebars)
Height:
Approx. 1060 mm (at seat)
Wheelbase:
Approx. 1345 mm
Ground Clearance:
Approx. 130 mm
Weights
Dry Weight:
Approx. 131 kg
Wet Weight:
Approx. 145 kg (fully fueled and with fluids)
Fuel Capacity:
Approx. 13 Liters (including 3-liter reserve)
Seat Height:
Approx. 810 mm
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety ratings differ from automotive; focus is on mechanical integrity and rider input)
Active Features
Braking System:
Front: 320mm single disc with 4-piston caliper; Rear: 220mm single disc with 2-piston caliper
Suspension Features:
Adjustable front forks (preload) and rear monoshock (preload, rebound damping) for optimized handling and stability.
Passive Features
Lighting:
Halogen headlamp, LED tail light, turn signals
Frame Construction:
Aluminum twin-spar perimeter frame, offering high rigidity and low weight.
Tires:
Front: 110/70-17; Rear: 150/60-17 (Common fitment, specific brands may vary)
💡 Technology Features
Infotainment
Infotainment System:
N/A (Focus on pure motorcycling experience, no digital infotainment features)
Driver Assistance
ABS:
Not equipped with ABS
Traction Control:
Not equipped with traction control
Connectivity
Connectivity Features:
N/A (Analog instrumentation, no Bluetooth or Wi-Fi connectivity)
Instrumentation
Dashboard:
Analog speedometer, tachometer, temperature gauge, fuel gauge, and indicator lights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or annually (engine oil, check manual for specific type and grade)
Spark Plug Replacement:
Every 5,000-8,000 km (recommended: NGK BR9EG or equivalent)
Air Filter Cleaning Replacement:
Every 2,000-4,000 km
Chain Lubrication Adjustment:
Every 500-1,000 km or after riding in wet conditions
Brake Fluid Change:
Every 2 years or as per manual recommendation
Coolant Change:
Every 2-3 years
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity and API rating for the gearbox. Often SAE 75W/90 or SAE 10W/40.
Brake Fluid Type:
DOT 4 (recommended)
Coolant Type:
Ethylene Glycol based, 50/50 mixture with distilled water
Known Issues
Carburetor Idling:
Can be prone to inconsistent idling if not properly maintained or jetted for altitude/temperature. Rebuild kits for Dell'Orto carbs are common.
Power Valve Operation:
The exhaust power valve (AEX) mechanism can seize or become gummed up, affecting engine performance. Requires regular cleaning and lubrication.
Cylinder Wear:
Due to its high-performance nature, regular wear on the cylinder bore and piston is expected, especially with aggressive use. Overtemping can accelerate wear.
Reed Valves:
Wear or damage to the reed valve petals can affect fuel mixture and performance. Inspections and replacements are part of regular maintenance.
Electrical Connections:
Corrosion or loose connections in the wiring harness can lead to intermittent electrical issues, especially on older models.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia has a rich history in motorcycle racing, particularly in the Grand Prix circuit, which heavily influenced the design and performance characteristics of their road-going sportbikes like the RS 125.
Model Evolution
Rs 125 Development:
The RS 125 evolved from earlier Aprilia sportbikes, consistently incorporating advanced technologies and race-derived components. The 2001 model represents a mature iteration of the design.
Production
Manufacturing Location:
Italy
Production Years:
Mid-1990s to early 2010s (various iterations)
🏆 Awards & Recognition
Recognitions
Motorcycle Press Reviews:
Consistently praised by motorcycle journalists for its agility, responsive engine, and track-day capability in its class.
Ratings
User Satisfaction:
Highly regarded by owners for its fun factor and performance, though requiring diligent maintenance.
Certifications
Emission Standards:
Compliant with European emission standards for its production era (Euro 1).
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