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Aprilia RS 125 2001 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 2001 Type: Motorcycle Codes Engine Code: Rotax 122 Vin Code: Vehicle Identification Number specific to model and production batch 👋 Introduction Market Position Market Position: The Aprilia RS 125 was positioned as a premium, high-performance entry-level sportbike, often considered a stepping stone to larger displacement motorcycles. It offered a blend of aggressive styling, track-inspired handling, and a potent two-stroke engine for its class. Competitive Analysis Competitive Analysis: Competed directly with other 125cc sportbikes of the era such as the Yamaha YZF-R125, Honda CBR125R, and Suzuki GSX-R125, offering a more exotic European flair and often a more aggressive riding experience. Key Features Key Features: Distinctive twin-spar aluminum frame, powerful Rotax 122 two-stroke engine, advanced suspension components, aggressive aerodynamic fairing, high-performance braking system, and a sharp, race-replica aesthetic. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive coverage for all mechanical and electrical systems of the Aprilia RS 125 (2001 model year). Page Count Page Count: Estimated 300-500 pages (typical for factory service manuals of this era). Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Systems Covered: Engine mechanical, engine electrical, fuel system, cooling system, lubrication system, exhaust system, transmission, clutch, chassis, suspension (front and rear), brakes (front and rear), wheels, tires, steering, electrical system (lighting, ignition, battery, charging), bodywork, maintenance procedures, troubleshooting, diagnostics, specifications, and torque values. Chassis Systems: Frame (steel/aluminum construction), swingarm, steering head bearings, fasteners and torque specifications. Braking System: Front and rear disc brakes, caliper service, master cylinder overhaul, brake line replacement, bleeding procedures, pad wear indicators. Electrical System: Wiring diagrams, lighting circuits, ignition coil, stator, rectifier/regulator, battery maintenance, starter motor (if applicable, though typically kick start), fuses, switches, sensors. Procedures Included Procedures Included: Routine maintenance, scheduled maintenance, disassembly and assembly of major components, engine rebuild procedures, carburetor adjustment and overhaul, electrical troubleshooting, brake bleeding and pad replacement, suspension fork servicing, chain and sprocket replacement, diagnostic flowcharts, component testing, and torque specifications for all fasteners. Engine Tuning: Carburetor jetting adjustment, power valve calibration, spark plug gap adjustment. Suspension Service: Front fork oil change, seal replacement, spring inspection. Rear shock absorber inspection and adjustments. Wheel And Tire: Tire pressure checks, tire wear inspection, wheel bearing service, chain and sprocket replacement, balancing. Technical Depth Technical Depth: In-depth, factory-level technical information suitable for professional technicians and experienced DIY mechanics. Covers everything from basic adjustments to complete engine and chassis overhauls. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High-resolution scans ensuring clarity of text, diagrams, and illustrations, suitable for printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder Displacement: 124.8 cc (7.6 cubic inches) Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 12.2:1 (typical, may vary slightly) Power Output: Approximately 30-35 HP (depending on market restrictions and specific tuning, e.g., 25 kW for European A1 license) Torque: Approximately 20-23 Nm (14.8-17.0 lb-ft) at ~8,000 RPM Ignition System: Electronic ignition, CDI (Capacitor Discharge Ignition) Starting System: Kick starter Cooling System: Liquid-cooled Performance Top Speed: Approximately 150-160 km/h (93-99 mph) Fuel System Fuel Delivery: Carburetor Carburetor Model: Dell'Orto VHST 28 BS (common specification) Fuel Type: Unleaded gasoline, minimum 95 RON Fuel Tank Capacity: 12.0 Liters (3.17 US Gallons) Oil Mixture Type: Premix or Automatic Oil Injection (depending on specific market/variant, typically automatic injection for this model year) Oil Type: Two-stroke engine oil (API TC or JASO FD rated) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh sequential gearbox Features Clutch Type: Wet, multi-plate, cable-actuated Final Drive: Chain drive Gear Ratios: Specific ratios detailed in the manual, typically optimized for sport riding performance. 📐 Dimensions Exterior Length: Approximately 1950 mm (76.8 inches) Width: Approximately 740 mm (29.1 inches) at handlebars Height: Approximately 1050 mm (41.3 inches) at seat Wheelbase: Approximately 1330 mm (52.4 inches) Ground Clearance: Approximately 140 mm (5.5 inches) Seat Height: Approximately 805 mm (31.7 inches) Weights Dry Weight: Approximately 131 kg (288.8 lbs) Wet Weight: Approximately 149 kg (328.5 lbs) (with all fluids) Max Load Capacity: Typically around 150-180 kg (rider + passenger + luggage) 🛡️ Safety Features Ratings Safety Ratings: Motorcycle safety is primarily dependent on rider skill and adherence to maintenance schedules. No standardized crash test ratings like automobiles. Active Features Active Features: Responsive braking system, agile handling chassis, powerful front disc brake, rear disc brake, good visibility from riding position. Passive Features Passive Features: Sturdy frame construction, protective fairing offering some rider protection from elements and minor impacts. 💡 Technology Features Infotainment Infotainment Features: Basic analog instrumentation including speedometer, tachometer, odometer, coolant temperature gauge, and indicator lights. No advanced infotainment systems. Driver Assistance Driver Assistance Features: N/A for this model year; focus...
