📚 Vehicle Manual Information

Aprilia Rs125 Motorcycle Service Repair Manual 1999-2003

🏷️ Basic Information

Make:

Aprilia

Model:

RS 125

Sub Model:

Sport Production

Start Year:

1999

End Year:

2003

Engine Codes:

Rotax 122

Chassis Codes:

RV125

👋 Introduction

Positioning:

High-performance 125cc sportbike, popular for track days and street use, often chosen by younger riders for its racing pedigree.

Competitors:

Yamaha YZF-R125 (later models), Honda CBR125R (later models), Cagiva Mito 125.

Unique Selling Points:

Race-derived styling, strong performance for its class, potent 2-stroke engine, sophisticated chassis and suspension.

Benefit To User:

Empowers owners to perform repairs and maintenance themselves, saving significant costs compared to professional shop labor. Provides in-depth knowledge for proper upkeep and restoration.

📋 Manual Details

Primary Coverage:

Full service, repair, diagnostics, maintenance, and restoration.

Secondary Coverage:

Technical specifications, troubleshooting guides, wiring diagrams.

Estimated Pages:

Refer to specific edition for exact count; comprehensive coverage implies extensive pages.

Type:

Service Repair Manual

Language:

English

Format:

PDF

Delivery:

Instant Digital Download

📖 Manual Coverage

Engine Mechanical:

General Information, Engine Removal and Installation, Cylinder Head/Valves, Crankcase/Piston/Cylinder, Crankshaft/Transmission/Balancer, Engine Combustion System.

Engine Ancillary:

Engine Fuel System, Engine Lubrication and Cooling, Lubrication System, Cooling System, Fuel Injection System.

Transmission:

Gearbox & Clutch, Transmission System.

Chassis And Suspension:

Front Wheel and Steering System, Rear Wheel System, Chassis, Suspension.

Brakes:

Braking System.

Electrical:

Alternator/Starter Clutch, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams.

Bodywork And Exhaust:

Fenders and Exhaust Pipe, Body & Fixtures, Frame/Body Panels/Exhaust System.

Wheels And Tires:

Wheels & Tyres.

Maintenance:

Periodic checks & Adjustments, routine service, fluid changes, filter replacements.

Repair:

Engine rebuild, gearbox overhaul, suspension service, brake caliper servicing, electrical component replacement.

Diagnostics:

Troubleshooting, fault finding, diagnostic flowcharts.

Disassembly Assembly:

Engine removal/installation, component disassembly and reassembly for all covered systems.

Depth:

Comprehensive, from basic maintenance to complete engine and chassis rebuilds, including detailed electrical schematics and fuel injection system diagnostics.

📊 Manual Specifications

File Type:

PDF

Readability:

Optimized for digital viewing and printing.

Printability:

All pages are printable.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Operating Systems:

All Versions of Windows & Mac

Software:

Adobe PDF Reader

⚙️ Engine Specifications

Engine Type:

2-stroke, single-cylinder

Displacement:

124.8 cc (7.6 cu in)

Bore X Stroke:

54 mm x 54.5 mm (2.13 in x 2.15 in)

Cooling System:

Liquid-cooled

Ignition System:

Electronic ignition (CDI)

Horsepower:

Approx. 30-35 HP (varies by market regulations and specific model variant)

Torque:

Approx. 20-23 Nm (varies)

Carburetor:

Dell'Orto PHBH 28 (or similar)

Fuel Injection:

May feature electronic fuel injection (CAT-I) on later models within this range.

Lubrication Type:

Pre-mix or Autolube system (depending on exact model variant)

🔧 Transmission

Gearbox Type:

6-speed constant mesh

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

📐 Dimensions

Length:

Approx. 2000 mm (78.7 in)

Width:

Approx. 700 mm (27.6 in)

Height:

Approx. 1130 mm (44.5 in)

Dry Weight:

Approx. 130-135 kg (287-298 lbs)

Fuel Capacity:

Approx. 7.8 - 9.5 Liters (2.0 - 2.5 Gallons), including reserve.

🛡️ Safety Features

Crash Safety:

Not officially rated in the same way as cars; relies on rider skill and protective gear.

Braking System:

Front: Disc brake (e.g., Brembo calipers); Rear: Disc brake.

Suspension Features:

Upside-down (USD) front forks, Monoshock rear suspension.

Lighting:

Halogen headlights, taillights, turn signals.

💡 Technology Features

Display:

Analog tachometer and speedometer, digital odometer and other indicators.

Assistance Systems:

No electronic rider aids such as ABS or traction control commonly found in this era and class.

Connectivity Features:

N/A

🔧 Maintenance

Oil Change:

Refer to manual for specific interval based on usage; 2-stroke requires oil for fuel/oil mixture or autolube system.

Spark Plug Inspection:

Typically every 3,000-5,000 km (1,800-3,000 miles).

Air Filter Cleaning:

Regular inspection and cleaning/replacement as per manual, often every 5,000-10,000 km.

Chain Lubrication Adjustment:

Every 500-1000 km, or after riding in wet conditions.

Coolant:

Ethylene glycol-based coolant (e.g., Motul Motocool Expert, Castrol Radicool).

Brake Fluid:

DOT 4

Gearbox Oil:

SAE 10W-40 API SG or higher, or specific Aprilia recommendation.

2-Stroke Oil:

High-quality synthetic 2-stroke engine oil for performance applications (e.g., Motul 710 2T, Castrol TTS).

Common Problems:

Potential for exhaust power valve issues if not maintained, carburetor jetting sensitivity to altitude/temperature, wear on the 2-stroke piston and rings at higher mileage.

Electrical Quirks:

Occasional issues with stator or rectifier on older models, wiring harness integrity.

Cooling System Maintenance:

Regular flushing and inspection of hoses due to the liquid-cooled nature of the engine.

📚 Vehicle History

Brand Focus:

Aprilia is renowned for its motorsport heritage, particularly in Grand Prix racing, specializing in high-performance sportbikes and scooters.

Rs125 Lineage:

The RS 125 is a long-standing model in Aprilia's lineup, evolving from earlier designs to incorporate advanced technologies and styling cues from larger Aprilia sportbikes.

Manufacturing Location:

Italy

🏆 Awards & Recognition

Motorsport Success:

The RS 125 platform has a strong racing pedigree and has been a dominant force in 125cc racing classes, contributing to its desirability and performance reputation.

Performance Reviews:

Generally praised for its handling, braking, and spirited engine performance, often considered one of the best in its class for its era.