Aprilia RS125 RS 125 1993-2002 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Model Designation: RS 125 Codes Chassis Code: AP8114303, AP8114304, AP8114305, AP8114306 (indicative, specific codes may vary by sub-model/region) Engine Code Prefix: Rotax 122 (indicative, engine variants exist) 👋 Introduction Market Position Target Audience: Enthusiasts and professional mechanics for the Aprilia RS125 model range from 1993-2002. Competitive Analysis Value Proposition: Provides complete, official factory service information, saving owners significant costs compared to dealership servicing or less comprehensive manuals. Key Features Manual Advantage: Offers in-depth, step-by-step instructions, detailed illustrations, and troubleshooting guides for all aspects of the motorcycle. Format Advantage: Instant download and printability offer convenience and cost savings. 📋 Manual Details Coverage Areas Years Covered: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Regions Covered: Global (factory specifications generally apply worldwide, minor regional variations may exist) Page Count Estimated Page Count: Hundreds (specific number not provided, but described as complete) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine top end, Engine lubrication system, Fuel system, Cooling system Drivetrain Systems: Clutch, Crankshaft/Transmission, Final Drive Chassis Systems: Wheels/Tires, Brakes, Suspension, Steering, Frame Electrical Systems: Electrical System, Wiring Diagrams Procedures Included Maintenance: Scheduled maintenance, Fluid checks and changes, Filter replacements, Inspections Diagnostics Troubleshooting: Problem diagnosis, Electrical system troubleshooting, Component testing Repair Rebuild: Complete disassembly and reassembly, Engine rebuilds, Transmission repair, Suspension overhaul, Brake system repair, Electrical component repair Installation Adjustment: Component installation, Carburetor tuning, Chain adjustment, Suspension adjustment Technical Depth Depth: Comprehensive factory-level detail, suitable for DIY enthusiasts and professional mechanics, includes step-by-step instructions with detailed illustrations and photos. Illustrations Diagrams: Hundreds of photos, drawings, and diagrams, including enlarged insets and detailed wiring diagrams. 📊 Manual Specifications File Format Format: PDF Compatibility: All PC-based Windows operating systems and Mac. Print Quality Printability: Printable without restriction, allowing for printing of entire manual or specific pages. Binding Type Binding: Digital Download (Printable upon user's discretion) Paper Type Medium: Digital (PDF) Delivery Method: Instant download via link on checkout page. Requirements Software: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Type: 2-stroke, single-cylinder, liquid-cooled (Rotax 122 series engine is common) Displacement: 124.8 cc (approximate) Bore X Stroke: 54 mm x 54.5 mm (typical for Rotax 122 series) Power Output Approx: 15 kW (20.4 hp) at 10,000 rpm (often restricted in some markets to comply with A1 license requirements, unrestricted versions produced more) Torque Approx: 12 Nm (approximate) Performance Compression Ratio: Approximately 8.1:1 to 8.9:1 (varies by specific model and market) Fuel System Carburetor: Dell'Orto VHST 28 or similar (specific model varies) Fuel Type: Unleaded gasoline with appropriate 2-stroke oil mixture (pre-mix or Autolube system) Fuel Tank Capacity: Approximately 7.4 liters (1.95 US gallons) Lubrication System: Autolube oil injection system or pre-mix (depending on variant) 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch: Wet multi-plate clutch Final Drive: Chain drive 📐 Dimensions Weights Dry Weight: Approximately 120 kg (264.5 lbs) Wet Weight: Approximately 137 kg (302 lbs) (with all fluids) 🛡️ Safety Features Ratings Classification: Sport Motorcycle, often categorised for A1 license holders in Europe. Active Features Braking System: Front: Single disc brake, Rear: Single disc brake. Often featured high-performance braking components for its class. Passive Features Frame Type: Aluminum twin-spar frame. 💡 Technology Features Infotainment Dashboard: Analog tachometer, speedometer, odometer, trip meter, coolant temperature warning light, oil level warning light. Driver Assistance Features: N/A (No electronic rider aids typically found on this model). 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific intervals; typically involves periodic checking and topping up of 2-stroke oil reservoir and ensuring proper autolube function. Spark Plug Replacement: Check and replace as per manual, often every 5,000-10,000 km or annually. Air Filter Cleaning: Clean or replace regularly, depending on riding conditions (e.g., every 2,000-5,000 km). Top End Overhaul: Recommended typically every 10,000-15,000 km for 2-stroke engines, but dependent on usage and maintenance quality. Fluid Specifications Engine Oil Type: High-quality 2-stroke synthetic or semi-synthetic oil, specifically for liquid-cooled engines (e.g., Motul 710, Castrol TTS). Coolant Type: Ethylene glycol-based antifreeze coolant, mixed with distilled water (50/50 ratio typical). Brake Fluid Type: DOT 4 or DOT 5.1 brake fluid. Transmission Oil: Refer to manual for specific grade, typically a specific gear oil for wet clutches. Known Issues Common Problems: Carburetor tuning sensitivity, potential for reed valve wear, power valve issues (if applicable to specific sub-models), ignition system component reliability, clutch wear. Maintenance Importance: Due to its 2-stroke nature, meticulous maintenance of the fuel system, lubrication, and top-end is crucial for longevity and performance. 📚 Vehicle History Brand Heritage Manufacturer Origin: Aprilia is an Italian manufacturer known for its performance-oriented motorcycles, particularly in the sportbike and racing segments. Model Evolution Rs125 Legacy: The RS125 has a long-standing reputation as a potent and stylish 125cc sportbike, often considered a benchmark...
