APRILIA RS125 ROTAX 122 Engine Digital Workshop Repair Manual 1999-2003
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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Engine Code: Rotax 122 Model Years Covered: 1999, 2000, 2001, 2002, 2003 Generation Generation Designation: Second Generation (EU homologation) 👋 Introduction Market Position Target Audience: Aprilia RS125 owners seeking to perform their own maintenance and repairs, professional mechanics, and restorers. Competitive Analysis Value Proposition: Provides access to professional-level repair information, enabling significant savings on service costs. Key Features Manual Advantage: Eliminates need for expensive or worn-out physical manuals; easy digital access and printing. Seller Credibility: Trusted seller offering genuine items. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive repair, maintenance, and rebuilding Page Count Estimated Page Count: Extensive (specific count not provided, but described as highly detailed) Manual Type Type: Digital Workshop Repair Manual Language Language: English (assumed based on common industry practice for international models and description) Format Format: Digital (viewable/printable) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, including top-end, bottom-end, cooling system, lubrication, fuel delivery, and ignition system. Transmission: Manual gearbox, clutch operation, and related components. Electrical System: Wiring diagrams, lighting, ignition, charging system, battery, and starter motor troubleshooting. Chassis And Suspension: Front forks, rear shock absorber, swingarm, steering system, and wheel bearing maintenance. Braking System: Front and rear brake caliper maintenance, master cylinders, brake fluid replacement, and pad wear. Fuel System: Carburetor (likely Dell'Orto PHBH or similar), fuel lines, and fuel tank maintenance. Procedures Included Maintenance: Routine servicing, oil changes, filter replacements, spark plug checks, coolant flushing. Troubleshooting: Diagnostic procedures for common issues, electrical faults, engine performance problems. Repair: Detailed step-by-step instructions for component replacement and repair, including engine rebuilding. Rebuilding: Full engine rebuild procedures, including piston, conrod, crankshaft, and cylinder servicing. Disassembly And Assembly: Complete breakdown and reassembly of all major vehicle components. Technical Depth Depth: Professional-level technical detail suitable for experienced mechanics and dedicated DIY enthusiasts. Diagnostic Capability: Advanced diagnostic procedures, including troubleshooting charts and electrical schematics. Restoration Support: Detailed information beneficial for vehicle restoration projects. 📊 Manual Specifications File Format Digital Format: Viewable and printable (likely PDF or similar). Print Quality Visuals: High quality photos, illustrations, and diagrams. Binding Type Binding: N/A (Digital format) Paper Type Paper Quality: N/A (Digital format) Software Compatibility Windows Os: Windows 95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7 Mac Os: All Mac Computers ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, liquid-cooled, single-cylinder Engine Displacement: 124.8 cc (approx.) Bore X Stroke: 54 mm x 54.5 mm (typical for Rotax 122 series) Compression Ratio: Approx. 8.7:1 to 9.2:1 (varies with specific model/tune) Power Output Hp: Approx. 30-34 HP (depending on market and tune) Power Output Kw: Approx. 22-25 kW Torque: Approx. 22-24 Nm (at specific RPM) Performance Top Speed: Approx. 150-160 km/h (depending on rider and conditions) Fuel System Carburetor Type: Dell'Orto PHBH 28/29/30 (common, specific size may vary) Fuel Type: Unleaded gasoline (min. 95 RON recommended) Oil Injection: Automatic oil injection system Cooling System Cooling Method: Liquid-cooled Ignition System Ignition Type: Electronic ignition (CDI) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh manual transmission Clutch Type: Wet multi-plate clutch Features Gearbox Operation: Positive engagement, suitable for sporty riding. 📐 Dimensions Exterior Length: Approx. 1950 mm Width: Approx. 740 mm Height: Approx. 1100 mm Weights Dry Weight: Approx. 125-130 kg Fuel Tank Capacity: Approx. 14 liters Oil Tank Capacity: Approx. 1.2 liters 🛡️ Safety Features Active Features Braking System Type: Hydraulic disc brakes, front and rear. Front Brake Disc Size: 320 mm (single disc, common) Rear Brake Disc Size: 220 mm (single disc, common) Passive Features Frame Type: Aluminum twin-spar frame Suspension Front: Upside-down telescopic forks (e.g., Marzocchi, WP), adjustable preload/damping on some variants. Suspension Rear: Monoshock with progressive linkage, adjustable preload and damping. 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, speedometer, odometer, trip meter, coolant temperature warning light. Driver Assistance ABS: Not typically equipped on models from this era (ABS became more common later). Connectivity Connectivity Features: None (basic mechanical and electrical systems). 🔧 Maintenance Service Intervals Oil Change Interval: As per manual (typically every few thousand km or annually). Spark Plug Check Interval: As per manual (e.g., every 5,000-10,000 km). Coolant Flush Interval: As per manual (typically every 2 years). Fluid Specifications Engine Oil Type: 2-stroke synthetic or semi-synthetic premix oil (specific grade and API standard as per manual). Coolant Type: Ethylene glycol-based antifreeze/coolant (e.g., Motul Motocool Expert, Castrol Radicool). Brake Fluid Type: DOT 4 (or DOT 5.1, as specified in manual). Transmission Oil Type: Gear oil (specific viscosity grade, e.g., SAE 75W/90, as per manual). Known Issues Engine Wear Points: Piston and ring wear due to two-stroke nature, potential crank seal leaks, exhaust valve (power valve) maintenance. Carburetor Tuning: Sensitivity to altitude and temperature changes; requires precise jetting for optimal performance. Electrical Gremlins: Can occur on older models due to wiring harness wear and corrosion. 📚 Vehicle History Brand Heritage Manufacturer Origin: Italy...
Gear oil (specific viscosity grade, e.g., SAE 75W/90, as per manual).
Known Issues
Engine Wear Points:
Piston and ring wear due to two-stroke nature, potential crank seal leaks, exhaust valve (power valve) maintenance.
Carburetor Tuning:
Sensitivity to altitude and temperature changes; requires precise jetting for optimal performance.
Electrical Gremlins:
Can occur on older models due to wiring harness wear and corrosion.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Italy
Model Evolution
Rs125 Legacy:
The RS125 has a long history as a highly regarded 125cc sportbike, known for its racing pedigree and performance.
Production
Production Period:
The RS125 model line has been in production for many years, with significant updates over time. The Rotax 122 engine was a staple for a considerable period.
🏆 Awards & Recognition
Recognitions
Racing Heritage:
The Aprilia RS125 platform has a strong history in racing, particularly in the 125cc Grand Prix categories, influencing its performance and design.
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