Segment:
Lightweight sport motorcycle segment.
Target Audience:
Enthusiast riders, track day participants, and owners seeking in-depth maintenance knowledge.
Competitors:
Yamaha YZF-R125 (later models), Honda CBR125R, Suzuki GSX-R125 (later models), Cagiva Mito 125.
Vehicle Design:
Sharp, aggressive styling mimicking larger sportbikes, agile handling, and a potent two-stroke engine.
Manual Value Proposition:
Empowers owners to perform complex maintenance and repairs, saving on dealership costs and ensuring optimal performance.
General Coverage:
Comprehensive service and repair for the Aprilia RS125 (1999-2003).
Specific Coverage:
Engine, transmission, chassis, electrical system, bodywork, suspension, brakes, cooling, fuel system, emissions control.
Estimated Page Count:
400+
Type:
Workshop Manual / Service Repair Manual
Format:
Digital (likely PDF, based on common digital manual distribution)
Engine System:
Detailed information on the Rotax 125cc two-stroke engine, including disassembly, assembly, troubleshooting, and component specifications.
Fuel System:
Carburetor adjustment and overhaul (likely Dell'Orto PHBH/PHVA), fuel lines, fuel pump (if applicable), oil injection system.
Cooling System:
Radiator, coolant, hoses, water pump, thermostat operation and maintenance.
Transmission System:
Gearbox operation, clutch service, chain and sprockets maintenance, gear oil specifications and change intervals.
Electrical System:
Wiring diagrams, battery service, ignition system troubleshooting, lighting, starter motor, indicators, and instrument cluster.
Suspension System:
Front fork service (e.g., Marzocchi), rear shock absorber inspection and adjustment, spring and damper specifications.
Braking System:
Front and rear brake caliper overhaul, master cylinder service, brake fluid specifications and bleeding procedures, pad replacement.
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm maintenance, wheel bearing replacement.
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank, and component fastener torque specifications.
Engine Overhaul:
Complete engine disassembly, inspection, cleaning, reassembly, and tuning procedures.
Scheduled Maintenance:
Routine maintenance tasks such as oil changes, spark plug replacement, air filter cleaning, chain lubrication, and brake checks.
Troubleshooting Guides:
Systematic diagnostic procedures for common issues encountered with the RS125.
Carburetor Tuning:
Detailed instructions for adjusting and rebuilding the carburetor for optimal performance.
Electrical Diagnostics:
Step-by-step guides for diagnosing electrical faults using wiring diagrams and test equipment.
Depth:
Full workshop level, suitable for professional technicians and experienced DIY mechanics.
Diagnostic Capabilities:
Includes troubleshooting charts, fault code interpretation (if applicable), and component testing procedures.
Repair Procedures:
Detailed instructions for component removal, repair, and installation, often with torque specifications.
Format Details:
Likely PDF, offering searchability and accessibility across devices.
Quality:
Assumed high quality, as the product description states manuals have been tested and read through.
Binding:
Not applicable for digital format; if printed, typically comb or spiral bound for lay-flat use.
Paper:
Not applicable for digital format.
Engine Type:
Two-stroke, single-cylinder, liquid-cooled
Bore X Stroke:
54 mm x 54.5 mm
Compression Ratio:
12.5:1 (approx.)
Valve Train:
Rotax 'RAVE' Exhaust System (electronically controlled exhaust port timing)
Horsepower Output:
Approx. 30-33 HP (depending on market regulations and tuning)
Torque Output:
Approx. 20-22 Nm
Carburetor Model:
Dell'Orto PHBH 28 or PHVA 28 (common variants)
Fuel Type:
Unleaded gasoline (minimum 95 RON)
Oil Delivery:
Automatic oil injection system
Safety Certification:
CE certified (common for European market motorcycles of this era)
Brakes:
Front: Single disc brake with 4-piston caliper; Rear: Single disc brake with 2-piston caliper.
Tires:
Sport-oriented tires, typically 110/70-17 front and 150/60-17 rear.
Lighting:
Halogen headlamp, LED taillight.
Instrument Cluster:
Analog tachometer, speedometer, odometer, trip meter, and warning lights. May include a basic LCD for fuel level or clock.
ABS:
ABS was not typically standard or commonly available on this model during these years.
Connectivity Features:
None (no Bluetooth, smartphone integration, etc.)
Oil Change:
Engine oil: Every 3,000-5,000 km or annually. Gearbox oil: Every 6,000-10,000 km or annually.
Spark Plug Replacement:
Every 6,000-8,000 km
Air Filter Cleaning:
Every 3,000-4,000 km, or as needed based on operating conditions.
Chain Maintenance:
Lubricate and adjust chain tension every 500-1000 km.
Engine Oil:
Two-stroke premix oil (e.g., Motul 710 2T, Castrol Power 1 TTS) or specified Aprilia 2T oil for injection system.
Gearbox Oil:
SAE 80W/90 API GL-4 or GL-5 gear oil (approx. 0.8 Liters)
Coolant:
50/50 mix of ethylene glycol-based antifreeze and distilled water.
Engine Wear:
Piston and cylinder wear due to the nature of high-performance two-strokes, especially if poorly maintained or over-revved.
Carburetor Issues:
Jetting can be sensitive to altitude and modifications; potential for needle wear or float bowl issues.
Electrical Gremlins:
Wiring harness degradation over time, particularly around high-stress areas like the steering head.
Rave System:
The exhaust valve control system (RAVE) can become sticky or fail, requiring cleaning or replacement.
Manufacturer:
Aprilia is an Italian manufacturer known for its racing heritage and sporty motorcycles.
Rs125 Lineage:
The RS125 has a long history, evolving from earlier models like the AF1 and Futura, consistently featuring a 125cc two-stroke engine and aggressive styling.
Manufacturing Location:
Italy
Significant Updates 1999-2003:
Minor aesthetic updates, potential ECU or carburetor revisions for emissions compliance.
