APRILIA 125 Rotax Engine 122 Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 / Tuono 125 (Rotax 122 Engine) Engine Code: Rotax 122 Codes Manual Product Code Indication: Likely specific to the Rotax 122 engine application, not a general Aprilia model code. 👋 Introduction Market Position Target Audience: Aprilia RS 125 and Tuono 125 owners, independent motorcycle repair shops, enthusiasts with the Rotax 122 engine. Competitive Analysis Manual Value Proposition: Provides essential, factory-level technical information for maintaining and repairing the Rotax 122 engine, a critical component in popular Aprilia sportbikes. Key Features Content Scope: Comprehensive coverage of mechanical, electrical, and chassis systems specific to models utilizing the Rotax 122 engine. Accessibility: Instant digital download in multiple languages, offering immediate access for urgent repairs or maintenance. 📋 Manual Details Coverage Areas Language Options: • Italian • English • German Page Count Total Pages: 137 Manual Type Manual Classification: Service and Repair Manual Format Delivery Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, assembly, disassembly, cylinder head, piston, crankshaft, connecting rod, balancing shafts, lubrication system, cooling system. Fuel System: Carburetor (likely Dell'Orto PHBH/PHVA), fuel pump, fuel lines, fuel tank servicing. Ignition System: CDI ignition, spark plug specifications, timing adjustments. Exhaust System: Expansion chamber tuning, muffler servicing, sealing. Transmission Gearbox: Gearbox disassembly, assembly, gear selection mechanism, clutch operation, lubrication. Cooling System: Radiator, coolant hoses, thermostat, coolant specifications, bleeding procedures. Chassis Frame: Frame inspection, welding points, mounting hardware torque specifications. Front Suspension: Fork disassembly, oil level and type, seals, bushings, spring rates. Rear Suspension: Shock absorber servicing, linkage maintenance, swingarm pivot, bearing checks. Braking System: Front and rear brake caliper servicing, master cylinder overhaul, brake pad replacement, fluid specifications, bleeding procedures, disc inspection. Electrical System: Wiring diagrams, component testing (lights, horn, starter), battery maintenance, fuse locations. Wheels Tires: Wheel bearing inspection, spoke tension (if applicable), tire pressure recommendations. Procedures Included Scheduled Maintenance: Routine servicing, oil changes, filter replacements, spark plug checks, chain adjustment and lubrication. Diagnostic Troubleshooting: Common problems, symptom identification, diagnostic flowcharts for engine and chassis issues. Engine Rebuild: Detailed steps for engine disassembly, component inspection, clearance measurements, and reassembly. Suspension Setup: Fork oil changes, seal replacements, general suspension adjustments. Carburetor Adjustment: Idle speed, mixture screw settings, jetting recommendations. Brake System Maintenance: Bleeding, fluid flush, pad and disc replacement procedures. Electrical Component Testing: Testing of ignition coil, stator, CDI unit, and related wiring. Technical Depth Diagnostic Level: Advanced diagnostics including component testing and troubleshooting charts. Repair Scope: Comprehensive repair procedures from minor adjustments to full engine and chassis rebuilds. Technical Data Inclusion: Precise torque specifications, clearance measurements, and assembly tolerances. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Resolution And Clarity: Excellent Factory Quality Image Quality: High-resolution images and diagrams. Binding Type Digital Access: Instant Download - No physical binding. Paper Type Digital Content: N/A (Digital file) Features Navigability: Yes (Zoom In/Out) Print Capability: Yes (Printable) ⚙️ Engine Specifications Primary Engine Engine Family: Rotax 122 Engine Type: Two-stroke, single-cylinder Bore: Approximately 54 mm (typical for Rotax 122) Stroke: Approximately 54.5 mm (typical for Rotax 122) Displacement: 124.8 cc (125cc class) Cooling Method: Liquid-cooled Valvetrain: Rotary disc intake valve, exhaust powervalve (APTC or RAVE system typically). Performance Horsepower Output: Variable depending on model year and tuning, typically 25-30+ HP (restricted versions exist for learner licenses). Torque Output: Specific figures vary, but designed for strong mid-range power delivery typical of performance two-strokes. Fuel System Carburetor Type: Likely Dell'Orto PHBH 28/30 or PHVA 28/30, sometimes Mikuni. Fuel Delivery: Premixed fuel/oil or separate oil injection system (depending on specific model and year). Recommended Fuel: Premium unleaded gasoline (e.g., 95 RON or higher). Lubrication Oil Type: High-quality 2-stroke synthetic oil (specific brand/grade may be in manual). 