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Aprilia RS 125 2000 All Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 2000 Codes Engine Code: Rotax 122 👋 Introduction Market Position Market Position: The Aprilia RS 125 was a highly regarded lightweight sports motorcycle in the late 1990s and early 2000s, competing against models from Yamaha (TZR 125), Honda (CBR125R - though later), and Cagiva (Mito). It was celebrated for its premium componentry, racing-derived styling, and strong performance for its class, appealing to younger riders and enthusiasts seeking a track-inspired experience on the road. Competitive Analysis Competitive Analysis: Compared to its contemporaries, the RS 125 often stood out with its sophisticated Rotax engine (sharing lineage with larger Aprilia models), upside-down front forks, powerful braking systems, and aggressive aesthetics. While some competitors offered simpler, less powerful options, the RS 125 provided a more potent and 'superbike' feel, albeit with higher maintenance requirements and costs. Key Features Key Features: Aggressive Italian styling, liquid-cooled two-stroke engine, capable chassis with quality suspension and brakes, often featuring premium components like Marzocchi forks and Brembo brakes. It was a gateway bike to higher-performance motorcycling. 📋 Manual Details Coverage Areas Coverage Areas: Full Service, Repair, Maintenance, Diagnostics, Troubleshooting, Wiring Diagrams Page Count Page Count: Estimated 300-500 pages (typical for comprehensive service manuals of this era) Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Systems Covered: Engine (Top-end, Bottom-end, Lubrication, Cooling), Fuel System (Carburetor, Fuel Delivery), Ignition System, Exhaust System, Transmission (Clutch, Gearbox, Shifting), Electrical System (Lighting, Charging, Starting, CDI, Sensors), Chassis (Frame, Suspension, Steering, Brakes, Wheels, Tires), Bodywork (Fairings, Seat, Fuel Tank), Special Tools, Torque Specifications, Troubleshooting Guides Procedures Included Procedures Included: Routine Maintenance, Oil Changes, Filter Replacements, Spark Plug Service, Carburetor Adjustment and Rebuild, Top End Rebuild (Piston, Rings, Cylinder), Bottom End Rebuild (Crankshaft, Bearings, Seals), Clutch Overhaul, Transmission Service, Brake System Bleeding and Rebuild, Electrical System Diagnostics and Repair, Suspension Adjustments and Rebuild, Wheel Bearing Replacement, Steering Head Bearing Service, De-carbonization Procedures, Troubleshooting Common Issues Technical Depth Technical Depth: Comprehensive; covers everything from basic scheduled maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics. Suitable for experienced DIY mechanics and professional technicians. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High Resolution (suitable for printing) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, single-cylinder Displacement: 124.8 cc Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: Approx. 12.5:1 Power Output: Approx. 30-34 HP (15 kW restricted for learner riders, up to 34 HP unrestricted) Torque: Approx. 20-22 Nm Cooling System: Liquid-cooled with electric fan Valve Actuation: N/A (2-stroke) Engine Lubrication: Pre-mix or Automatic Oil Injection (depending on market/variant) Performance Top Speed: Approx. 150-160 km/h (unrestricted) Fuel System Carburetor: Dell'Orto PHBH 28 (or similar 28mm carburetor) Fuel Type: Unleaded gasoline (95 RON or higher recommended) Fuel Capacity: Approx. 13 Liters Intake: Reed valve induction Exhaust: Expansion chamber exhaust system 🔧 Transmission Standard Transmission Type: 6-speed manual constant mesh gearbox Features Clutch Type: Wet, multi-plate, cable-actuated Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1950 mm Width: Approx. 720 mm Height: Approx. 1100 mm Wheelbase: Approx. 1330 mm Seat Height: Approx. 805 mm Weights Dry Weight: Approx. 130 kg Wet Weight: Approx. 140-145 kg (with fluids) Payload Capacity: Not Specified (typically rider + minimal luggage) Cargo Cargo Capacity: Minimal; under-seat storage usually limited 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles are not typically rated by agencies like NHTSA or Euro NCAP in the same way as cars) Active Features Active Features: Front and Rear Disc Brakes, capable chassis for stability, effective suspension damping. Passive Features Passive Features: Robust frame construction, fairing for rider protection from elements. Brakes Front Brake Type: Hydraulic disc (often Brembo, 320mm single disc in many configurations) Rear Brake Type: Hydraulic disc (often Brembo, 220mm single disc) Wheels Tires Front Wheel Size: 17 inch Rear Wheel Size: 17 inch Front Tire Size: 110/70-17 Rear Tire Size: 150/60-17 💡 Technology Features Infotainment Infotainment System: N/A (Basic analogue instrumentation: speedometer, tachometer, temperature gauge, odometer, trip meter) Lighting Headlight Type: Halogen (often dual headlights) Taillight Type: Incandescent bulb 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km or annually (engine oil in gearbox) Spark Plug Replacement: Every 5,000-8,000 km (NGK BR9EG or equivalent recommended) Air Filter Cleaning: Every 3,000-6,000 km or as needed based on conditions Top End Rebuild: Recommended every 10,000-15,000 km for optimal performance and longevity (piston, rings, cylinder) Carburetor Cleaning Service: Every 10,000-15,000 km or if performance issues arise Fluid Specifications Engine Oil Type: 90-weight GL-4 hypoid gear oil for the gearbox. For 2-stroke oil injection, use a high-quality 2-stroke synthetic or semi-synthetic oil meeting JASO FD or API TC standards. Coolant Type: Ethylene...
