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Aprilia RS 125 1993-2002 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Model Variant: Rotax 122 Generation Code: RS 125 (Extrema/Replica) Codes Engine Code: Rotax 122 (Two-stroke, single-cylinder) 👋 Introduction Market Position Segment: Lightweight sportbike, popular among younger riders and for track day use Competitive Analysis Competitors: Yamaha YZF-R125, Honda CBR125R, Kawasaki Ninja ZX-12R (prior models) Key Features Design: Aggressive sportbike styling, aluminium twin-spar frame, racing heritage Performance: Lightweight, agile handling, potent two-stroke engine for its class Manual Value Benefit: Empowers owners to perform maintenance and repairs, saving costs and maintaining optimal performance Manual Availability Delivery: Instant PDF download, no shipping delays or costs 📋 Manual Details Coverage Areas Years Covered: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Page Count Number Of Pages: 291 Manual Type Type: Workshop Service Manual for Repair Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, lubrication, cooling, fuel system (carburetor, fuel injection for later models), exhaust system, ignition system, starting system, engine management (CDI) Transmission: Gearbox inspection, maintenance, repair, clutch operation, gear selection mechanism Chassis: Frame inspection, steering head bearings, swingarm, rear shock absorber adjustment and maintenance, front forks (disassembly, seals, oil, springs) Brakes: Front and rear brake system (hydraulic), caliper maintenance, disc inspection, pad replacement, bleeding procedure, master cylinder overhaul Electrical: Wiring diagrams, lighting system, charging system (alternator, battery), ignition switch, instrument panel, starter motor, fuses, relays Fuel System: Carburetor identification (e.g., Dell'Orto PHBH 28/30), jetting specifications, float adjustment, fuel lines, fuel filter Cooling System: Radiator inspection, coolant capacity, thermostat, hoses, water pump maintenance Bodywork: Fairing removal and installation, seat, tank, fenders, plastics, decals Wheels Tires: Wheel bearing maintenance, tire pressure specifications, tire sizes, wheel balancing Procedures Included Maintenance: Regular servicing, oil changes, filter replacements, spark plug checks, chain adjustment and lubrication, brake fluid changes Troubleshooting: Diagnostic charts for common problems, electrical fault finding, engine running issues Repair: Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly Rebuilds: Engine top-end rebuild (piston, cylinder, head), gearbox rebuild, carburetor overhaul Adjustments: Carburetor idle speed and mixture, clutch lever free play, brake lever free play, suspension settings Technical Depth Depth: Comprehensive, from routine maintenance to complete engine and chassis overhauls, suitable for professional mechanics and advanced DIY enthusiasts 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution scans, clear text and diagrams Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Searchability Text Search: Likely searchable text, enabling quick access to specific information ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder, liquid-cooled Bore X Stroke: 54 mm x 54.5 mm Displacement: 124.8 cc Compression Ratio: 12.0:1 (approx.) Power Output: Approx. 30-34 HP @ 11,000 RPM (depending on market restrictions) Torque: Approx. 17-19 Nm @ 10,500 RPM Fuel System Carburetor: Dell'Orto PHBH 28/30 (typical), or specific models may have updated Dell'Orto or Mikuni variants Fuel Type: Unleaded gasoline (95 RON recommended) Lubrication Oil System: Automatic oil injection (separate reservoir) Cooling System Type: Liquid-cooled 🔧 Transmission Standard Type: 6-speed constant mesh, sequential Features Clutch: Wet multi-plate clutch, hydraulically operated Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1940 mm (varies slightly by year/model) Width: Approx. 710 mm Height: Approx. 1130 mm Wheelbase: Approx. 1350 mm Weights Dry Weight: Approx. 120-130 kg Wet Weight: Approx. 135-145 kg 🛡️ Safety Features Ratings Certification: N/A (Motorcycle, typically assessed by rider experience and handling) Active Features Braking: Dual disc front brakes, single disc rear brake Suspension: Adjustable front forks, adjustable rear monoshock Passive Features Frame: Aluminium alloy twin-spar frame for rigidity and rider confidence 💡 Technology Features Infotainment Features: Basic analog instrument cluster (speedometer, tachometer, fuel gauge, warning lights) Driver Assistance Features: N/A (Focus is on rider control and chassis dynamics) 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 km or annually (check manual for exact interval based on usage) Spark Plug Check: Every 3,000-6,000 km Chain Maintenance: Lubrication and tension check every 500-1,000 km Fluid Specifications Engine Oil: 2-stroke engine oil (API TC or JASO FD compliant, specific grade recommended in manual, e.g., 10W-30 for transmission) Coolant: Ethylene glycol-based antifreeze mixture with distilled water (50/50 ratio) Brake Fluid: DOT 4 Known Issues Common Problems: Carburetor jetting sensitivity to altitude/temperature, potential for wear on two-stroke components (piston, rings) with high mileage, exhaust valve operation (if equipped), electrical connections Common Issues Maintenance Focus: Regular cleaning and adjustment of the carburetor is critical for optimal performance. Proper two-stroke oil usage is paramount. 📚 Vehicle History Brand Heritage Manufacturer: Aprilia, an Italian manufacturer known for its performance motorcycles Model Evolution Development: Evolved from earlier Aprilia RS models, incorporating advanced chassis and engine technologies for its class Production Origin: Italy Engine Supplier: Rotax (Bombardier Recreational Products) 🏆 Awards & Recognition Recognitions Awards: N/A (While a popular and well-regarded model, specific published awards for this model year are not widely...
