🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Production Years Covered: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Chassis Codes: RP, Extrema, Replica, Chesterfield, Rotax 👋 Introduction Market Position Segment: Lightweight Supersport Motorcycle Target Audience: Enthusiasts, performance-oriented riders, track day participants, DIY mechanics. Competitive Analysis Key Competitors: Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125, Kawasaki Ninja 125 (and comparable older models). Key Features Design Philosophy: Race-inspired styling, aerodynamic fairings, sporty ergonomics, high-performance two-stroke engine. Engine Technology: Rotax 123 two-stroke, liquid-cooled, reed valve induction, often with power valve ( ஏPRC - Aprilia Performance নিশ্চিত Race Cylinder). Handling: Renowned for sharp handling, excellent chassis dynamics, and adjustable suspension components. 📋 Manual Details Coverage Areas Content Scope: Comprehensive service and repair for all aspects of the Aprilia RS 125 from 1993-2006. Page Count Estimated Pages: 500+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Top-end (cylinder, piston, cylinder head), bottom-end (crankshaft, connecting rod, bearings), timing, valve train (if applicable to two-stroke variations in assembly), cooling system. Fuel System: Carburetor(s) (e.g., Dell'Orto PHBH, VHSH) service and adjustment, fuel pump, fuel lines, fuel tank. Ignition System: CDI ignition, spark plugs, stator, rotor, wiring. Exhaust System: Expansion chamber, silencer, mounting and sealing. Transmission: Clutch (operation, adjustment, replacement), gearbox (ratios, overhaul, lubrication), shift mechanism. Chassis And Frame: Frame inspection, welds, component mounting, steering head bearings. Suspension: Front fork (oil levels, seals, damping adjustments, disassembly/reassembly), rear shock absorber (servicing, adjustment, replacement), linkage systems. Brakes: Front and rear brake systems (hydraulic), caliper service, master cylinder overhaul, brake pad replacement, fluid bleeding, disc inspection, line routing. Wheels And Tires: Wheel bearing service, tire mounting/balancing, rim inspection, spoke tensioning (if applicable to certain models). Electrical System: Battery, charging system (alternator/stator), lighting (headlight, taillight, indicators), horn, wiring diagrams, fuses, switches, starter system (if applicable). Bodywork And Fairings: Fairing removal and installation, seat, tank, fenders, graphics, fasteners. Procedures Included Routine Maintenance: Oil changes (gear oil), chain adjustment and lubrication, spark plug replacement, air filter cleaning/replacement, brake fluid replacement, coolant checks. Engine Overhaul: Top-end rebuild (piston rings, piston, cylinder hone), crankshaft and connecting rod replacement, bearing replacement, seal replacement. Carburetor Tuning: Jetting recommendations, idle speed adjustment, mixture screw settings, float height adjustment. Suspension Servicing: Fork seal replacement, fork oil change, rear shock service. Brake System Maintenance: Brake fluid flush and bleed, caliper piston cleaning and lubrication, pad replacement. Electrical Troubleshooting: Diagnostic procedures for common electrical faults, wiring diagram interpretation. Chassis Maintenance: Steering head bearing adjustment and replacement, swingarm bearing inspection. Technical Depth Depth Level: Expert-level, covering complete disassembly, repair, and reassembly of all major vehicle components. Includes torque specifications, clearances, and diagnostic procedures. 📊 Manual Specifications File Format Digital Quality: High-resolution scans for clear text and diagrams, searchable text for easy navigation. Print Quality Print Compatibility: Printable pages for on-the-go reference. Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder Displacement: 124.8 cc (approx.) Bore X Stroke: 54 mm x 54.5 mm (approx.) Cooling System: Liquid-cooled Induction System: Reed valve, carburetor Power Valve: Yes (Rotax Power Valve - RPV) Performance Horsepower Output: Approx. 30-34 hp (varies by year and market regulations) Torque Output: Approx. 22-24 Nm (varies) Fuel System Carburetor Model: Dell'Orto PHBH 28, VHSH 30 (or similar, depending on variant) Fuel Type: Unleaded gasoline, minimum 95 RON (recommended 98 RON for optimal performance) Oil Mixture: Pre-mix or separate oil injection system (check model specifics) 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch Type: Wet, multi-plate Gear Ratios: Detailed in manual (specific ratios vary slightly by year and model variant) 📐 Dimensions Exterior Length: Approx. 1950 mm (varies slightly) Width: Approx. 700 mm (varies slightly) Height: Approx. 1100 mm (varies slightly) Wheelbase: Approx. 1345 mm (varies slightly) Weights Dry Weight: Approx. 130-140 kg (varies by model and equipment) Fuel Tank Capacity: Approx. 12-13 Liters Oil Tank Capacity: Approx. 1.2 Liters (for separate injection) Cooling System Capacity: Approx. 1.0 Liters 🛡️ Safety Features Ratings Crash Test Results: Motorcycle safety is assessed differently than cars; emphasis on handling, braking, and rider protection equipment. Active Features Braking System: High-performance disc brakes (e.g., Brembo calipers on some models), hydraulic actuation. Suspension Adjustability: Adjustable front forks (pre-load, compression, rebound on higher-spec models), adjustable rear shock preload. Passive Features Frame Construction: Aluminum alloy or steel trellis frame for rigidity and light weight. 💡 Technology Features Infotainment Display Type: Analog tachometer and speedometer, LCD for odometer/trip meter. Driver Assistance ABS: Not typically available on this model range. Connectivity Bluetooth: Not available. 🔧 Maintenance Service Intervals Oil Change Gearbox: Every 6,000 km or annually (check manual for specific recommendation) Spark Plug Replacement: Every 4,000-6,000 km (depending on plug type and usage) Air Filter Cleaning: Every 4,000 km Chain Lubrication Adjustment:...