🔧 Transmission Standard Gearbox Type: 6-speed sequential manual transmission Clutch Type: Wet, multi-plate clutch (hydraulic actuation typically) Features Gear Ratios: Specific ratios are detailed within the manual for optimal performance tuning. Final Drive: Chain drive (sprocket sizes and chain maintenance covered). 📐 Dimensions Exterior Wheelbase: Varies by model, typically around 1350-1370 mm for RS/Tuono 125. Weights Dry Weight: Varies by model, generally around 110-120 kg for RS 125. Fuel Tank Capacity: Typically around 10-11 liters. 🛡️ Safety Features Active Features Braking System: Disc brakes front and rear (often Brembo components), capable of strong deceleration. Tires: Sport-oriented tires, recommended pressures detailed in manual. Passive Features Lighting: Headlight, taillight, brake lights, turn signals (electrical system section covers diagnosis). 💡 Technology Features Infotainment Instrumentation: Analog tachometer, speedometer, coolant temperature gauge, odometer, trip meter. Specific indicators for oil/fuel levels. Driver Assistance Engine Management: CDI ignition system, with potential for electronic power valve control (RAVE/APTC). Connectivity Diagnostic Ports: While not OBD-II like cars, diagnostic connectors for checking CDI and sensor signals may be present, detailed in the manual's electrical section. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3000-5000 km or annually, as per...
Likely specific to the Rotax 122 engine application, not a general Aprilia model code.
👋 Introduction
Market Position
Target Audience:
Aprilia RS 125 and Tuono 125 owners, independent motorcycle repair shops, enthusiasts with the Rotax 122 engine.
Competitive Analysis
Manual Value Proposition:
Provides essential, factory-level technical information for maintaining and repairing the Rotax 122 engine, a critical component in popular Aprilia sportbikes.
Key Features
Content Scope:
Comprehensive coverage of mechanical, electrical, and chassis systems specific to models utilizing the Rotax 122 engine.
Accessibility:
Instant digital download in multiple languages, offering immediate access for urgent repairs or maintenance.
Analog tachometer, speedometer, coolant temperature gauge, odometer, trip meter. Specific indicators for oil/fuel levels.
Driver Assistance
Engine Management:
CDI ignition system, with potential for electronic power valve control (RAVE/APTC).
Connectivity
Diagnostic Ports:
While not OBD-II like cars, diagnostic connectors for checking CDI and sensor signals may be present, detailed in the manual's electrical section.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3000-5000 km or annually, as per manual recommendations. For two-stroke, critical focus on gearbox oil.
Spark Plug Replacement:
Intervals vary based on plug type and usage, typically every 5000-10000 km.
Top End Rebuild:
Recommended every 15,000-20,000 km depending on usage and condition, detailed in manual.
Fluid Specifications
Engine Oil:
2-stroke synthetic engine oil (specific grade and pre-mix ratio if applicable will be in manual).
Gearbox Oil:
Typically SAE 75W/90 or 80W/90 GL-4 gear oil. Capacity specified in manual.
Coolant:
Ethylene glycol based coolant, typically 50/50 mix with distilled water. Specific capacity and type in manual.
Brake Fluid:
DOT 4 or DOT 5.1 brake fluid, depending on manufacturer specification. Manual will confirm.
Known Issues
Power Valve Sticking:
Common on two-strokes due to carbon buildup; requires regular cleaning. Manual provides cleaning procedures.
Carburetor Tuning Sensitivity:
Can be sensitive to altitude and temperature changes; proper jetting is crucial. Manual offers tuning guidance.
Coolant Leaks:
Aging hoses or radiator can develop leaks; manual details inspection and replacement.
Clutch Wear:
Clutch plates can wear over time, leading to slippage. Manual details inspection and replacement procedures.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia has a strong heritage in Grand Prix racing and producing high-performance small-displacement motorcycles, particularly known for their innovative 125cc two-stroke machines.
Model Evolution
Rotax 122 Application:
The Rotax 122 engine was the powerplant for several generations of the Aprilia RS 125 and Tuono 125, a highly successful and popular model in the sportbike segment for many years.
Production
Production Period Indication:
The Rotax 122 engine powered Aprilia 125 models from the early 1990s through the early 2000s, with variations and updates.