🏷️ Basic Information Identification Make: Aprilia Model: RS125 Years Covered By Manual: 1993-2003 Engine Code Family: Rotax 122 Codes Chassis Codes: RS125 (Various chassis codes depending on year, typically prefixed with AP04xxx) 👋 Introduction Market Position Vehicle Segment: Lightweight sportbike (125cc class), popular for younger riders and performance enthusiasts in its category. Competitors: Yamaha YZF-R125 (later models), Honda CBR125R, Cagiva Mito 125, Suzuki GSX-R125 (later models). Key Features Performance Focus: Designed for sporty performance within the 125cc segment, often featuring advanced chassis and suspension for its class. Design Heritage: Evokes the styling and racing pedigree of larger Aprilia sportbikes. Engine Technology: Employs a potent Rotax 2-stroke engine known for its power output in the 125cc displacement class. Manual Value Proposition Comprehensive Support: Provides in-depth technical information crucial for maintaining and repairing the Aprilia RS125, bridging the gap for owners who want to perform their own work. Parts Catalog Inclusion: The inclusion of a parts catalog (for 99-03 models) greatly enhances its utility for identifying and sourcing correct replacement parts. 📋 Manual Details Coverage Areas Primary Coverage: Factory Service Repair Manual & Parts Catalog (for 1999-2003 models) Secondary Coverage: Engine Rotax 122 Repair Manual (applicable across the 1993-2003 range) Page Count Estimated Page Count: Hundreds (Specific count not provided, but described as comprehensive) Manual Type Manual Type 1: Factory Service Repair Manual Manual Type 2: Parts Catalog (1999-2003) Manual Type 3: Engine Repair Manual (Rotax 122) Language Language: ENGLISH Format File Format: PDF (within a Zip archive) 📖 Manual Coverage Systems Covered Engine System: Complete disassembly, assembly, troubleshooting, and repair of the Rotax 122 engine (2-stroke, liquid-cooled). Fuel System: Carburetor (e.g., Dell'Orto PHBH 28), fuel pump, fuel lines, fuel tank. Ignition System: CDI ignition, spark plug, stator, ignition coil, wiring. Cooling System: Radiator, water pump, coolant hoses, thermostat, fan. Exhaust System: Expansion chamber, silencer, gaskets, mounting. Transmission System: 6-speed gearbox, clutch (wet multi-plate), gear shift mechanism, lubrication. Chassis Frame: Frame construction, welds, alignment, bodywork mounting points. Suspension Front: Upside-down telescopic forks (e.g., Marzocchi or Paioli), adjustment (preload, compression, rebound if applicable), seals, oil. Suspension Rear: Monoshock (e.g., Sachs), linkage system, swingarm, adjustment, bearings. Braking System Front: Hydraulic disc brake, caliper (e.g., Brembo), master cylinder, brake lines, pads, rotor specifications. Braking System Rear: Hydraulic disc brake, caliper, master cylinder, brake lines, pads, rotor specifications. Wheel And Tire: Wheel types (e.g., alloy), bearings, axle specifications, recommended tire sizes and pressures. Electrical System: Wiring diagrams, lighting (headlight, taillight, turn signals), battery, charging system (alternator/stator), starter motor, switches, sensors. Bodywork And Trim: Fairings, seat, handlebars, footpegs, decals, fasteners. Procedures Included Maintenance Procedures: Routine checks, oil changes, filter replacements, chain adjustment, brake bleeding, coolant flush, spark plug replacement, carburetor cleaning and adjustment. Repair Procedures: Complete engine rebuild, gearbox overhaul, fork seal replacement, shock absorber rebuild, brake caliper service, electrical component testing and replacement. Troubleshooting: Diagnosing common faults, electrical issues, engine performance problems, starting difficulties. Disassembly Reassembly: Detailed step-by-step instructions with photographic guidance for all major components and systems. Technical Depth Depth Level: Comprehensive: Covers basic maintenance to full engine and component overhauls, suitable for experienced home mechanics and professional technicians. Diagnostic Capabilities: Includes diagnostic flowcharts and electrical troubleshooting for common issues. Special Tools: Lists required special tools for specific procedures. 📊 Manual Specifications File Format File Type: PDF (within a Zip archive) Searchability: Likely searchable text if digitally rendered properly (typical for high-quality PDFs). Print Quality Printability: HIGH QUALITY & FULLY PRINTABLE Image Resolution: High resolution photos and diagrams suitable for printing. Binding Type Binding Type: Digital (PDF) - requires printing and binding by user. Paper Type Recommended Paper Type: Standard printer paper; consider heavier stock for frequent use. ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled, single-cylinder Engine Family: Rotax 122 Displacement: 124.8 cc (approx.) Bore X Stroke: 54 mm x 54.5 mm (typical for Rotax 122) Compression Ratio: Approx. 12.5:1 (varies slightly by model year/tune) Power Output: Typically around 30-34 HP (15kW restricted for learner categories) at 10,500-11,750 RPM (unrestricted). Torque: Around 2.0-2.2 kgf-m (approx. 14.5-15.9 lb-ft) at 9,000-10,000 RPM. Valvetrain: Reed valve induction, Rotary disc valve (on some versions). Cooling Method: Liquid cooling Lubrication System: Pre-mix or separate oil injection system (depending on model year). Fuel System Carburetor Type: Dell'Orto PHBH 28 or similar, manual or electric start. Fuel Type: Unleaded gasoline, minimum 95 RON (91 AKI) recommended. Fuel Tank Capacity: Approx. 7.0 - 7.5 liters (1.85 - 1.98 US gallons). 🔧 Transmission Standard Transmission Type: 6-speed constant mesh sequential gearbox Clutch Type: Wet, multi-plate Features Gear Ratios: Specific ratios detailed within the manual, crucial for performance tuning. Transmission Fluid Type: Commonly uses motorcycle-specific gear oil or some engine oils with appropriate JASO rating. Refer to manual for exact specification. Final Drive: Chain drive 📐 Dimensions Exterior Overall Length: Approx. 1940 mm (76.4 in) - varies slightly by year. Overall Width: Approx....