APRILIA RS125 Digital Workshop Repair Manual 2006 ONWARDS
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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year Coverage: 2006 onwards Codes Engine Code: Rotax 125cc 2-stroke (Specific codes vary by market and year, e.g., 123, 138) 👋 Introduction Market Position Market Position: The Aprilia RS125 is a highly regarded 125cc sportbike, known for its racing heritage and premium feel within its class. It appeals to younger riders seeking a stylish and performance-oriented machine, often as an entry into sportbike ownership. Competitive Analysis Competitors: Competed against models like the Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125, and Kawasaki Ninja 125. Key Features Key Features: Powerful 2-stroke engine, sophisticated chassis derived from larger Aprilia models, aggressive styling, high-quality suspension components, capable of high performance for its displacement. 📋 Manual Details Coverage Areas Coverage Type: Comprehensive workshop and repair Page Count Page Count: Estimated 300-500+ pages (typical for detailed workshop manuals of this era) Manual Type Manual Type: Digital Workshop Repair Manual Language Language: English (Standard for international release, potential for multilingual versions) Format Format: Digital (Likely PDF or similar accessible format) 📖 Manual Coverage Systems Covered Engine System: Complete overhaul, tuning, carburetor settings, ignition system, cooling system, lubrication, exhaust system Transmission System: Gearbox disassembly, inspection, repair, clutch operation and adjustment, chain drive maintenance Chassis System: Frame, swingarm, bearings, suspension (front forks, rear shock absorber), steering system Braking System: Front and rear brake systems (disc brakes), caliper maintenance, fluid replacement, bleeding procedures Electrical System: Wiring diagrams, lighting, starter motor, battery, ignition, instruments, fault diagnosis Fuel System: Fuel tank, fuel lines, fuel pump (if applicable), carburetor (Dell'Orto PHBH or similar), fuel filter replacement Cooling System: Radiator, coolant, fan, hoses, water pump maintenance and repair Bodywork And Trim: Fairings, seat, fuel tank cover, fenders, mirrors, indicators, decals Procedures Included Maintenance: Regular servicing, oil changes, filter replacements, spark plug checks, chain lubrication and adjustment Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides Repair: Detailed step-by-step repair instructions for all major components and systems Rebuild: Full engine and gearbox rebuild procedures, including component specifications and tolerances Installation: Instructions for fitting aftermarket parts or replacing major assemblies Technical Depth Depth: Detailed technical specifications, torque values, clearances, and diagnostic data for professional mechanics and experienced enthusiasts 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) - typically searchable and printable Print Quality Print Quality: High-resolution, suitable for printing individual pages or the entire manual Binding Type Binding Type: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) ⚙️ 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 (typical, may vary slightly) Compression Ratio: Approximately 12.5:1 (subject to specific model variant) Valve Train: Reed valve induction, Aprilia's APS (Aprilia Performance System) exhaust power valve Performance Horsepower: Typically around 15-30 HP (depending on market regulations and specific tuning, with restricted versions for A1 license holders) Torque: Varies with horsepower output, typically in the range of 12-18 Nm Fuel System Fuel Delivery: Carburetor (e.g., Dell'Orto PHBH 28) with automatic oil injection Fuel Type: Unleaded gasoline, minimum 95 RON Engine Components Ignition: Electronic CDI ignition system Exhaust: Expansion chamber exhaust system with catalytic converter (for emissions compliance) Lubrication Oil System: Separate oil injection system for 2-stroke oil 2 Stroke Oil Type: High-quality synthetic 2-stroke engine oil meeting JASO FD or ISO-L-EGD specifications 🔧 Transmission Standard Transmission Type: 6-speed constant mesh manual gearbox Optional Optional Transmission: N/A (Standard for this model) Features Clutch Type: Wet multi-plate clutch, hydraulically operated Final Drive: Chain drive Transmission Fluid Transmission Oil Type: Gear oil (refer to manual for specific viscosity, e.g., SAE 75W/90 or 10W/40) 📐 Dimensions Exterior Length: Approx. 1950 mm Width: Approx. 740 mm Height: Approx. 1100 mm Wheelbase: Approx. 1335 mm Weights Dry Weight: Approx. 140 kg Wet Weight: Approx. 155 kg (with all fluids) Fuel Tank Capacity: 13 Liters (including 3-liter reserve) Suspension Front Suspension Type: Upside-down telescopic fork, Marzocchi or Paioli (model dependent), adjustable preload and damping Front Fork Diameter: 40 mm Rear Suspension Type: Monoshock absorber, progressive linkage system, adjustable preload and rebound damping Wheels And Tires Front Wheel Size: 17 inch Rear Wheel Size: 17 inch Front Tire Size: 110/70-17 Rear Tire Size: 140/70-17 Wheel Bolt Pattern: N/A (Spoked or Cast Wheels, Hub Assembly) Brakes Front Brake Type: Hydraulic disc brake, dual piston caliper Front Brake Disc Diameter: 320 mm Rear Brake Type: Hydraulic disc brake, single piston caliper Rear Brake Disc Diameter: 210 mm 🛡️ Safety Features Ratings Safety Ratings: Not typically rated by official agencies like NHTSA for motorcycles; safety relies on design and rider skill. Active Features Active Safety: Responsive braking system, good handling characteristics, effective suspension Passive Features Passive Safety: Sturdy frame construction, fairing for rider protection from elements 💡 Technology Features Infotainment Infotainment System: Basic analogue and digital instrument cluster (speedometer, tachometer, odometer, trip meter, coolant temperature warning)...
Rotax 125cc 2-stroke (Specific codes vary by market and year, e.g., 123, 138)
👋 Introduction
Market Position
Market Position:
The Aprilia RS125 is a highly regarded 125cc sportbike, known for its racing heritage and premium feel within its class. It appeals to younger riders seeking a stylish and performance-oriented machine, often as an entry into sportbike ownership.
