🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Year: 1996 Codes Product Code: Not specified in product data 👋 Introduction Market Position Segment: Sportbike, Lightweight Supersport Target Audience: Young riders seeking performance and aggressive styling, often used in track days and entry-level racing. Competitive Analysis Key Competitors Era: Yamaha YZF-R125 (later models), Honda CBR125R (later models), Suzuki GSX-R125 (later models), Cagiva Mito 125. Key Features Design Philosophy: Inspired by Aprilia's larger RS series superbikes, featuring aggressive styling, aerodynamic fairings, and a focus on rider engagement. Engine Type: High-performance 2-stroke, liquid-cooled, offering a strong power-to-weight ratio for its class. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive repair and service information primarily for professional technicians, but with adequate data for advanced enthusiasts. Page Count Page Count: Not specified in product data (PDF indicates extensive coverage) Manual Type Manual Type: Repair Service Manual Language Language: English (assumed based on product description) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: 2-stroke Rotax 122 engine, cylinder, piston, crankshaft, lubrication, cooling, ignition system (CDI), exhaust system. Fuel System: Carburetor (Dell'Orto PHBH 28 AS/BS), fuel pump, fuel tank, fuel lines, airbox. Transmission Drivetrain: 6-speed gearbox, clutch assembly, chain drive, final drive sprocket, gearbox lubrication. Chassis Frame: Aluminum alloy twin-spar frame, subframe, swingarm, rear suspension linkage. Suspension Front: Upside-down (USD) telescopic forks (e.g., Marzocchi or Paioli), internal damping, spring preload adjustment. Suspension Rear: Monoshock rear suspension with adjustable preload and rebound damping, linkage system. Brakes Front: Hydraulic disc brake, caliper type (e.g., Brembo 4-piston), rotor specifications, brake fluid type and bleeding procedures. Brakes Rear: Hydraulic disc brake, caliper type (e.g., Brembo 2-piston), rotor specifications, brake fluid type and bleeding procedures. Electrical System: 12V system, battery, stator, regulator/rectifier, wiring diagrams, lighting, horn, starter motor, electronic control unit (ECU). Bodywork Fairings: Front fairing, side panels, seat, tail section, fuel tank cover, mounting points, removal/installation. Procedures Included Routine Maintenance: Oil change intervals, spark plug replacement, air filter cleaning/replacement, chain adjustment and lubrication, brake pad inspection. Troubleshooting: Diagnostic procedures for common issues, fault finding for electrical and mechanical problems, error codes (if applicable). Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly procedures, including piston ring gap, cylinder bore, and bearing clearances. Suspension Forks: Fork oil change, seal replacement, damping adjustment, and fork leg disassembly/reassembly. Rear Shock Service: Shock absorber inspection, seal replacement, and linkage bearing maintenance. Brake System Service: Brake bleeding, caliper overhaul, master cylinder inspection, pad and rotor replacement. Carburetor Adjustment: Idle speed adjustment, jetting recommendations, float level setting, and carburetor cleaning. Electrical Diagnostics: Testing of ignition components, charging system analysis, and troubleshooting of lighting and starter circuits. Technical Depth Depth Level: In-depth diagnostic and repair procedures suitable for professional mechanics, including torque specifications, tolerances, and detailed component breakdowns. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Digital PDF, allowing for clear viewing and printing of diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Rotax 122, 2-stroke, single-cylinder Displacement: 124.8 cc (7.62 cu in) Bore X Stroke: 54 mm x 54.5 mm (2.13 in x 2.15 in) Compression Ratio: Approximately 12.5:1 (varies slightly by market) Cooling System: Liquid-cooled Power Delivery: Known for its aggressive powerband, typical of 2-stroke engines, requiring higher RPM for peak performance. Performance Horsepower Approx: Around 30-34 HP (at crankshaft, varies by market and restrictions) Torque Approx: Around 20-22 Nm (at crankshaft) Fuel System Carburetor Model: Dell'Orto PHBH 28 AS or BS Fuel Type: Unleaded gasoline (RON 95 or higher recommended), with 2-stroke oil pre-mix or Autolube system. Autolube System: Separate oil injection system for 2-stroke lubrication (requires specific 2T oil). 🔧 Transmission Standard Gearbox Type: 6-speed constant mesh sequential gearbox Clutch Type: Wet multi-plate clutch, hydraulically operated Features Gear Ratios: Specific gear ratios detailed within the manual, critical for performance tuning and maintenance. Final Drive: Chain drive (e.g., 16T front sprocket, 47T rear sprocket common) Gearbox Oil: Specific API GL-4 or GL-5 gear oil, capacity detailed in manual. 📐 Dimensions Exterior Length Approx: 2000 mm (approx. 78.7 in) Width Approx: 700 mm (approx. 27.6 in) Height Approx: 1100 mm (approx. 43.3 in) Weights Dry Weight Approx: 140-145 kg (approx. 309-320 lbs) Wet Weight Approx: 155-160 kg (approx. 342-353 lbs) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles are not typically crash-tested by organizations like NHTSA/Euro NCAP. Safety relies on design and rider skill). Active Features Braking System: Dual disc brakes (front and rear) with hydraulic actuation for strong stopping power. Suspension Design: Performance-oriented USD front forks and adjustable monoshock rear suspension contribute to stable handling. Passive Features Chassis Construction: Sturdy aluminum alloy frame provides rigidity and rider confidence. Lighting: Halogen headlights for good visibility, LED taillight (on some later variants/upgrades). 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, speedometer, odometer, coolant...
Testing of ignition components, charging system analysis, and troubleshooting of lighting and starter circuits.
