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APRILIA RS125 Complete Workshop Repair Manual 2006 Onward

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Model Year Start: 2006 Model Year End: Present (with updates) Codes Chassis Codes: RP (various suffixes depending on year/market) 👋 Introduction Market Position Segment: Lightweight Sportbike / Performance Motorcycle Target Audience: Enthusiast riders, aspiring racers, budget-conscious performance riders, DIY mechanics. Competitive Analysis Key Competitors: Yamaha YZF-R125, Honda CBR125R, KTM RC125, Suzuki GSX-R125. Unique Selling Points: Renowned Aprilia racing heritage, aggressive styling, typically a potent 2-stroke engine (pre-2008 models and some later variations), capable chassis and suspension for its class. Key Features Manual Features: Easy to navigate, clear diagrams, step-by-step instructions, troubleshooting tips, comprehensive coverage. Vehicle Features Highlighted: High-performance engine for its displacement, sharp handling, track-day capability, customizable options. 📋 Manual Details Coverage Areas Countries: Global (all markets where RS125 is sold) Page Count Estimated Page Count: High (typically 500+ pages for comprehensive manuals) Manual Type Manual Type: Workshop Repair Manual / Service Manual Language Language: English Format Format: Digital Download (PDF/eBook) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, top-end (cylinder, piston, head), bottom-end (crankshaft, connecting rod, bearings), timing, lubrication system. Fuel System: Carburetor (Dell'Orto PHBH/PHBL typically) tuning, cleaning, overhaul, fuel pump, fuel lines, fuel tank maintenance. Cooling System: Radiator, hoses, water pump, thermostat, coolant specifications and bleeding procedures. Ignition System: CDI unit, ignition coils, spark plugs, timing checks, stator and rotor testing. Exhaust System: Expansion chamber, silencer, gasket replacement, performance tuning considerations. Transmission: 6-speed gearbox, clutch (wet multi-plate), gear selection mechanism, gearbox oil specifications and change intervals. Frame And Suspension: Frame inspection, front fork (upside-down type, often Marzocchi or Paioli) overhaul, fork oil specifications and levels, rear shock absorber adjustment and overhaul. Brakes: Front and rear disc brakes, brake caliper service, hydraulic system bleeding, brake fluid specifications, pad replacement, rotor inspection. Electrical System: Wiring diagrams, battery maintenance, lighting system (headlights, taillights, indicators), starter motor, charging system (alternator/stator). Bodywork And Fairings: Fairing removal and installation, seat, fuel tank, fenders, graphics. Procedures Included Preventative Maintenance: Oil changes, filter replacements, chain adjustment, brake checks, tire pressure checks, coolant checks, spark plug replacement. Troubleshooting: Diagnostic charts for common starting issues, running problems, electrical faults, and performance degradation. Engine Rebuild: Detailed step-by-step instructions for complete engine disassembly, inspection, part replacement (piston rings, gaskets, bearings), and reassembly. Suspension Overhaul: Fork seal replacement, fork oil change, shock absorber service. Clutch Replacement: Service and replacement of clutch plates and springs. Brake System Service: Fluid flushing, caliper rebuild, pad and rotor replacement. Electrical Component Testing: Testing of starter, alternator, CDI unit, and other electrical components using multimeters. Technical Depth Depth Level: Comprehensive (from basic maintenance to full engine rebuilds and advanced diagnostics) Diagnostic Capabilities: Detailed troubleshooting guides, wiring diagrams, and component testing procedures. Torque Specifications: All critical bolt and nut torque values provided for engine, chassis, and suspension components. Clearances And Tolerances: Specifications for piston-to-cylinder wall, bearing clearances, valve clearances (if applicable to specific models/years), etc. 📊 Manual Specifications File Format File Format: PDF (Searchable Text, Printable Pages) Print Quality Print Quality: High Resolution (suitable for printing individual pages or the entire manual) Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, single-cylinder (typically Rotax 122 or similar variants for 2006 onwards, though some later models may have 4-stroke variants depending on market). Bore X Stroke: 54 mm x 54.5 mm (typical for Rotax 122) Displacement: 124.8 cc Compression Ratio: Approximately 11.5:1 to 12.5:1 (varies slightly by model year) Valve Mechanism: Reed valve intake, exhaust power valve (Rotax 'V' or 'APTS' system). Performance Horsepower: Approx. 15 kW (20.4 PS) @ 9,000 rpm (Europe restricted for A1 license); unrestricted versions can be significantly higher, up to 30-33 hp. Torque: Approx. 12.2 Nm (9 lb-ft) @ 8,000 rpm (restricted); higher for unrestricted. Fuel System Carburetor Model: Dell'Orto PHBH 28 or PHBL 26 (depending on market and emissions regulations) Fuel Type: Unleaded gasoline, minimum 95 RON (Octane Rating) Oil Mixture: Premixed (manual) or Autolube (oil injection system) depending on model year/market. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-plate Features Gear Ratios: Specific gear ratios are detailed within the manual, crucial for performance tuning. Gearbox Oil: Typically SAE 75W-90 or SAE 10W-40 API GL-4 motorcycle gear oil. 📐 Dimensions Exterior Length: Approx. 1,950 mm (varies slightly) Width: Approx. 720 mm (at handlebars) Height: Approx. 1,135 mm (at seat) Weights Dry Weight: Approx. 115-120 kg (varies) Wet Weight: Approx. 130-135 kg (with fluids) 🛡️ Safety Features Ratings Safety Certification: Meets relevant European (CE) and international safety standards for motorcycles. Active Features Braking System: Hydraulic disc brakes front and rear, often with braided steel lines on performance variants. Passive Features Chassis Design: Sturdy perimeter frame (often aluminum alloy) for stability and rigidity. 💡 Technology Features Infotainment Infotainment System: Basic analog instrumentation (speedometer, tachometer, fuel...
