Aprilia RS125 RS 125 2000 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: 2000 Product Name: Aprilia RS125 RS 125 2000 Factory Service Repair Manual Download PDF Codes Chassis Codes: WK000 👋 Introduction Market Position Segment: Lightweight sportbike, popular in the entry-level performance motorcycle segment. Competitive Analysis Competitors: Competed against models like the Yamaha YZF-R125, Honda CBR125R, and Suzuki GSX-R125 (depending on market availability for the year). Key Features Performance Focus: Known for its sharp styling, agile handling, and spirited two-stroke performance, often used for track days and enthusiastic street riding. Design Inspiration: Reflected Aprilia's experience in Grand Prix racing, featuring a sporty chassis and aerodynamic fairings. 📋 Manual Details Coverage Areas Primary Coverage: Complete factory service and repair procedures for the 2000 Aprilia RS125. Page Count Estimated Pages: Hundreds (specific number not provided in product description, but implies comprehensive coverage). Manual Type Type: Factory Service Repair Manual Language Language: English (assumed, standard for factory service manuals unless otherwise specified). Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, and overhaul for the Rotax 125cc two-stroke engine, including carburetor tuning, piston/cylinder assembly, crankshaft, ignition system, and cooling. Transmission: Clutch operation, gearbox disassembly and assembly, shift mechanism, and lubrication. Fuel System: Carburetor identification (e.g., Dell'Orto PHBH 28), jetting, fuel pump, fuel tank, and fuel lines. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), ignition system (CDI), lighting, starting system, and instrumentation. Brakes: Front and rear brake system service, including caliper overhaul, master cylinder service, brake pad replacement, rotor inspection, and hydraulic fluid bleeding. Suspension: Front fork (e.g., Marzocchi) service, including oil changes, seal replacement, spring inspection, and rear shock absorber adjustment and service. Chassis And Bodywork: Frame inspection, fairing removal and installation, seat, handlebars, footpegs, and general bodywork maintenance. Cooling System: Radiator inspection, coolant specifications, hose replacement, and water pump service. Procedures Included Maintenance: Scheduled maintenance tasks, fluid level checks and changes, filter replacements, chain adjustment, and spark plug service. Troubleshooting: Systematic diagnostic procedures for common and uncommon problems, including no-start conditions, poor performance, and electrical faults. Repair: Step-by-step instructions for component removal, repair, reassembly, and adjustment. Overhaul: Complete engine and transmission rebuild procedures, including critical tolerances and torque specifications. Special Tools: Identification and usage of specialized tools required for specific service procedures. Technical Depth Depth: Comprehensive, covering basic maintenance to full engine and component rebuilds, suitable for both DIY enthusiasts and professional technicians. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable PDF for efficient information retrieval (standard for factory manuals). Print Quality Quality: High resolution, designed for clear printing of diagrams, illustrations, and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Rotax 122 E2, Liquid-cooled, 2-stroke, single cylinder Displacement: 125 cc (124.8 cc) Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 12.2:1 (typical for the era, can vary slightly) Valve Train: Reed valve intake, exhaust powervalve (APTS - Aprilia Performance Valve System) Performance Horsepower Hp: Approximately 30-34 hp (at crankshaft) in unrestricted European/international spec (restricted versions were common in some markets). Torque Lb-Ft: Approximately 17-19 lb-ft (at crankshaft) in unrestricted spec. Fuel System Carburetor: Dell'Orto PHBH 28 DD (or similar 28mm carb) Fuel Type: Unleaded gasoline (95 RON minimum recommended) Fuel Delivery: Gravity feed from tank to carburetor, with a vacuum-operated fuel tap. Lubrication System: Pre-mix (manual or automatic oil injection system) and engine oil sump. Ignition System: Electronic ignition (CDI - Capacitor Discharge Ignition) with variable ignition timing controlled by the ECU, often with a performance curve adjustment. 🔧 Transmission Standard Type: 6-speed constant mesh manual gearbox Features Clutch: Wet, multi-plate clutch operated by hydraulic system. Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1950 mm (76.8 in) Width: Approx. 730 mm (28.7 in) Height: Approx. 1070 mm (42.1 in) Wheelbase: Approx. 1335 mm (52.6 in) Weights Dry Weight: Approx. 130 kg (287 lbs) Wet Weight: Approx. 145 kg (320 lbs) (with fluids) Load Capacity: Typically rider and minimal luggage. 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycle safety is primarily assessed through handling, braking, and rider aids, not standardized crash ratings as for cars). Active Features Braking System: Hydraulic disc brakes front and rear. Front typically a larger diameter disc (e.g., 320mm) with a dual-piston caliper. Rear a smaller disc (e.g., 210mm) with a single-piston caliper. Tires: Sport-oriented radial tires. Typical sizes: Front 110/70-17, Rear 150/60-17. Suspension Features: USD (Upside-Down) front forks for improved rigidity and responsiveness. Adjustable rear monoshock with preload and rebound damping. Passive Features Lighting: Halogen headlamp, taillight, brake lights, and turn signals. Chassis Design: Aluminium alloy twin-spar frame providing excellent rigidity and feedback to the rider. 💡 Technology Features Infotainment Instrumentation: Analog tachometer, speedometer, odometer, trip meter, coolant temperature gauge, and warning lights (e.g., oil level, neutral, turn signals, high beam). Driver Assistance Rider Aids:...