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Type: Motorcycle
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Sku: 320617
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Aprilia RS 125 2001 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Year:
2001
Type:
Motorcycle
Codes
Engine Code:
Rotax 122
Vin Code:
Vehicle Identification Number specific to model and production batch
👋 Introduction
Market Position
Market Position:
The Aprilia RS 125 was positioned as a premium, high-performance entry-level sportbike, often considered a stepping stone to larger displacement motorcycles. It offered a blend of aggressive styling, track-inspired handling, and a potent two-stroke engine for its class.
Competitive Analysis
Competitive Analysis:
Competed directly with other 125cc sportbikes of the era such as the Yamaha YZF-R125, Honda CBR125R, and Suzuki GSX-R125, offering a more exotic European flair and often a more aggressive riding experience.
Key Features
Key Features:
Distinctive twin-spar aluminum frame, powerful Rotax 122 two-stroke engine, advanced suspension components, aggressive aerodynamic fairing, high-performance braking system, and a sharp, race-replica aesthetic.
📋 Manual Details
Coverage Areas
Coverage Areas:
Comprehensive coverage for all mechanical and electrical systems of the Aprilia RS 125 (2001 model year).
Page Count
Page Count:
Estimated 300-500 pages (typical for factory service manuals of this era).
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine mechanical, engine electrical, fuel system, cooling system, lubrication system, exhaust system, transmission, clutch, chassis, suspension (front and rear), brakes (front and rear), wheels, tires, steering, electrical system (lighting, ignition, battery, charging), bodywork, maintenance procedures, troubleshooting, diagnostics, specifications, and torque values.
Chassis Systems:
Frame (steel/aluminum construction), swingarm, steering head bearings, fasteners and torque specifications.
Braking System:
Front and rear disc brakes, caliper service, master cylinder overhaul, brake line replacement, bleeding procedures, pad wear indicators.
Electrical System:
Wiring diagrams, lighting circuits, ignition coil, stator, rectifier/regulator, battery maintenance, starter motor (if applicable, though typically kick start), fuses, switches, sensors.
Procedures Included
Procedures Included:
Routine maintenance, scheduled maintenance, disassembly and assembly of major components, engine rebuild procedures, carburetor adjustment and overhaul, electrical troubleshooting, brake bleeding and pad replacement, suspension fork servicing, chain and sprocket replacement, diagnostic flowcharts, component testing, and torque specifications for all fasteners.
Engine Tuning:
Carburetor jetting adjustment, power valve calibration, spark plug gap adjustment.
Suspension Service:
Front fork oil change, seal replacement, spring inspection. Rear shock absorber inspection and adjustments.
Wheel And Tire:
Tire pressure checks, tire wear inspection, wheel bearing service, chain and sprocket replacement, balancing.
Technical Depth
Technical Depth:
In-depth, factory-level technical information suitable for professional technicians and experienced DIY mechanics. Covers everything from basic adjustments to complete engine and chassis overhauls.