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APRILIA RS125 Complete Workshop Repair Manual 2006 Onward
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Model Year Start:
2006
Model Year End:
Present (with updates)
Codes
Chassis Codes:
RP (various suffixes depending on year/market)
👋 Introduction
Market Position
Segment:
Lightweight Sportbike / Performance Motorcycle
Target Audience:
Enthusiast riders, aspiring racers, budget-conscious performance riders, DIY mechanics.
Competitive Analysis
Key Competitors:
Yamaha YZF-R125, Honda CBR125R, KTM RC125, Suzuki GSX-R125.
Unique Selling Points:
Renowned Aprilia racing heritage, aggressive styling, typically a potent 2-stroke engine (pre-2008 models and some later variations), capable chassis and suspension for its class.
Key Features
Manual Features:
Easy to navigate, clear diagrams, step-by-step instructions, troubleshooting tips, comprehensive coverage.
Vehicle Features Highlighted:
High-performance engine for its displacement, sharp handling, track-day capability, customizable options.
📋 Manual Details
Coverage Areas
Countries:
Global (all markets where RS125 is sold)
Page Count
Estimated Page Count:
High (typically 500+ pages for comprehensive manuals)
Manual Type
Manual Type:
Workshop Repair Manual / Service Manual
Language
Language:
English
Format
Format:
Digital Download (PDF/eBook)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, top-end (cylinder, piston, head), bottom-end (crankshaft, connecting rod, bearings), timing, lubrication system.
Fuel System:
Carburetor (Dell'Orto PHBH/PHBL typically) tuning, cleaning, overhaul, fuel pump, fuel lines, fuel tank maintenance.
Cooling System:
Radiator, hoses, water pump, thermostat, coolant specifications and bleeding procedures.
Ignition System:
CDI unit, ignition coils, spark plugs, timing checks, stator and rotor testing.
Exhaust System:
Expansion chamber, silencer, gasket replacement, performance tuning considerations.
Transmission:
6-speed gearbox, clutch (wet multi-plate), gear selection mechanism, gearbox oil specifications and change intervals.
Frame And Suspension:
Frame inspection, front fork (upside-down type, often Marzocchi or Paioli) overhaul, fork oil specifications and levels, rear shock absorber adjustment and overhaul.
Brakes:
Front and rear disc brakes, brake caliper service, hydraulic system bleeding, brake fluid specifications, pad replacement, rotor inspection.
Electrical System:
Wiring diagrams, battery maintenance, lighting system (headlights, taillights, indicators), starter motor, charging system (alternator/stator).
Bodywork And Fairings:
Fairing removal and installation, seat, fuel tank, fenders, graphics.
Procedures Included
Preventative Maintenance:
Oil changes, filter replacements, chain adjustment, brake checks, tire pressure checks, coolant checks, spark plug replacement.
Troubleshooting:
Diagnostic charts for common starting issues, running problems, electrical faults, and performance degradation.
Engine Rebuild:
Detailed step-by-step instructions for complete engine disassembly, inspection, part replacement (piston rings, gaskets, bearings), and reassembly.
Suspension Overhaul:
Fork seal replacement, fork oil change, shock absorber service.
Clutch Replacement:
Service and replacement of clutch plates and springs.
Brake System Service:
Fluid flushing, caliper rebuild, pad and rotor replacement.
Electrical Component Testing:
Testing of starter, alternator, CDI unit, and other electrical components using multimeters.
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to full engine rebuilds and advanced diagnostics)
Diagnostic Capabilities:
Detailed troubleshooting guides, wiring diagrams, and component testing procedures.
Torque Specifications:
All critical bolt and nut torque values provided for engine, chassis, and suspension components.
Clearances And Tolerances:
Specifications for piston-to-cylinder wall, bearing clearances, valve clearances (if applicable to specific models/years), etc.