Technical Depth
Depth Level:
In-depth diagnostic and repair procedures suitable for professional mechanics, including torque specifications, tolerances, and detailed component breakdowns.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Digital PDF, allowing for clear viewing and printing of diagrams and text.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotax 122, 2-stroke, single-cylinder
Displacement:
124.8 cc (7.62 cu in)
Bore X Stroke:
54 mm x 54.5 mm (2.13 in x 2.15 in)
Compression Ratio:
Approximately 12.5:1 (varies slightly by market)
Cooling System:
Liquid-cooled
Power Delivery:
Known for its aggressive powerband, typical of 2-stroke engines, requiring higher RPM for peak performance.
Performance
Horsepower Approx:
Around 30-34 HP (at crankshaft, varies by market and restrictions)
Torque Approx:
Around 20-22 Nm (at crankshaft)
Fuel System
Carburetor Model:
Dell'Orto PHBH 28 AS or BS
Fuel Type:
Unleaded gasoline (RON 95 or higher recommended), with 2-stroke oil pre-mix or Autolube system.
Autolube System:
Separate oil injection system for 2-stroke lubrication (requires specific 2T oil).
🔧 Transmission
Standard
Gearbox Type:
6-speed constant mesh sequential gearbox
Clutch Type:
Wet multi-plate clutch, hydraulically operated
Features
Gear Ratios:
Specific gear ratios detailed within the manual, critical for performance tuning and maintenance.
Final Drive:
Chain drive (e.g., 16T front sprocket, 47T rear sprocket common)
Gearbox Oil:
Specific API GL-4 or GL-5 gear oil, capacity detailed in manual.
📐 Dimensions
Exterior
Length Approx:
2000 mm (approx. 78.7 in)
Width Approx:
700 mm (approx. 27.6 in)
Height Approx:
1100 mm (approx. 43.3 in)
Weights
Dry Weight Approx:
140-145 kg (approx. 309-320 lbs)
Wet Weight Approx:
155-160 kg (approx. 342-353 lbs)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles are not typically crash-tested by organizations like NHTSA/Euro NCAP. Safety relies on design and rider skill).
Active Features
Braking System:
Dual disc brakes (front and rear) with hydraulic actuation for strong stopping power.
Suspension Design:
Performance-oriented USD front forks and adjustable monoshock rear suspension contribute to stable handling.
Passive Features
Chassis Construction:
Sturdy aluminum alloy frame provides rigidity and rider confidence.
Lighting:
Halogen headlights for good visibility, LED taillight (on some later variants/upgrades).
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, speedometer, odometer, coolant temperature gauge, and indicator lights. Minimal electronic features compared to modern bikes.
Driver Assistance
ABS:
ABS was not a standard feature on the 1996 RS 125. Optional fitment may exist on very late models or aftermarket.
Connectivity
Connectivity Features:
N/A - no modern electronic connectivity features such as Bluetooth or Wi-Fi.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or annually. Check manual for specific recommendations based on usage. 2-stroke oil injection system requires regular topping up.
Spark Plug Replacement:
Typically every 5,000-10,000 km, depending on plug type and usage. Manual will specify recommended plug type (e.g., NGK BR9EG).
Chain Lubrication Adjustment:
Check and lubricate chain every 500-1000 km, and adjust tension as needed. Manual provides specific slack measurement.
Air Filter Cleaning:
Clean every 5,000-10,000 km or more frequently in dusty conditions. Manual specifies cleaning method (e.g., washing with specific cleaner).
Brake Fluid Flush:
Recommended every 2 years for optimal performance and safety.
Fluid Specifications
Engine Oil 2T:
Specific 2-stroke synthetic or semi-synthetic oil suitable for high-performance liquid-cooled engines (e.g., Motul 710 2T, Castrol TTS). Manual specifies grade and properties.
Gearbox Oil:
API GL-4 or GL-5 rated transmission oil, viscosity like SAE 75W-90 or 10W-40 (check manual for exact specification and capacity).
Coolant:
Mixture of distilled water and ethylene glycol-based antifreeze (e.g., 50/50 mix). Manual specifies capacity and type.
Brake Fluid:
DOT 4 hydraulic brake fluid (ensure it's fresh and from a sealed container).
Known Issues
Power Valve Sticking:
The exhaust power valve system can become carboned up and stick, affecting performance. Requires regular cleaning and lubrication. Covered in the manual's troubleshooting section.
Carburetor Jetting:
Can be sensitive to changes in air filter, exhaust, or altitude, requiring careful jetting adjustments for optimal performance. Manual provides base settings.
Clutch Wear:
Due to the sporty nature and high-revving engine, clutch wear can be accelerated with aggressive riding. Manual covers clutch inspection and replacement.
Rotax Engine Wear:
While robust, proper 2-stroke maintenance (correct oil, clean air filter, avoid lugging the engine) is crucial to prevent premature wear on pistons and cylinders. Manual emphasizes this.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian motorcycle manufacturer with a strong heritage in racing, particularly in the 125cc and 250cc Grand Prix classes.
Model Evolution
Rs125 Lineage:
The RS 125 has a long and successful history, evolving from earlier models like the AF1 series. The 1996 model represents a significant iteration in its development, featuring advanced technology for its time.
Production
Production Years:
The RS 125 model line was produced for many years, with the first generation starting in the early 1990s and continuing with updates through the early 2000s.
Manufacturing Location:
Primarily manufactured in Italy by Aprilia.
🏆 Awards & Recognition
Recognitions
Racing Success:
The Aprilia RS 125 platform has a significant history of success in motorcycle racing, particularly in the FIM Grand Prix World Championship 125cc class, demonstrating its performance pedigree.