APRILIA RS125 Workshop Repair Manual All 2006 ONWARDS ModelS COVERED
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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Model Variant: Sportbike Generation Covered Generation: Post-2006 Models Codes Chassis Code Examples: E3, RP, RP0 👋 Introduction Market Position Segment: Lightweight Sportbike / Entry-Level Performance Motorcycle Competitive Analysis Key Competitors: Yamaha YZF-R125, Honda CBR125R, KTM RC125, Suzuki GSX-R125 Key Features Manual Selling Points: Instant download, comprehensive coverage, detailed diagrams and illustrations, step-by-step instructions, PC/Mac compatibility, essential for DIY enthusiasts and professional mechanics. Vehicle Selling Points: Aggressive styling, lightweight chassis, agile handling, sporty performance for its class, premium Italian brand heritage. 📋 Manual Details Coverage Areas Technical Focus: Workshop Service and Repair Page Count Estimated Page Count: 300-500+ (typical for comprehensive workshop manuals) Manual Type Type: Workshop Repair Manual Language Language: English Format Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine: Complete engine assembly, disassembly, rebuilding, troubleshooting, cooling system, lubrication system, ignition system, fuel system (carburetion), exhaust system. Transmission: Gearbox assembly, disassembly, clutch system (dry or wet clutch depending on variant), shift mechanism, lubrication. Chassis And Suspension: Front fork (USD), rear shock absorber, swingarm, steering system, wheel bearings, rear suspension linkage (if applicable). Brakes: Front and rear brake systems (disc brakes), caliper overhaul, master cylinder, brake lines, fluid replacement and bleeding procedures. Electrical System: Wiring diagrams, battery, charging system (alternator/stator), ignition coil, starter motor, lighting (headlight, taillight, indicators), dashboard indicators, fuses, relays, troubleshooting electrical faults. Fuel System: Carburetor types (e.g., Dell'Orto PHBH), jetting, float adjustment, fuel tank, fuel lines, fuel petcock. Bodywork And Trim: Fairing removal and installation, seat, fuel tank installation, tail section, fenders. Procedures Included Maintenance: Oil changes, filter replacement, spark plug service, air filter cleaning/replacement, chain adjustment and lubrication, brake fluid flush, coolant flush, tire pressure checks. Troubleshooting: Diagnostic procedures for common engine, electrical, and mechanical issues, symptom-based troubleshooting charts. Repair And Rebuild: Detailed step-by-step instructions for major component overhauls, including engine teardown, gearbox rebuilding, suspension component replacement, brake caliper rebuild. Adjustments: Carburetor synchronization and adjustment, valve clearance adjustment (if applicable to 2-stroke tuning), clutch lever free play, brake lever free play. Technical Depth Level Of Detail: Comprehensive: Covers everything from basic maintenance to full engine and gearbox rebuilds, including diagnostic procedures and detailed specifications. Diagnostic Capability: Advanced diagnostic procedures, including wiring diagrams for electrical troubleshooting and symptom analysis for mechanical faults. Rebuild Procedures: Detailed exploded views and step-by-step instructions for complete component rebuilds, including tolerances and torque specifications. 📊 Manual Specifications File Format Compatibility: PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, Windows 7 & 8, macOS, Linux) Print Quality Readability: High-quality PDF with clear text and easily discernible diagrams/illustrations. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke, Single Cylinder, Liquid-Cooled Displacement: 124.8 cc Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: Approx. 9.5:1 (varies slightly by sub-model) Power Output: Approx. 11 kW (15 hp) at 9,000 rpm (often restricted to 11kW for A1 license in Europe) Torque: Approx. 12 Nm at 8,000 rpm (varies) Performance Top Speed: Approx. 110-120 km/h (depending on rider, conditions, and restrictions) Fuel System Carburetor Type: Dell'Orto PHBH 28 BS (or similar, e.g., VM26) Fuel Type: Unleaded Gasoline, minimum 95 RON Oil Mixing: Automatic Oil Injection System (Separate Oil Tank) 🔧 Transmission Standard Transmission Type: 6-Speed Constant Mesh Clutch Type: Dry Multi-Plate Clutch (or Wet Multi-Plate Clutch depending on specific sub-model/revision) Final Drive: Chain Drive (520 O-ring) Features Gear Ratios: Specific ratios vary by model year, consult manual for exact values. Gearbox Oil: Specific gear oil type required, consult manual for specifications (e.g., SAE 75W/90 or similar). 📐 Dimensions Exterior Length: Approx. 1950 mm Width: Approx. 720 mm (at handlebars) Height: Approx. 1050 mm (at seat) Wheelbase: Approx. 1345 mm Weights Dry Weight: Approx. 120-130 kg Fuel Tank Capacity: Approx. 11 liters 🛡️ Safety Features Ratings Crash Test Information: N/A (Motorcycles are not subject to the same standardized crash testing as passenger cars). Active Features Braking System: Hydraulic disc brakes front and rear, braided steel lines on some models for improved feel. Passive Features Lighting: Halogen headlight, LED taillight/brake light, amber front and rear turn signals. 💡 Technology Features Infotainment Dashboard Features: Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature warning light, oil level warning light, neutral indicator, turn signal indicators. Driver Assistance N A: N/A (Motorcycles in this class typically do not feature electronic driver assistance systems beyond basic ABS on some later models, which is not explicitly stated as covered here). 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 km or annually, depending on usage. Consult manual for exact mileage and conditions. Spark Plug Service: Every 6,000-10,000 km. Recommended plug: NGK BR9EG or equivalent. Air Filter Service: Inspect every 3,000 km, clean/replace as needed. Replacement filter often available from K&N or Pipercross. Chain Maintenance: Lubricate and adjust chain...