📊 Manual Specifications
File Format
File Format:
PDF (Searchable Text, Printable Pages)
Print Quality
Print Quality:
High Resolution (suitable for printing individual pages or the entire manual)
Binding Type
Binding Type:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder (typically Rotax 122 or similar variants for 2006 onwards, though some later models may have 4-stroke variants depending on market).
Bore X Stroke:
54 mm x 54.5 mm (typical for Rotax 122)
Displacement:
124.8 cc
Compression Ratio:
Approximately 11.5:1 to 12.5:1 (varies slightly by model year)
Valve Mechanism:
Reed valve intake, exhaust power valve (Rotax 'V' or 'APTS' system).
Performance
Horsepower:
Approx. 15 kW (20.4 PS) @ 9,000 rpm (Europe restricted for A1 license); unrestricted versions can be significantly higher, up to 30-33 hp.
Torque:
Approx. 12.2 Nm (9 lb-ft) @ 8,000 rpm (restricted); higher for unrestricted.
Fuel System
Carburetor Model:
Dell'Orto PHBH 28 or PHBL 26 (depending on market and emissions regulations)
Fuel Type:
Unleaded gasoline, minimum 95 RON (Octane Rating)
Oil Mixture:
Premixed (manual) or Autolube (oil injection system) depending on model year/market.
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet multi-plate
Features
Gear Ratios:
Specific gear ratios are detailed within the manual, crucial for performance tuning.
Gearbox Oil:
Typically SAE 75W-90 or SAE 10W-40 API GL-4 motorcycle gear oil.
📐 Dimensions
Exterior
Length:
Approx. 1,950 mm (varies slightly)
Width:
Approx. 720 mm (at handlebars)
Height:
Approx. 1,135 mm (at seat)
Weights
Dry Weight:
Approx. 115-120 kg (varies)
Wet Weight:
Approx. 130-135 kg (with fluids)
🛡️ Safety Features
Ratings
Safety Certification:
Meets relevant European (CE) and international safety standards for motorcycles.
Active Features
Braking System:
Hydraulic disc brakes front and rear, often with braided steel lines on performance variants.
Passive Features
Chassis Design:
Sturdy perimeter frame (often aluminum alloy) for stability and rigidity.
💡 Technology Features
Infotainment
Infotainment System:
Basic analog instrumentation (speedometer, tachometer, fuel gauge, warning lights). No modern infotainment features.
Driver Assistance
Electronic Aids:
Limited; some models may feature electric start. ABS was not common on this model in early years but may be present on later iterations depending on market.
Connectivity
Connectivity Features:
None (vehicle technology focused on mechanical and electrical systems).
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-7,500 km or annually (for gearbox oil); 2-stroke oil level check much more frequently.
Spark Plug Replacement:
Every 5,000-10,000 km, depending on type and usage.
Air Filter Cleaning Or Replacement:
Every 5,000-10,000 km, depending on conditions.
Chain Lubrication And Adjustment:
Every 500-1000 km, and as needed.
Brake Fluid Replacement:
Every 2 years (DOT 4 typically).
Top End Rebuild:
Recommended every 15,000-20,000 km for optimal performance and longevity of piston and cylinder.
Fluid Specifications
Engine Oil Type:
Fully synthetic 2-stroke motorcycle oil (for autolube systems) or 2-stroke oil for manual premixing. Specific API TC or JASO FD/FE ratings are recommended.
Coolant Type:
Ethylene glycol-based coolant, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Fork Oil Type:
Typically SAE 5W or 7.5W fork oil. Specific viscosity and level are critical for proper damping.
Known Issues
Common Wear Items:
Clutch plates, piston rings, reed valves, exhaust power valve servo motor, fork seals, wheel bearings.
Carburetor Tuning:
Requires precise tuning for optimal performance and clean running; sensitive to altitude and temperature changes.
Power Valve Sticking:
Carbon buildup can cause the exhaust power valve to stick, impacting performance; requires regular cleaning.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Aprilia has a rich racing heritage, particularly in smaller displacement categories (125cc and 250cc GP racing), which heavily influences the design and performance of the RS125.
Model Evolution
Development:
The RS125 has been a flagship model for Aprilia in the 125cc segment for many years, evolving through various chassis, engine, and aerodynamic updates to maintain its competitive edge and adapt to emissions standards. The 2006 onwards models represent a mature and refined iteration.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Motorcycle Publications:
Consistently praised in motorcycle publications for its sharp handling, strong performance for a 125cc, and aggressive styling, often winning '125cc Bike of the Year' awards in its segment.
Ratings
Performance Ratings:
High performance ratings for its class, often cited as a benchmark for handling and engine power in the lightweight sportbike category.
Certifications
Emissions Compliance:
Designed to meet Euro 2 or Euro 3 emissions standards depending on the specific model year and market, with the manual covering adjustments for compliance.
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