Front and rear brake systems (hydraulic), caliper service, master cylinder overhaul, brake pad replacement, fluid bleeding, disc inspection, line routing.
Wheels And Tires:
Wheel bearing service, tire mounting/balancing, rim inspection, spoke tensioning (if applicable to certain models).
Electrical System:
Battery, charging system (alternator/stator), lighting (headlight, taillight, indicators), horn, wiring diagrams, fuses, switches, starter system (if applicable).
Bodywork And Fairings:
Fairing removal and installation, seat, tank, fenders, graphics, fasteners.
Procedures Included
Routine Maintenance:
Oil changes (gear oil), chain adjustment and lubrication, spark plug replacement, air filter cleaning/replacement, brake fluid replacement, coolant checks.
Engine Overhaul:
Top-end rebuild (piston rings, piston, cylinder hone), crankshaft and connecting rod replacement, bearing replacement, seal replacement.
Fork seal replacement, fork oil change, rear shock service.
Brake System Maintenance:
Brake fluid flush and bleed, caliper piston cleaning and lubrication, pad replacement.
Electrical Troubleshooting:
Diagnostic procedures for common electrical faults, wiring diagram interpretation.
Chassis Maintenance:
Steering head bearing adjustment and replacement, swingarm bearing inspection.
Technical Depth
Depth Level:
Expert-level, covering complete disassembly, repair, and reassembly of all major vehicle components. Includes torque specifications, clearances, and diagnostic procedures.
📊 Manual Specifications
File Format
Digital Quality:
High-resolution scans for clear text and diagrams, searchable text for easy navigation.
Print Quality
Print Compatibility:
Printable pages for on-the-go reference.
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Two-stroke, single-cylinder
Displacement:
124.8 cc (approx.)
Bore X Stroke:
54 mm x 54.5 mm (approx.)
Cooling System:
Liquid-cooled
Induction System:
Reed valve, carburetor
Power Valve:
Yes (Rotax Power Valve - RPV)
Performance
Horsepower Output:
Approx. 30-34 hp (varies by year and market regulations)
Torque Output:
Approx. 22-24 Nm (varies)
Fuel System
Carburetor Model:
Dell'Orto PHBH 28, VHSH 30 (or similar, depending on variant)
Fuel Type:
Unleaded gasoline, minimum 95 RON (recommended 98 RON for optimal performance)
Oil Mixture:
Pre-mix or separate oil injection system (check model specifics)
🔧 Transmission
Standard
Type:
6-speed constant mesh
Features
Clutch Type:
Wet, multi-plate
Gear Ratios:
Detailed in manual (specific ratios vary slightly by year and model variant)
📐 Dimensions
Exterior
Length:
Approx. 1950 mm (varies slightly)
Width:
Approx. 700 mm (varies slightly)
Height:
Approx. 1100 mm (varies slightly)
Wheelbase:
Approx. 1345 mm (varies slightly)
Weights
Dry Weight:
Approx. 130-140 kg (varies by model and equipment)
Fuel Tank Capacity:
Approx. 12-13 Liters
Oil Tank Capacity:
Approx. 1.2 Liters (for separate injection)
Cooling System Capacity:
Approx. 1.0 Liters
🛡️ Safety Features
Ratings
Crash Test Results:
Motorcycle safety is assessed differently than cars; emphasis on handling, braking, and rider protection equipment.
Active Features
Braking System:
High-performance disc brakes (e.g., Brembo calipers on some models), hydraulic actuation.
Suspension Adjustability:
Adjustable front forks (pre-load, compression, rebound on higher-spec models), adjustable rear shock preload.
Passive Features
Frame Construction:
Aluminum alloy or steel trellis frame for rigidity and light weight.
💡 Technology Features
Infotainment
Display Type:
Analog tachometer and speedometer, LCD for odometer/trip meter.
Driver Assistance
ABS:
Not typically available on this model range.
Connectivity
Bluetooth:
Not available.
🔧 Maintenance
Service Intervals
Oil Change Gearbox:
Every 6,000 km or annually (check manual for specific recommendation)
Spark Plug Replacement:
Every 4,000-6,000 km (depending on plug type and usage)
Air Filter Cleaning:
Every 4,000 km
Chain Lubrication Adjustment:
Every 1,000 km and after washing/rain
Brake Fluid Replacement:
Every 2 years
Top End Overhaul:
Recommended between 15,000 - 25,000 km, depending on usage and maintenance (piston and rings)
Fluid Specifications
Gearbox Oil:
SAE 75W/90 API GL-4 or GL-5 synthetic gear oil (capacity ~0.75 Liters)
Coolant:
Ethylene glycol-based antifreeze mixture (50/50 with distilled water)
Brake Fluid:
DOT 4
Known Issues
Common Problems:
Worn power valve mechanism, carburetor jetting sensitivity, coolant leaks from hose connections, clutch wear, exhaust header pipe cracks (on some early models), vibration-induced loosening of fasteners.
Maintenance Tips:
Regular cleaning and lubrication of the power valve, precise carburetor setup, checking coolant and oil levels, and torquing fasteners are crucial for longevity.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Italy
Motorsport Connection:
Aprilia has a strong heritage in Grand Prix racing, particularly in the 125cc and 250cc classes, which heavily influenced the RS 125's development.
Model Evolution
Generations Covered:
This manual covers the significant evolutionary period of the RS 125, from its early iterations through various updates in styling, engine performance, and componentry.
Key Variants:
Extrema, Replica, Chesterfield Replica, etc., often distinguished by graphics, minor component upgrades, or suspension tuning.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Market Perception:
Widely regarded as one of the best 125cc sports bikes of its era, praised for performance and handling that punched above its weight class.
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