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality:
High-resolution scans ensuring clarity of text, diagrams, and illustrations, suitable for printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, two-stroke, single-cylinder
Displacement:
124.8 cc (7.6 cubic inches)
Bore X Stroke:
54 mm x 54.5 mm
Compression Ratio:
12.2:1 (typical, may vary slightly)
Power Output:
Approximately 30-35 HP (depending on market restrictions and specific tuning, e.g., 25 kW for European A1 license)
Torque:
Approximately 20-23 Nm (14.8-17.0 lb-ft) at ~8,000 RPM
Ignition System:
Electronic ignition, CDI (Capacitor Discharge Ignition)
Starting System:
Kick starter
Cooling System:
Liquid-cooled
Performance
Top Speed:
Approximately 150-160 km/h (93-99 mph)
Fuel System
Fuel Delivery:
Carburetor
Carburetor Model:
Dell'Orto VHST 28 BS (common specification)
Fuel Type:
Unleaded gasoline, minimum 95 RON
Fuel Tank Capacity:
12.0 Liters (3.17 US Gallons)
Oil Mixture Type:
Premix or Automatic Oil Injection (depending on specific market/variant, typically automatic injection for this model year)
Oil Type:
Two-stroke engine oil (API TC or JASO FD rated)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh sequential gearbox
Features
Clutch Type:
Wet, multi-plate, cable-actuated
Final Drive:
Chain drive
Gear Ratios:
Specific ratios detailed in the manual, typically optimized for sport riding performance.
📐 Dimensions
Exterior
Length:
Approximately 1950 mm (76.8 inches)
Width:
Approximately 740 mm (29.1 inches) at handlebars
Height:
Approximately 1050 mm (41.3 inches) at seat
Wheelbase:
Approximately 1330 mm (52.4 inches)
Ground Clearance:
Approximately 140 mm (5.5 inches)
Seat Height:
Approximately 805 mm (31.7 inches)
Weights
Dry Weight:
Approximately 131 kg (288.8 lbs)
Wet Weight:
Approximately 149 kg (328.5 lbs) (with all fluids)
Max Load Capacity:
Typically around 150-180 kg (rider + passenger + luggage)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycle safety is primarily dependent on rider skill and adherence to maintenance schedules. No standardized crash test ratings like automobiles.
Active Features
Active Features:
Responsive braking system, agile handling chassis, powerful front disc brake, rear disc brake, good visibility from riding position.
Passive Features
Passive Features:
Sturdy frame construction, protective fairing offering some rider protection from elements and minor impacts.
💡 Technology Features
Infotainment
Infotainment Features:
Basic analog instrumentation including speedometer, tachometer, odometer, coolant temperature gauge, and indicator lights. No advanced infotainment systems.
Driver Assistance
Driver Assistance Features:
N/A for this model year; focus is on mechanical and rider control.
🔧 Maintenance
Service Intervals
Service Intervals:
Detailed in the manual, typically includes oil changes (for premix models), spark plug checks/replacement, air filter cleaning/replacement, chain lubrication/adjustment, brake fluid checks, coolant checks, and regular inspections of wear items. Major engine services are often recommended at specific mileage intervals.
Fluid Specifications
Engine Oil Type:
Fully synthetic 2-stroke engine oil meeting API TC or JASO FD standards. Specific Aprilia recommendations may be in the manual.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, mixed with distilled water at a 50/50 ratio.
Brake Fluid Type:
DOT 4 brake fluid (or as specified by Aprilia)
Transmission Oil Type:
Specific gearbox oil as recommended by Aprilia (e.g., SAE 75W/80 or 10W-40 motorcycle gearbox oil).
Known Issues
Known Issues:
Common issues can include wear on the exhaust valve (power valve) mechanism, carburetor jetting sensitivity, wear in the clutch plates, and general maintenance of the two-stroke engine's performance. The manual addresses these proactively through maintenance procedures and troubleshooting guides.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Aprilia is an Italian manufacturer renowned for its racing heritage, particularly in the Grand Prix motorcycle racing scene, and its focus on high-performance, sporty motorcycles. This heritage is reflected in the RS 125's design and capabilities.
Model Evolution
Model Evolution:
The RS 125 has a long lineage, with the 2001 model representing an evolution of Aprilia's successful 125cc sportbike platform. Subsequent models saw updates in styling, electronics, and engine performance to meet evolving emissions standards.
Production
Production Period:
The RS 125 was produced for many years, with the Rotax 122 engine variant being prevalent through the late 1990s and early 2000s.
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for the 2001 model may not be readily documented, the Aprilia RS 125 platform has historically been recognized for its performance, handling, and success in various racing series, particularly in the 125cc class.
Ratings
Ratings:
Owner reviews and industry publications often lauded the RS 125 for its exciting engine, sharp handling, and premium feel, making it a popular choice for aspiring racers and sportbike enthusiasts.
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