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Aprilia RS 125 1993-2002 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Model Variant:
Rotax 122
Generation
Code:
RS 125 (Extrema/Replica)
Codes
Engine Code:
Rotax 122 (Two-stroke, single-cylinder)
👋 Introduction
Market Position
Segment:
Lightweight sportbike, popular among younger riders and for track day use
Competitive Analysis
Competitors:
Yamaha YZF-R125, Honda CBR125R, Kawasaki Ninja ZX-12R (prior models)
Key Features
Design:
Aggressive sportbike styling, aluminium twin-spar frame, racing heritage
Performance:
Lightweight, agile handling, potent two-stroke engine for its class
Manual Value
Benefit:
Empowers owners to perform maintenance and repairs, saving costs and maintaining optimal performance
Manual Availability
Delivery:
Instant PDF download, no shipping delays or costs
📋 Manual Details
Coverage Areas
Years Covered:
1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002
Page Count
Number Of Pages:
291
Manual Type
Type:
Workshop Service Manual for Repair
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, lubrication, cooling, fuel system (carburetor, fuel injection for later models), exhaust system, ignition system, starting system, engine management (CDI)
Transmission:
Gearbox inspection, maintenance, repair, clutch operation, gear selection mechanism
Chassis:
Frame inspection, steering head bearings, swingarm, rear shock absorber adjustment and maintenance, front forks (disassembly, seals, oil, springs)
Brakes:
Front and rear brake system (hydraulic), caliper maintenance, disc inspection, pad replacement, bleeding procedure, master cylinder overhaul
Electrical:
Wiring diagrams, lighting system, charging system (alternator, battery), ignition switch, instrument panel, starter motor, fuses, relays
Fuel System:
Carburetor identification (e.g., Dell'Orto PHBH 28/30), jetting specifications, float adjustment, fuel lines, fuel filter
Cooling System:
Radiator inspection, coolant capacity, thermostat, hoses, water pump maintenance
Bodywork:
Fairing removal and installation, seat, tank, fenders, plastics, decals
Wheels Tires:
Wheel bearing maintenance, tire pressure specifications, tire sizes, wheel balancing
Procedures Included
Maintenance:
Regular servicing, oil changes, filter replacements, spark plug checks, chain adjustment and lubrication, brake fluid changes
Troubleshooting:
Diagnostic charts for common problems, electrical fault finding, engine running issues
Repair:
Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly
Rebuilds:
Engine top-end rebuild (piston, cylinder, head), gearbox rebuild, carburetor overhaul
Adjustments:
Carburetor idle speed and mixture, clutch lever free play, brake lever free play, suspension settings
Technical Depth
Depth:
Comprehensive, from routine maintenance to complete engine and chassis overhauls, suitable for professional mechanics and advanced DIY enthusiasts
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution scans, clear text and diagrams
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
Searchability
Text Search:
Likely searchable text, enabling quick access to specific information
⚙️ Engine Specifications
Primary Engine
Engine Type:
Two-stroke, single-cylinder, liquid-cooled
Bore X Stroke:
54 mm x 54.5 mm
Displacement:
124.8 cc
Compression Ratio:
12.0:1 (approx.)
Power Output:
Approx. 30-34 HP @ 11,000 RPM (depending on market restrictions)
Torque:
Approx. 17-19 Nm @ 10,500 RPM
Fuel System
Carburetor:
Dell'Orto PHBH 28/30 (typical), or specific models may have updated Dell'Orto or Mikuni variants
Fuel Type:
Unleaded gasoline (95 RON recommended)
Lubrication
Oil System:
Automatic oil injection (separate reservoir)
Cooling System
Type:
Liquid-cooled
🔧 Transmission
Standard
Type:
6-speed constant mesh, sequential
Features
Clutch:
Wet multi-plate clutch, hydraulically operated
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 1940 mm (varies slightly by year/model)
Width:
Approx. 710 mm
Height:
Approx. 1130 mm
Wheelbase:
Approx. 1350 mm
Weights
Dry Weight:
Approx. 120-130 kg
Wet Weight:
Approx. 135-145 kg
🛡️ Safety Features
Ratings
Certification:
N/A (Motorcycle, typically assessed by rider experience and handling)
Active Features
Braking:
Dual disc front brakes, single disc rear brake
Suspension:
Adjustable front forks, adjustable rear monoshock
Passive Features
Frame:
Aluminium alloy twin-spar frame for rigidity and rider confidence
💡 Technology Features
Infotainment
Features:
Basic analog instrument cluster (speedometer, tachometer, fuel gauge, warning lights)
Driver Assistance
Features:
N/A (Focus is on rider control and chassis dynamics)
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 km or annually (check manual for exact interval based on usage)
Spark Plug Check:
Every 3,000-6,000 km
Chain Maintenance:
Lubrication and tension check every 500-1,000 km
Fluid Specifications
Engine Oil:
2-stroke engine oil (API TC or JASO FD compliant, specific grade recommended in manual, e.g., 10W-30 for transmission)
Coolant:
Ethylene glycol-based antifreeze mixture with distilled water (50/50 ratio)
Brake Fluid:
DOT 4
Known Issues
Common Problems:
Carburetor jetting sensitivity to altitude/temperature, potential for wear on two-stroke components (piston, rings) with high mileage, exhaust valve operation (if equipped), electrical connections
Common Issues
Maintenance Focus:
Regular cleaning and adjustment of the carburetor is critical for optimal performance. Proper two-stroke oil usage is paramount.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia, an Italian manufacturer known for its performance motorcycles
Model Evolution
Development:
Evolved from earlier Aprilia RS models, incorporating advanced chassis and engine technologies for its class
Production
Origin:
Italy
Engine Supplier:
Rotax (Bombardier Recreational Products)
🏆 Awards & Recognition
Recognitions
Awards:
N/A (While a popular and well-regarded model, specific published awards for this model year are not widely documented)
Ratings
Rider Reviews:
Consistently praised for its handling, aggressive styling, and performance in the 125cc class
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