AP8114303, AP8114304, AP8114305, AP8114306 (indicative, specific codes may vary by sub-model/region)
Engine Code Prefix:
Rotax 122 (indicative, engine variants exist)
👋 Introduction
Market Position
Target Audience:
Enthusiasts and professional mechanics for the Aprilia RS125 model range from 1993-2002.
Competitive Analysis
Value Proposition:
Provides complete, official factory service information, saving owners significant costs compared to dealership servicing or less comprehensive manuals.
Key Features
Manual Advantage:
Offers in-depth, step-by-step instructions, detailed illustrations, and troubleshooting guides for all aspects of the motorcycle.
Format Advantage:
Instant download and printability offer convenience and cost savings.
Comprehensive factory-level detail, suitable for DIY enthusiasts and professional mechanics, includes step-by-step instructions with detailed illustrations and photos.
Illustrations Diagrams:
Hundreds of photos, drawings, and diagrams, including enlarged insets and detailed wiring diagrams.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All PC-based Windows operating systems and Mac.
Print Quality
Printability:
Printable without restriction, allowing for printing of entire manual or specific pages.
Binding Type
Binding:
Digital Download (Printable upon user's discretion)
Paper Type
Medium:
Digital (PDF)
Delivery
Method:
Instant download via link on checkout page.
Requirements
Software:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Type:
2-stroke, single-cylinder, liquid-cooled (Rotax 122 series engine is common)
Displacement:
124.8 cc (approximate)
Bore X Stroke:
54 mm x 54.5 mm (typical for Rotax 122 series)
Power Output Approx:
15 kW (20.4 hp) at 10,000 rpm (often restricted in some markets to comply with A1 license requirements, unrestricted versions produced more)
Torque Approx:
12 Nm (approximate)
Performance
Compression Ratio:
Approximately 8.1:1 to 8.9:1 (varies by specific model and market)
Fuel System
Carburetor:
Dell'Orto VHST 28 or similar (specific model varies)
Fuel Type:
Unleaded gasoline with appropriate 2-stroke oil mixture (pre-mix or Autolube system)
Fuel Tank Capacity:
Approximately 7.4 liters (1.95 US gallons)
Lubrication
System:
Autolube oil injection system or pre-mix (depending on variant)
🔧 Transmission
Standard
Type:
6-speed constant mesh
Features
Clutch:
Wet multi-plate clutch
Final Drive:
Chain drive
📐 Dimensions
Weights
Dry Weight:
Approximately 120 kg (264.5 lbs)
Wet Weight:
Approximately 137 kg (302 lbs) (with all fluids)
🛡️ Safety Features
Ratings
Classification:
Sport Motorcycle, often categorised for A1 license holders in Europe.
Active Features
Braking System:
Front: Single disc brake, Rear: Single disc brake. Often featured high-performance braking components for its class.
Passive Features
Frame Type:
Aluminum twin-spar frame.
💡 Technology Features
Infotainment
Dashboard:
Analog tachometer, speedometer, odometer, trip meter, coolant temperature warning light, oil level warning light.
Driver Assistance
Features:
N/A (No electronic rider aids typically found on this model).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific intervals; typically involves periodic checking and topping up of 2-stroke oil reservoir and ensuring proper autolube function.
Spark Plug Replacement:
Check and replace as per manual, often every 5,000-10,000 km or annually.
Air Filter Cleaning:
Clean or replace regularly, depending on riding conditions (e.g., every 2,000-5,000 km).
Top End Overhaul:
Recommended typically every 10,000-15,000 km for 2-stroke engines, but dependent on usage and maintenance quality.
Fluid Specifications
Engine Oil Type:
High-quality 2-stroke synthetic or semi-synthetic oil, specifically for liquid-cooled engines (e.g., Motul 710, Castrol TTS).
Coolant Type:
Ethylene glycol-based antifreeze coolant, mixed with distilled water (50/50 ratio typical).
Brake Fluid Type:
DOT 4 or DOT 5.1 brake fluid.
Transmission Oil:
Refer to manual for specific grade, typically a specific gear oil for wet clutches.
Known Issues
Common Problems:
Carburetor tuning sensitivity, potential for reed valve wear, power valve issues (if applicable to specific sub-models), ignition system component reliability, clutch wear.
Maintenance Importance:
Due to its 2-stroke nature, meticulous maintenance of the fuel system, lubrication, and top-end is crucial for longevity and performance.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian manufacturer known for its performance-oriented motorcycles, particularly in the sportbike and racing segments.
Model Evolution
Rs125 Legacy:
The RS125 has a long-standing reputation as a potent and stylish 125cc sportbike, often considered a benchmark in its class. This generation represents a significant evolution from earlier models.
Production
Manufacturing Base:
Primarily manufactured in Italy.
🏆 Awards & Recognition
Recognitions
Segment Standing:
Consistently recognized as one of the premier 125cc sportbikes of its era, often praised for its handling, performance, and aesthetics, rivaling other European and Japanese competitors.