Instant download, comprehensive coverage, detailed diagrams and illustrations, step-by-step instructions, PC/Mac compatibility, essential for DIY enthusiasts and professional mechanics.
Vehicle Selling Points:
Aggressive styling, lightweight chassis, agile handling, sporty performance for its class, premium Italian brand heritage.
📋 Manual Details
Coverage Areas
Technical Focus:
Workshop Service and Repair
Page Count
Estimated Page Count:
300-500+ (typical for comprehensive workshop manuals)
Diagnostic procedures for common engine, electrical, and mechanical issues, symptom-based troubleshooting charts.
Repair And Rebuild:
Detailed step-by-step instructions for major component overhauls, including engine teardown, gearbox rebuilding, suspension component replacement, brake caliper rebuild.
Adjustments:
Carburetor synchronization and adjustment, valve clearance adjustment (if applicable to 2-stroke tuning), clutch lever free play, brake lever free play.
Technical Depth
Level Of Detail:
Comprehensive: Covers everything from basic maintenance to full engine and gearbox rebuilds, including diagnostic procedures and detailed specifications.
Diagnostic Capability:
Advanced diagnostic procedures, including wiring diagrams for electrical troubleshooting and symptom analysis for mechanical faults.
Rebuild Procedures:
Detailed exploded views and step-by-step instructions for complete component rebuilds, including tolerances and torque specifications.
📊 Manual Specifications
File Format
Compatibility:
PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, Windows 7 & 8, macOS, Linux)
Print Quality
Readability:
High-quality PDF with clear text and easily discernible diagrams/illustrations.
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-Stroke, Single Cylinder, Liquid-Cooled
Displacement:
124.8 cc
Bore X Stroke:
54 mm x 54.5 mm
Compression Ratio:
Approx. 9.5:1 (varies slightly by sub-model)
Power Output:
Approx. 11 kW (15 hp) at 9,000 rpm (often restricted to 11kW for A1 license in Europe)
Torque:
Approx. 12 Nm at 8,000 rpm (varies)
Performance
Top Speed:
Approx. 110-120 km/h (depending on rider, conditions, and restrictions)
Fuel System
Carburetor Type:
Dell'Orto PHBH 28 BS (or similar, e.g., VM26)
Fuel Type:
Unleaded Gasoline, minimum 95 RON
Oil Mixing:
Automatic Oil Injection System (Separate Oil Tank)
🔧 Transmission
Standard
Transmission Type:
6-Speed Constant Mesh
Clutch Type:
Dry Multi-Plate Clutch (or Wet Multi-Plate Clutch depending on specific sub-model/revision)
Final Drive:
Chain Drive (520 O-ring)
Features
Gear Ratios:
Specific ratios vary by model year, consult manual for exact values.
Gearbox Oil:
Specific gear oil type required, consult manual for specifications (e.g., SAE 75W/90 or similar).
📐 Dimensions
Exterior
Length:
Approx. 1950 mm
Width:
Approx. 720 mm (at handlebars)
Height:
Approx. 1050 mm (at seat)
Wheelbase:
Approx. 1345 mm
Weights
Dry Weight:
Approx. 120-130 kg
Fuel Tank Capacity:
Approx. 11 liters
🛡️ Safety Features
Ratings
Crash Test Information:
N/A (Motorcycles are not subject to the same standardized crash testing as passenger cars).
Active Features
Braking System:
Hydraulic disc brakes front and rear, braided steel lines on some models for improved feel.
Passive Features
Lighting:
Halogen headlight, LED taillight/brake light, amber front and rear turn signals.
💡 Technology Features
Infotainment
Dashboard Features:
Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature warning light, oil level warning light, neutral indicator, turn signal indicators.
Driver Assistance
N A:
N/A (Motorcycles in this class typically do not feature electronic driver assistance systems beyond basic ABS on some later models, which is not explicitly stated as covered here).
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 km or annually, depending on usage. Consult manual for exact mileage and conditions.
Spark Plug Service:
Every 6,000-10,000 km. Recommended plug: NGK BR9EG or equivalent.
Air Filter Service:
Inspect every 3,000 km, clean/replace as needed. Replacement filter often available from K&N or Pipercross.
Chain Maintenance:
Lubricate and adjust chain every 500-1,000 km or after washing/rain. Check tension regularly.
Fluid Specifications
Engine Oil:
For 2-stroke premix (if applicable, though most post-2006 have oil injection): High-quality 2-stroke synthetic racing oil (e.g., Motul 7100 2T, Castrol Power 1 Racing 2T).
Gearbox Oil:
Refer to manual. Typically SAE 75W/90 synthetic gear oil. Capacity: ~0.7-0.8 Liters.
Coolant:
Ethylene glycol-based coolant mixed with distilled water (50/50). Ensure freeze protection. Capacity: ~0.9-1.0 Liters.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Known Issues
Common Problems:
Carburetor jetting sensitivity to altitude/temperature, potential for crank seal leaks, exhaust valve issues (if equipped), electrical gremlins in older models, clutch wear (especially if ridden hard).
Performance Tuning Considerations:
The RS125 is a popular platform for tuning. Modifications often include aftermarket exhaust systems, performance air filters, re-jetted carburetors, and sometimes even larger bore kits. The manual is crucial for understanding stock specifications before undertaking modifications.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia (Italian motorcycle manufacturer, known for performance and racing heritage).
Model Evolution
Generations:
The RS125 has a long history, with significant updates to engine, chassis, and styling over the years. The post-2006 models often feature updated aerodynamics, chassis components, and potentially Euro 3 compliant engines (though some markets may have unrestricted versions).
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Industry Accolades:
The Aprilia RS125 is generally well-regarded for its styling, handling, and performance in the 125cc sportbike segment, often winning accolades for its design and rider experience within its class.