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Aprilia RS125 Parts Diagrams
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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Model Years Covered: 1999, 2000, 2001, 2002, 2003 Engine Variant Covered: Rotax 122 two-stroke, single-cylinder Product Type: Parts Diagrams / Parts Catalog...
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🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Model Years Covered:
1999, 2000, 2001, 2002, 2003
Engine Variant Covered:
Rotax 122 two-stroke, single-cylinder
Product Type:
Parts Diagrams / Parts Catalog
Codes
Product Identifier:
Aprilia RS125 Parts Diagrams Exploded 1999-2003
👋 Introduction
Market Position
Segment:
Lightweight sportbike, popular in entry-level performance motorcycle segments.
Target Audience:
Enthusiasts, DIY mechanics, and service professionals working on Aprilia RS125 models.
Competitive Analysis
Key Competitors Era:
Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125 (though RS125 predates some of these).
Key Features
Performance Focus:
The RS125 is known for its potent Rotax two-stroke engine, offering class-leading power for its displacement.
Handling:
Agile chassis and sporty suspension contribute to excellent handling characteristics.
Design:
Racetrack-inspired styling, reflecting Aprilia's racing heritage.
📋 Manual Details
Coverage Areas
Primary Coverage:
Component identification and assembly order for the Aprilia RS125
Secondary Coverage:
Illustrations of all major assemblies and sub-assemblies
Page Count
Estimated Page Count:
100-150 (typical for this type of catalog)
Manual Type
Type:
Parts Catalog / Exploded View Diagrams
Language
Language:
English
Format
Format:
Digital (likely PDF) or Print
📖 Manual Coverage
Systems Covered
Engine:
Full engine assembly, including cylinder, piston, crankshaft, gearbox components, lubrication, and cooling systems.
Fuel System:
Carburetor assembly (likely Dell'Orto PHBH), intake manifold, fuel lines, and fuel tank components.
Exhaust System:
Expansion chamber, silencer, and associated mounting hardware.
Transmission:
Gearbox internal components, clutch assembly (likely wet multi-plate), shift mechanism, and final drive (chain and sprockets).
Chassis:
Frame components, sub-frame, swingarm, and associated fasteners.
Suspension:
Front fork assembly (upside-down type), rear shock absorber, linkage (if applicable), and mounting hardware.
Brakes:
Front and rear brake calipers, master cylinders, brake lines, discs, pads, and pedal/lever mechanisms.
Wheels Tires:
Wheels (front and rear), spokes, hubs, bearings, and tire fitment.
Electrical System:
Ignition system (CDI), lighting (headlight, taillight, indicators), wiring harness, battery, starter motor (if applicable), and switchgear.
Bodywork:
Fairings, seat, fuel tank, fenders, and related trim components.
Procedures Included
Part Identification:
Detailed exploded views with numbered parts for accurate identification.
Assembly Disassembly Order:
Illustrates the sequence of component installation and removal.
Part Number Reference:
Essential for ordering correct replacement parts.
Fastener Identification:
Visual representation of bolts, nuts, washers, and their placement.
Technical Depth
Depth:
Component-level breakdown for replacement and parts sourcing.
Diagnostic Assistance:
Indirectly assists with diagnosis by identifying component relationships and potential failure points.
Repair Guidance:
Primarily supports repair by ensuring correct part selection and understanding of assembly.
📊 Manual Specifications
File Format
Digital Format Features:
Searchable text, zoomable images, bookmarking capabilities.
Print Quality
Image Clarity:
High-resolution images suitable for clear part identification.
Binding Type
Print Binding:
Coil-bound or stapled for lay-flat usability (typical).
Paper Type
Print Paper:
Durable paper stock resistant to workshop conditions.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotax 122, liquid-cooled, two-stroke, single-cylinder
Displacement:
124.8 cc
Bore X Stroke:
54 mm x 54.5 mm
Compression Ratio:
12.5:1 (typical for this engine)
Valve Mechanism:
Reed valve induction, exhaust power valve (A.E.S. - Aprilia Exhaust System).