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Aprilia RS 125 2000 All Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Year:
2000
Codes
Engine Code:
Rotax 122
👋 Introduction
Market Position
Market Position:
The Aprilia RS 125 was a highly regarded lightweight sports motorcycle in the late 1990s and early 2000s, competing against models from Yamaha (TZR 125), Honda (CBR125R - though later), and Cagiva (Mito). It was celebrated for its premium componentry, racing-derived styling, and strong performance for its class, appealing to younger riders and enthusiasts seeking a track-inspired experience on the road.
Competitive Analysis
Competitive Analysis:
Compared to its contemporaries, the RS 125 often stood out with its sophisticated Rotax engine (sharing lineage with larger Aprilia models), upside-down front forks, powerful braking systems, and aggressive aesthetics. While some competitors offered simpler, less powerful options, the RS 125 provided a more potent and 'superbike' feel, albeit with higher maintenance requirements and costs.
Key Features
Key Features:
Aggressive Italian styling, liquid-cooled two-stroke engine, capable chassis with quality suspension and brakes, often featuring premium components like Marzocchi forks and Brembo brakes. It was a gateway bike to higher-performance motorcycling.
📋 Manual Details
Coverage Areas
Coverage Areas:
Full Service, Repair, Maintenance, Diagnostics, Troubleshooting, Wiring Diagrams
Page Count
Page Count:
Estimated 300-500 pages (typical for comprehensive service manuals of this era)
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine (Top-end, Bottom-end, Lubrication, Cooling), Fuel System (Carburetor, Fuel Delivery), Ignition System, Exhaust System, Transmission (Clutch, Gearbox, Shifting), Electrical System (Lighting, Charging, Starting, CDI, Sensors), Chassis (Frame, Suspension, Steering, Brakes, Wheels, Tires), Bodywork (Fairings, Seat, Fuel Tank), Special Tools, Torque Specifications, Troubleshooting Guides
Procedures Included
Procedures Included:
Routine Maintenance, Oil Changes, Filter Replacements, Spark Plug Service, Carburetor Adjustment and Rebuild, Top End Rebuild (Piston, Rings, Cylinder), Bottom End Rebuild (Crankshaft, Bearings, Seals), Clutch Overhaul, Transmission Service, Brake System Bleeding and Rebuild, Electrical System Diagnostics and Repair, Suspension Adjustments and Rebuild, Wheel Bearing Replacement, Steering Head Bearing Service, De-carbonization Procedures, Troubleshooting Common Issues
Technical Depth
Technical Depth:
Comprehensive; covers everything from basic scheduled maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics. Suitable for experienced DIY mechanics and professional technicians.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High Resolution (suitable for printing)
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
124.8 cc
Bore X Stroke:
54 mm x 54.5 mm
Compression Ratio:
Approx. 12.5:1
Power Output:
Approx. 30-34 HP (15 kW restricted for learner riders, up to 34 HP unrestricted)
Torque:
Approx. 20-22 Nm
Cooling System:
Liquid-cooled with electric fan
Valve Actuation:
N/A (2-stroke)
Engine Lubrication:
Pre-mix or Automatic Oil Injection (depending on market/variant)
Performance
Top Speed:
Approx. 150-160 km/h (unrestricted)
Fuel System
Carburetor:
Dell'Orto PHBH 28 (or similar 28mm carburetor)
Fuel Type:
Unleaded gasoline (95 RON or higher recommended)
Fuel Capacity:
Approx. 13 Liters
Intake:
Reed valve induction
Exhaust:
Expansion chamber exhaust system
🔧 Transmission
Standard
Transmission Type:
6-speed manual constant mesh gearbox
Features
Clutch Type:
Wet, multi-plate, cable-actuated
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 1950 mm
Width:
Approx. 720 mm
Height:
Approx. 1100 mm
Wheelbase:
Approx. 1330 mm
Seat Height:
Approx. 805 mm
Weights
Dry Weight:
Approx. 130 kg
Wet Weight:
Approx. 140-145 kg (with fluids)
Payload Capacity:
Not Specified (typically rider + minimal luggage)
Cargo
Cargo Capacity:
Minimal; under-seat storage usually limited
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles are not typically rated by agencies like NHTSA or Euro NCAP in the same way as cars)
Active Features
Active Features:
Front and Rear Disc Brakes, capable chassis for stability, effective suspension damping.
