Aprilia RS125 RS 125 2001 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 2001 Codes Vin Prefix: ZAPG0001 / ZAPG0002 (depending on specific market and engine variant) Generation Generation Identifier: 1995-2010 (Pre-Rotax 125 2-stroke evolution) 👋 Introduction Market Position Market Position: Performance-oriented 125cc sportbike, popular among younger riders and track day enthusiasts. Competitive Analysis Competitors: Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125 (though the RS125's 2-stroke engine offered a distinct performance advantage in its era). Key Features Key Features: Lightweight chassis, potent 2-stroke engine, aggressive styling, race-derived suspension and braking components. Manual Value Proposition Cost Saving Potential: Enables DIY maintenance and repairs, potentially saving hundreds to thousands of dollars in labor costs. Manual Utility Professional Advantage: Provides access to the same comprehensive diagnostic, repair, and maintenance information used by professional technicians. 📋 Manual Details Coverage Areas Global Coverage: All Models/Engines/Trim/Transmissions Types Page Count Estimated Page Count: Hundreds of pages (as per product description) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Fuel System, Cooling System, Engine Top End, Engine Lubrication System, Crankshaft/Transmission, Engine Removal/Installation Chassis Systems: Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame Electrical Systems: Electrical System, Wiring Diagrams Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, lubrication Repair Procedures: Disassembly, assembly, cleaning, reinstallation, troubleshooting of all major components Diagnostic Procedures: Troubleshooting guides for common issues, electrical system diagnostics Technical Depth Technical Depth: Professional-level diagnostics, detailed repair procedures, critical specifications, exploded diagrams, troubleshooting charts 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Full Printable Zoom Functionality Zoom In Out: YES Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip Compatibility Operating System Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, single-cylinder, Reed Valve Induction Bore X Stroke: 54 mm x 54.5 mm (typical for Rotax 123/122 based engines) Displacement: 124.8 cc Compression Ratio: 12.0:1 (approximate, can vary) Performance Horsepower: Approx. 30-34 HP (at crankshaft, depending on market regulations and specific tuning) Torque: Approx. 2.1-2.3 kgf-m (at approx. 7,500-8,000 rpm) Fuel System Carburetor: Dell'Orto VHST 28 (or similar performance carburetor) Fuel Type: Unleaded gasoline (minimum 95 RON recommended) Fuel Tank Capacity: Approx. 7.2 liters (1.9 US gal) Lubrication Lubrication System: Premix or separate oil injection system (depending on specific model variant) Cooling System Cooling Type: Liquid Cooling Coolant Type: Ethylene Glycol based coolant (50/50 mix with distilled water recommended) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh sequential gearbox Features Clutch Type: Wet, multi-plate, cable-actuated Gear Ratios: Specific ratios detailed in the manual (e.g., 1st: ~3.0, 2nd: ~2.0, 3rd: ~1.5, 4th: ~1.25, 5th: ~1.1, 6th: ~1.0) Final Drive: Chain drive (e.g., 17/50 tooth sprockets) 📐 Dimensions Exterior Length: Approx. 1960 mm Width: Approx. 720 mm Height: Approx. 1140 mm Weights Dry Weight: Approx. 131 kg Wet Weight: Approx. 149 kg (fully fueled) Max Load: Approx. 180 kg (rider and passenger) 🛡️ Safety Features Active Features Braking System Front: Dual-piston caliper, 320mm disc (e.g., by Brembo or similar) Braking System Rear: Single-piston caliper, 220mm disc Tires Front: 110/70-17 Tires Rear: 150/60-17 Passive Features Frame Type: Aluminum alloy twin-spar frame Suspension Front: Upside-down telescopic forks (e.g., Marzocchi or Paioli), 40mm stanchion diameter, adjustable preload/rebound (on some variants) Suspension Rear: Monoshock absorber with adjustable preload and rebound damping (e.g., Sachs) 💡 Technology Features Infotainment Infotainment System: N/A (Basic analog instrumentation: speedometer, tachometer, odometer, engine temperature gauge) Driver Assistance Driver Assistance: N/A (Focus on rider control and machine feedback) Lighting Headlight Type: Halogen (dual headlights) 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time recommendations (typically every 3,000-5,000 km or annually). Spark Plug Replacement: Refer to manual for specific intervals (typically every 5,000-10,000 km). Top End Rebuild Interval: For a 2-stroke, this is critical. Refer to manual for recommended piston/ring replacement intervals based on usage (can range from 10,000-20,000 km for spirited riding). Fluid Specifications Engine Oil Type 2 Stroke: High-quality 2-stroke synthetic or semi-synthetic oil (e.g., Motul 7100 2T, Castrol TTS, or Aprilia branded 2-stroke oil). Transmission Oil Type: SAE 75W/80 or SAE 75W/90 GL-4 gear oil (refer to manual for exact specification). Brake Fluid Type: DOT 4 brake fluid Known Issues Known Issues: Potential for wear on the 2-stroke top end if not maintained, carburetor jetting sensitivity to atmospheric conditions, exhaust power valve sticking, clutch wear with aggressive use. 📚 Vehicle History Brand Heritage Brand Heritage: Aprilia is an Italian manufacturer with a strong racing heritage, particularly in smaller displacement categories. Model Evolution Model Evolution: The RS 125 has a long lineage, with the 2001 model representing a mature iteration of Aprilia's lightweight 2-stroke sportbike platform, building on earlier RS 125 models. It was renowned for its race-replica styling and potent performance for its class. Production Production Period: The RS 125 platform...