Performance
Horsepower:
Approx. 30-33 hp @ 10,500 rpm (depending on market and emissions regulations)
Torque:
Approx. 18 Nm @ 10,000 rpm
Fuel System
Carburetor:
Dell'Orto PHBH 28, or similar.
Fuel Type:
Unleaded gasoline (RON 95 or higher recommended)
Lubrication
Oil System:
Automatic oil injection (pre-mix reservoir).
Cooling
Cooling System:
Liquid-cooled, with thermostat and fan.
🔧 Transmission
Standard
Gearbox:
6-speed constant mesh
Clutch:
Wet, multi-plate
Features
Gear Ratios:
Specific ratios vary but are optimized for sportbike performance.
Final Drive:
Chain drive, 13/48 (example ratio) sprockets.
📐 Dimensions
Exterior
Length:
Approx. 1950 mm
Width:
Approx. 720 mm
Height:
Approx. 1135 mm
Wheelbase:
Approx. 1375 mm
Weights
Dry Weight:
Approx. 135 kg
Fuel Capacity:
Approx. 12 liters (including reserve)
🛡️ Safety Features
Ratings
Safety Certification:
CE compliant (typical for European market models)
Active Features
Braking System:
Hydraulic disc brakes front and rear. Often a larger diameter disc on the front.
Suspension Features:
Upside-down front forks and adjustable rear monoshock for stable handling.
Passive Features
Lighting:
Halogen headlight, LED taillight, front and rear turn signals.
💡 Technology Features
Infotainment
Dashboard:
Analog tachometer, speedometer, odometer, fuel gauge, and indicator lights.
Driver Assistance
ABS:
ABS was not a common feature on this generation of RS125.
Connectivity
Connectivity Features:
N/A (basic motorcycle electronics)
🔧 Maintenance
Service Intervals
Oil Change Frequency:
Refer to specific service manual for 2-stroke oil level checks and top-ups. Gearbox oil change every 6,000-10,000 km.
Spark Plug Replacement:
Typically every 5,000-7,500 km, depending on plug type and usage.
Air Filter Cleaning:
Inspect and clean every 3,000-5,000 km; replace as needed.
Chain Maintenance:
Clean and lubricate chain every 500-1000 km; adjust tension as needed.
Fluid Specifications
Engine Oil Type:
High-quality 2-stroke synthetic or semi-synthetic oil for automatic injection systems.
Gearbox Oil Type:
API GL-4, SAE 75W/90 or 10W/40 motorcycle gearbox oil.
Coolant Type:
Ethylene glycol-based coolant (50% mixture with distilled water).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Known Issues
Two Stroke Maintenance:
Two-stroke engines require diligent maintenance of the powervalve system, proper pre-mix ratios, and can be sensitive to fuel quality and jetting.
Carburetor Issues:
Carburetor can be sensitive to dirt and require regular cleaning and tuning for optimal performance.
Electrical Connections:
Older wiring harnesses can sometimes develop corroded connections, especially if exposed to moisture.
Powervalve Sticking:
Carbon buildup can cause the powervalve to stick, affecting engine performance, requiring periodic cleaning.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia has a strong racing pedigree, particularly in smaller displacement classes and Grand Prix racing, influencing the RS125's design and performance focus.
Model Evolution
Rs125 Lineage:
The RS125 evolved from earlier Aprilia sportbike models, consistently offering a high-performance experience in the 125cc segment.
Production
Manufacturing Origin:
Italy
Production Span:
The RS125 model line has been in production for many years, with significant updates over its lifespan. This specific manual covers the 1999-2003 generation.
🏆 Awards & Recognition
Recognitions
Performance Acclaim:
Often lauded in motorcycle publications for its performance and handling in the 125cc class during its production run.
Ratings
Competitor Comparisons:
Consistently ranked highly against its direct competitors for outright power and track-day suitability.