Competitive Analysis
Competitors:
Competed against models like the Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125, and Kawasaki Ninja 125.
Key Features
Key Features:
Powerful 2-stroke engine, sophisticated chassis derived from larger Aprilia models, aggressive styling, high-quality suspension components, capable of high performance for its displacement.
📋 Manual Details
Coverage Areas
Coverage Type:
Comprehensive workshop and repair
Page Count
Page Count:
Estimated 300-500+ pages (typical for detailed workshop manuals of this era)
Manual Type
Manual Type:
Digital Workshop Repair Manual
Language
Language:
English (Standard for international release, potential for multilingual versions)
Typically around 15-30 HP (depending on market regulations and specific tuning, with restricted versions for A1 license holders)
Torque:
Varies with horsepower output, typically in the range of 12-18 Nm
Fuel System
Fuel Delivery:
Carburetor (e.g., Dell'Orto PHBH 28) with automatic oil injection
Fuel Type:
Unleaded gasoline, minimum 95 RON
Engine Components
Ignition:
Electronic CDI ignition system
Exhaust:
Expansion chamber exhaust system with catalytic converter (for emissions compliance)
Lubrication
Oil System:
Separate oil injection system for 2-stroke oil
2 Stroke Oil Type:
High-quality synthetic 2-stroke engine oil meeting JASO FD or ISO-L-EGD specifications
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh manual gearbox
Optional
Optional Transmission:
N/A (Standard for this model)
Features
Clutch Type:
Wet multi-plate clutch, hydraulically operated
Final Drive:
Chain drive
Transmission Fluid
Transmission Oil Type:
Gear oil (refer to manual for specific viscosity, e.g., SAE 75W/90 or 10W/40)
📐 Dimensions
Exterior
Length:
Approx. 1950 mm
Width:
Approx. 740 mm
Height:
Approx. 1100 mm
Wheelbase:
Approx. 1335 mm
Weights
Dry Weight:
Approx. 140 kg
Wet Weight:
Approx. 155 kg (with all fluids)
Fuel Tank Capacity:
13 Liters (including 3-liter reserve)
Suspension
Front Suspension Type:
Upside-down telescopic fork, Marzocchi or Paioli (model dependent), adjustable preload and damping
Front Fork Diameter:
40 mm
Rear Suspension Type:
Monoshock absorber, progressive linkage system, adjustable preload and rebound damping
Wheels And Tires
Front Wheel Size:
17 inch
Rear Wheel Size:
17 inch
Front Tire Size:
110/70-17
Rear Tire Size:
140/70-17
Wheel Bolt Pattern:
N/A (Spoked or Cast Wheels, Hub Assembly)
Brakes
Front Brake Type:
Hydraulic disc brake, dual piston caliper
Front Brake Disc Diameter:
320 mm
Rear Brake Type:
Hydraulic disc brake, single piston caliper
Rear Brake Disc Diameter:
210 mm
🛡️ Safety Features
Ratings
Safety Ratings:
Not typically rated by official agencies like NHTSA for motorcycles; safety relies on design and rider skill.
Active Features
Active Safety:
Responsive braking system, good handling characteristics, effective suspension
Passive Features
Passive Safety:
Sturdy frame construction, fairing for rider protection from elements
💡 Technology Features
Infotainment
Infotainment System:
Basic analogue and digital instrument cluster (speedometer, tachometer, odometer, trip meter, coolant temperature warning)
Driver Assistance
Driver Assistance Features:
N/A (No electronic rider aids typically found on this model)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual; typically every 3,000-5,000 km or annually
Spark Plug Replacement:
Refer to manual; typically every 5,000-10,000 km
Air Filter Cleaning Or Replacement:
Refer to manual; typically every 5,000-10,000 km
Coolant Replacement:
Refer to manual; typically every 2 years
Chain Lubrication And Adjustment:
Regularly, every 500-1000 km or after riding in wet conditions
Fluid Specifications
Engine Oil Type:
N/A (2-stroke, oil injection)
2 Stroke Oil Spec:
JASO FD / API TC / ISO-L-EGD compliant synthetic 2-stroke oil
Coolant Type:
Ethylene glycol-based antifreeze coolant with corrosion inhibitors (e.g., Motul Motocool Expert or equivalent)
Brake Fluid Type:
DOT 4 brake fluid
Fork Oil Type:
Refer to manual for viscosity (e.g., 5W or 10W)
Known Issues
Common Issues:
Carburetor jetting sensitivity to altitude and temperature, wear on exhaust power valve (APS system), occasional electrical gremlins, piston and ring wear due to demanding 2-stroke nature, clutch wear.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Aprilia has a strong racing heritage, particularly in the 125cc and 250cc classes, winning numerous world championships. This racing DNA is evident in the design and performance of the RS125.
Model Evolution
Model Evolution:
The RS125 has undergone several visual and minor mechanical updates since its inception. The 2006 onwards models represent a significant styling refresh and often featured improved components or engine tuning compared to earlier generations.
Production
Production Period:
The RS125 has been in continuous production for many years, with significant updates in the late 1990s and early 2000s. The 2006 onwards designation specifically refers to a generation of models that continued production for a considerable period.
🏆 Awards & Recognition
Recognitions
Motorcycle Press Awards:
Often praised by motorcycle journalists for its performance, handling, and 'big bike' feel. Frequently featured in 'best 125cc sportbike' comparisons.
Ratings
Owner Satisfaction Ratings:
Generally high owner satisfaction for its performance and styling, though maintenance requirements are noted.
Certifications
Emissions Certification:
Euro 3 compliant (for models sold in Europe post-2006) through advanced engine design and catalytic converter.
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