Dell'Orto VHST 28 (or similar performance carburetor)
Fuel Type:
Unleaded gasoline (minimum 95 RON recommended)
Fuel Tank Capacity:
Approx. 7.2 liters (1.9 US gal)
Lubrication
Lubrication System:
Premix or separate oil injection system (depending on specific model variant)
Cooling System
Cooling Type:
Liquid Cooling
Coolant Type:
Ethylene Glycol based coolant (50/50 mix with distilled water recommended)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh sequential gearbox
Features
Clutch Type:
Wet, multi-plate, cable-actuated
Gear Ratios:
Specific ratios detailed in the manual (e.g., 1st: ~3.0, 2nd: ~2.0, 3rd: ~1.5, 4th: ~1.25, 5th: ~1.1, 6th: ~1.0)
Final Drive:
Chain drive (e.g., 17/50 tooth sprockets)
📐 Dimensions
Exterior
Length:
Approx. 1960 mm
Width:
Approx. 720 mm
Height:
Approx. 1140 mm
Weights
Dry Weight:
Approx. 131 kg
Wet Weight:
Approx. 149 kg (fully fueled)
Max Load:
Approx. 180 kg (rider and passenger)
🛡️ Safety Features
Active Features
Braking System Front:
Dual-piston caliper, 320mm disc (e.g., by Brembo or similar)
Braking System Rear:
Single-piston caliper, 220mm disc
Tires Front:
110/70-17
Tires Rear:
150/60-17
Passive Features
Frame Type:
Aluminum alloy twin-spar frame
Suspension Front:
Upside-down telescopic forks (e.g., Marzocchi or Paioli), 40mm stanchion diameter, adjustable preload/rebound (on some variants)
Suspension Rear:
Monoshock absorber with adjustable preload and rebound damping (e.g., Sachs)
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic analog instrumentation: speedometer, tachometer, odometer, engine temperature gauge)
Driver Assistance
Driver Assistance:
N/A (Focus on rider control and machine feedback)
Lighting
Headlight Type:
Halogen (dual headlights)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time recommendations (typically every 3,000-5,000 km or annually).
Spark Plug Replacement:
Refer to manual for specific intervals (typically every 5,000-10,000 km).
Top End Rebuild Interval:
For a 2-stroke, this is critical. Refer to manual for recommended piston/ring replacement intervals based on usage (can range from 10,000-20,000 km for spirited riding).
Fluid Specifications
Engine Oil Type 2 Stroke:
High-quality 2-stroke synthetic or semi-synthetic oil (e.g., Motul 7100 2T, Castrol TTS, or Aprilia branded 2-stroke oil).
Transmission Oil Type:
SAE 75W/80 or SAE 75W/90 GL-4 gear oil (refer to manual for exact specification).
Brake Fluid Type:
DOT 4 brake fluid
Known Issues
Known Issues:
Potential for wear on the 2-stroke top end if not maintained, carburetor jetting sensitivity to atmospheric conditions, exhaust power valve sticking, clutch wear with aggressive use.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Aprilia is an Italian manufacturer with a strong racing heritage, particularly in smaller displacement categories.
Model Evolution
Model Evolution:
The RS 125 has a long lineage, with the 2001 model representing a mature iteration of Aprilia's lightweight 2-stroke sportbike platform, building on earlier RS 125 models. It was renowned for its race-replica styling and potent performance for its class.
Production
Production Period:
The RS 125 platform was produced for many years, with the 2001 model being part of the second generation (roughly 1995-2010) before the transition to 4-stroke engines in some markets.
🏆 Awards & Recognition
Recognitions
Market Recognition:
Highly regarded for its performance and handling in the 125cc sportbike segment during its production years. Often praised for its 'big bike' feel and race replica styling.