Passive Features
Passive Features:
Robust frame construction, fairing for rider protection from elements.
Brakes
Front Brake Type:
Hydraulic disc (often Brembo, 320mm single disc in many configurations)
Rear Brake Type:
Hydraulic disc (often Brembo, 220mm single disc)
Wheels Tires
Front Wheel Size:
17 inch
Rear Wheel Size:
17 inch
Front Tire Size:
110/70-17
Rear Tire Size:
150/60-17
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic analogue instrumentation: speedometer, tachometer, temperature gauge, odometer, trip meter)
Lighting
Headlight Type:
Halogen (often dual headlights)
Taillight Type:
Incandescent bulb
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or annually (engine oil in gearbox)
Spark Plug Replacement:
Every 5,000-8,000 km (NGK BR9EG or equivalent recommended)
Air Filter Cleaning:
Every 3,000-6,000 km or as needed based on conditions
Top End Rebuild:
Recommended every 10,000-15,000 km for optimal performance and longevity (piston, rings, cylinder)
Carburetor Cleaning Service:
Every 10,000-15,000 km or if performance issues arise
Fluid Specifications
Engine Oil Type:
90-weight GL-4 hypoid gear oil for the gearbox. For 2-stroke oil injection, use a high-quality 2-stroke synthetic or semi-synthetic oil meeting JASO FD or API TC standards.
Coolant Type:
Ethylene glycol based antifreeze mixed with distilled water (50/50 ratio recommended)
Brake Fluid Type:
DOT 4
Fork Oil Type:
10W or 15W fork oil (specific viscosity may vary by suspension type; consult manual)
Gearbox Oil Capacity:
Approx. 0.75 Liters
Known Issues
Known Issues:
Valve seat wear (on the exhaust port, common in 2-strokes), carburetor jetting sensitivity, reed valve wear, ignition coil failures, rear shock absorber degradation over time, fairing mounting bracket issues, clutch cable adjustments. 2-stroke engines require diligent maintenance for longevity.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Aprilia is an Italian manufacturer with a strong racing pedigree, particularly in the smaller displacement categories (125cc and 250cc Grand Prix racing). This heritage heavily influenced the design and performance focus of models like the RS 125, making it a popular choice for aspiring racers and track-day enthusiasts.
Model Evolution
Model Evolution:
The RS 125 lineage began in the early 1990s and saw continuous updates. The 2000 model represents a mature iteration of the design, benefiting from refinements in engine performance, chassis components, and styling. It was a long-running and successful model for Aprilia, eventually giving way to updated versions with different engine configurations and electronics in later years.
Production
Production Period:
The RS 125 was produced for many years, with the 2000 model being a key year in its development. Production spanned from the early 1990s through to the early 2010s in various forms.
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for the 2000 model year are not widely documented, the Aprilia RS 125 has consistently been praised in motorcycle media for its performance, handling, and styling, often winning '125cc class' comparisons for its sporty nature and premium feel.
Ratings
Ratings:
Consistently rated highly by motorcycle journalists and owners for its sporty performance and handling characteristics in the 125cc segment.
Certifications
Certifications:
N/A (Motorcycle certifications typically relate to emissions and road legality, not specific awards.)
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