Aprilia RS125 RS 125 2000 Factory Service Repair Manual Download PDF
Codes
Chassis Codes:
WK000
👋 Introduction
Market Position
Segment:
Lightweight sportbike, popular in the entry-level performance motorcycle segment.
Competitive Analysis
Competitors:
Competed against models like the Yamaha YZF-R125, Honda CBR125R, and Suzuki GSX-R125 (depending on market availability for the year).
Key Features
Performance Focus:
Known for its sharp styling, agile handling, and spirited two-stroke performance, often used for track days and enthusiastic street riding.
Design Inspiration:
Reflected Aprilia's experience in Grand Prix racing, featuring a sporty chassis and aerodynamic fairings.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete factory service and repair procedures for the 2000 Aprilia RS125.
Page Count
Estimated Pages:
Hundreds (specific number not provided in product description, but implies comprehensive coverage).
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (assumed, standard for factory service manuals unless otherwise specified).
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, and overhaul for the Rotax 125cc two-stroke engine, including carburetor tuning, piston/cylinder assembly, crankshaft, ignition system, and cooling.
Transmission:
Clutch operation, gearbox disassembly and assembly, shift mechanism, and lubrication.
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), ignition system (CDI), lighting, starting system, and instrumentation.
Brakes:
Front and rear brake system service, including caliper overhaul, master cylinder service, brake pad replacement, rotor inspection, and hydraulic fluid bleeding.
Suspension:
Front fork (e.g., Marzocchi) service, including oil changes, seal replacement, spring inspection, and rear shock absorber adjustment and service.
Chassis And Bodywork:
Frame inspection, fairing removal and installation, seat, handlebars, footpegs, and general bodywork maintenance.
Cooling System:
Radiator inspection, coolant specifications, hose replacement, and water pump service.
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid level checks and changes, filter replacements, chain adjustment, and spark plug service.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, including no-start conditions, poor performance, and electrical faults.
Repair:
Step-by-step instructions for component removal, repair, reassembly, and adjustment.
Overhaul:
Complete engine and transmission rebuild procedures, including critical tolerances and torque specifications.
Special Tools:
Identification and usage of specialized tools required for specific service procedures.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to full engine and component rebuilds, suitable for both DIY enthusiasts and professional technicians.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable PDF for efficient information retrieval (standard for factory manuals).
Print Quality
Quality:
High resolution, designed for clear printing of diagrams, illustrations, and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotax 122 E2, Liquid-cooled, 2-stroke, single cylinder
Approximately 30-34 hp (at crankshaft) in unrestricted European/international spec (restricted versions were common in some markets).
Torque Lb-Ft:
Approximately 17-19 lb-ft (at crankshaft) in unrestricted spec.
Fuel System
Carburetor:
Dell'Orto PHBH 28 DD (or similar 28mm carb)
Fuel Type:
Unleaded gasoline (95 RON minimum recommended)
Fuel Delivery:
Gravity feed from tank to carburetor, with a vacuum-operated fuel tap.
