🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 2002 Codes Vin Prefix: ZDA 👋 Introduction Market Position Positioning: The Aprilia RS 125 has long been a benchmark for small-displacement sportbikes, offering a blend of performance, handling, and aggressive styling typically found in larger machines. This manual serves owners and technicians looking to maintain and repair this iconic 125cc sportbike. Competitive Analysis Competitors: Competes with models like the Yamaha YZF-R125, Honda CBR125R, and Suzuki GSX-R125 (though later models). Key Features Vehicle Appeal: Nimble handling, high-revving two-stroke engine (for its era), sharp styling, track-day capability. 📋 Manual Details Coverage Areas General Coverage: Complete Service and Repair Manual Page Count Estimated Pages: 400+ Manual Type Type: Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Full overhaul, top-end, bottom-end, cooling system, lubrication, fuel system (carburetor tuning, jetting), exhaust system, ignition system. Transmission: Clutch, gearbox internals, shift mechanism, lubrication, troubleshooting. Chassis And Suspension: Front forks (disassembly, sealing, fluid changes), rear shock absorber, swingarm, bearings, steering head bearings. Brakes: Front and rear hydraulic brake systems, caliper maintenance, brake fluid replacement, bleeding procedures, master cylinder overhaul. Electrical System: Wiring diagrams, lighting system, starting system, charging system (stator, regulator/rectifier), battery maintenance, fuses, switches, troubleshooting electrical faults. Fuel System: Fuel tank, fuel lines, carburetor identification (Dell'Orto PHBH/PHVB), jetting specifications, float height adjustment, cleaning and reassembly. Bodywork And Fairings: Fairing removal and installation, seat, tank cover, minor body repairs. Procedures Included Maintenance: Routine checks, oil changes, filter replacements, spark plug service, chain adjustment, lubrication points. Troubleshooting: Diagnostic flowcharts for common starting, running, and electrical issues. Repair And Rebuild: Step-by-step instructions for major component disassembly, repair, and reassembly. Special Tools: Identification of necessary specialized tools for specific tasks. Technical Depth Depth: Comprehensive coverage from basic maintenance to full engine rebuilds and advanced electrical troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval. Print Quality Printability: Optimized for clear printing of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: 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: 12.0:1 (approx.) Power Output: Approx. 30-34 hp (depending on market and specific tuning) Torque Output: Approx. 20-23 Nm Cooling System: Liquid Cooling with Radiator and Fan Performance Redline: 11,500 rpm (approx.) Fuel System Carburetor: Dell'Orto PHBH 28 (or PHVB 26 depending on exact market variant) Fuel Type: Unleaded gasoline (95-98 RON) Lubrication Lubrication System: Pre-mix or separate oil injection system (Rotax 123 engine variant) Ignition Ignition Type: Electronic CDI 🔧 Transmission Standard Transmission Type: 6-speed manual constant mesh Features Clutch Type: Wet, multi-plate Final Drive: Chain driven 📐 Dimensions Exterior Length: Approx. 1,970 mm Width: Approx. 720 mm Height: Approx. 1,100 mm Wheelbase: Approx. 1,375 mm Weights Dry Weight: Approx. 130 kg Fuel Capacity: 10.5 Liters (including 1.5 Liter reserve) Oil Capacity: Approx. 0.6 Liters (for separate oil injection system, if applicable) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle, typically not rated by consumer safety organizations) Active Features Braking System: Dual-circuit hydraulic disc brakes front and rear. Tires: Sport-biased radial tires; commonly 110/70-17 front, 150/60-17 rear. Passive Features Frame: Aluminum alloy twin-spar frame for rigidity and light weight. 💡 Technology Features Infotainment Infotainment System: Basic analogue instrumentation: speedometer, tachometer, odometer, temperature gauge, indicator lights. No advanced infotainment features. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km or annually. For 2-stroke oil injection, regular checking of the reservoir is critical. Spark Plug Replacement: Every 6,000-10,000 km, depending on plug type and usage. Air Filter Cleaning: Every 3,000-6,000 km, depending on operating conditions. Chain Lubrication Adjustment: Lubricate every 500-1000 km; adjust slack as needed per manual specifications. Fluid Specifications Engine Oil Type: For separate oil injection: JASO FD certified 2-stroke synthetic oil. For pre-mix: High-quality 2-stroke racing oil. Coolant Type: Ethylene glycol-based coolant (50% mixture with distilled water) Brake Fluid Type: DOT 4 Transmission Oil Type: SAE 10W/40 motorcycle gear oil (check manual for specific API rating). Known Issues Common Issues: Carburetor tuning sensitivity, potential for carbon buildup in two-stroke engines, aging electrical components, wear on steering head bearings, fork seal leaks. Performance Tips: Proper jetting for ambient conditions is crucial for two-stroke performance. Regular decarbonization of the exhaust port and cylinder head can improve power delivery. 📚 Vehicle History Brand Heritage Manufacturer Heritage: Aprilia is an Italian motorcycle manufacturer renowned for its performance-oriented motorcycles, particularly in the sportbike and off-road segments. Founded in 1945, Aprilia has a strong racing pedigree. Model Evolution Model History: The RS 125 platform has been in production for many years, with continuous updates to styling, engine technology (transitioning from early Rotax designs to later Aprilia-specific engines), and components. The 2002 model represents a mature iteration of the design. Production...