Lubrication
System:
Pre-mix (manual or automatic oil injection system) and engine oil sump.
Ignition
System:
Electronic ignition (CDI - Capacitor Discharge Ignition) with variable ignition timing controlled by the ECU, often with a performance curve adjustment.
🔧 Transmission
Standard
Type:
6-speed constant mesh manual gearbox
Features
Clutch:
Wet, multi-plate clutch operated by hydraulic system.
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 1950 mm (76.8 in)
Width:
Approx. 730 mm (28.7 in)
Height:
Approx. 1070 mm (42.1 in)
Wheelbase:
Approx. 1335 mm (52.6 in)
Weights
Dry Weight:
Approx. 130 kg (287 lbs)
Wet Weight:
Approx. 145 kg (320 lbs) (with fluids)
Load Capacity:
Typically rider and minimal luggage.
🛡️ Safety Features
Ratings
Crash Safety:
N/A (Motorcycle safety is primarily assessed through handling, braking, and rider aids, not standardized crash ratings as for cars).
Active Features
Braking System:
Hydraulic disc brakes front and rear. Front typically a larger diameter disc (e.g., 320mm) with a dual-piston caliper. Rear a smaller disc (e.g., 210mm) with a single-piston caliper.
Tires:
Sport-oriented radial tires. Typical sizes: Front 110/70-17, Rear 150/60-17.
Suspension Features:
USD (Upside-Down) front forks for improved rigidity and responsiveness. Adjustable rear monoshock with preload and rebound damping.
Passive Features
Lighting:
Halogen headlamp, taillight, brake lights, and turn signals.
Chassis Design:
Aluminium alloy twin-spar frame providing excellent rigidity and feedback to the rider.
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer, speedometer, odometer, trip meter, coolant temperature gauge, and warning lights (e.g., oil level, neutral, turn signals, high beam).
Driver Assistance
Rider Aids:
None (ABS, traction control, or ride modes were not features of this model).
🔧 Maintenance
Service Intervals
Oil Change Engine:
Refer to manual for specific interval, typically every few thousand kilometers, depending on usage. Two-stroke requires periodic top-end checks.
Spark Plug Replacement:
Recommended every 5,000-8,000 km (or as specified by plug type).
Chain Lubrication Adjustment:
Check and lubricate every 500-1000 km, adjust tension as needed.
Brake Fluid Flush:
Recommended every 1-2 years.
Coolant Flush:
Recommended every 2-3 years.
Fluid Specifications
Engine Oil:
Two-stroke specific, API TC or JASO FD rated synthetic oil for automatic injection system. Check manual for specific blend recommendations.
Gearbox Oil:
API GL-4 or GL-5 gear oil (e.g., Motul Gear 300 75W-90 or equivalent). Capacity typically around 0.8-1.0 liter.
Coolant:
Ethylene glycol-based antifreeze mixed 50/50 with distilled water. Specific coolant type may be recommended by Aprilia.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Known Issues
Powervalve Sticking:
Common issue on two-strokes due to carbon buildup. Regular cleaning and lubrication are essential.
Carburetor Clogging:
Can occur if fuel is left stagnant for long periods or if poor quality fuel is used. Requires cleaning and potential jet replacement.
Exhaust System Carbon Fouling:
Two-stroke exhaust systems can accumulate carbon, affecting performance. Periodic de-coking may be necessary.
Electrical Connector Corrosion:
In humid or coastal environments, electrical connectors can corrode, leading to intermittent faults.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia has a strong heritage in motorcycle racing, particularly in the Grand Prix 125cc and 250cc classes, which heavily influenced the design and performance of their road-going sportbikes.
Model Evolution
Rs125 Lineage:
The RS125 was a key model in Aprilia's lineup for many years, evolving through various iterations and engine updates. The 2000 model represents a significant stage in its development, often featuring improvements from earlier models.
Production
Manufacturing Location:
Italy
Production Years:
The RS125 platform was produced for many years, with the 2000 model falling within its prominent early production phase.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
While specific awards for the 2000 model year aren't readily available, the RS125 as a model line consistently received praise in motorcycle publications for its performance, handling, and styling in its class.
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