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APRILIA RS125 Service Repair Workshop Manual 2006 Onward

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year Covered: 2006 onwards Codes Product Code: APRILIA-RS125-2006-SM 👋 Introduction Market Position Target Audience: Aprilia RS125 owners, independent repair shops, motorcycle enthusiasts with DIY capabilities Competitive Analysis Advantage Over Alternatives: Claims to be the 'Best Manual Available' and 'Complete Manual - No Missing Pages', suggesting superior detail and accuracy compared to cheaper, incomplete alternatives. Emphasis on 'Do it Right the First Time'. Key Features Completeness: Advertised as a 'Complete Manual - No Missing Pages', assuring users of full coverage. Customer Satisfaction: Guaranteed customer satisfaction, indicating a focus on quality and support. Quality Assurance: Explicitly contrasts with 'cheap, incomplete, inferior manuals', highlighting a commitment to high standards. 📋 Manual Details Coverage Areas Primary Focus: Service, Repair, Workshop Geographic Coverage: Global (based on Aprilia's standard market distribution) Page Count Estimated Page Count: Comprehensive (advertised as complete, typical for this type of manual would be 300-500+ pages) Manual Type Type: Workshop Manual / Service Manual / Repair Manual Language Language: Likely English (standard for international sales, but verification recommended) Format Format: Digital (PDF implied by sales platform, possibility of print-on-demand) 📖 Manual Coverage Systems Covered Engine: Complete disassembly, assembly, tuning, troubleshooting, component diagnostics (cylinder, piston, crank, bearings, reed valve, exhaust, cooling system) Fuel System: Carburetor (Dell'Orto PHBH series, jetting, float height, idle adjustment), fuel pump, fuel lines, fuel tank maintenance Ignition System: CDI unit, spark plug selection and gap, stator and rotor troubleshooting, wiring diagrams Transmission: Clutch (operation, adjustment, friction plates), gearbox (gear selection, ratios, maintenance, inspection), chain drive maintenance Chassis Frame: Frame inspection, geometry, steering head bearings, swingarm bearings, rear shock absorber mounting Suspension: Front forks (dismantling, oil change, spring replacement, seal replacement, damping adjustment), rear shock absorber (adjustment, overhaul) Brakes: Front and rear brake systems (caliper overhaul, pad replacement, fluid flush and bleed, master cylinder maintenance, rotor inspection) Electrical System: Wiring diagrams (color-coded), lighting system, battery maintenance, charging system, starter motor, switchgear, instrumentation Cooling System: Liquid cooling system, radiator, water pump, thermostat, coolant specifications and capacity Bodywork: Fairing removal and installation, seat, fuel tank, body panel component identification and repair Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug checks, tire pressure, brake fluid checks Troubleshooting: Diagnostic flowcharts, common problems and solutions, electrical fault finding Engine Rebuild: Complete engine overhaul procedures, torque specifications, piston ring gap, cylinder honing Suspension Overhaul: Fork seal replacement, shock absorber rebuild, steering bearing adjustment Brake System Maintenance: Brake bleeding, caliper rebuild, master cylinder overhaul Electrical Diagnostics: Wiring diagram interpretation, component testing, fault diagnosis Technical Depth Level Of Detail: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts Diagnostic Capabilities: Advanced diagnostics for engine performance, electrical systems, and mechanical components Special Tool Requirements: Likely specifies required special tools for specific procedures (e.g., flywheel puller, clutch holder) 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) - typically optimized for searchability and printability Print Quality Image Resolution: High resolution for clear diagrams, schematics, and photographs Binding Type Physical Manual Binding: If printed, likely spiral-bound or saddle-stitched for lay-flat usability in a workshop environment Paper Type Physical Manual Paper: If printed, typically on durable, coated paper to resist grease and shop wear ⚙️ Engine Specifications Primary Engine Type: Two-stroke, single-cylinder, liquid-cooled Displacement: 124.8 cc (approx.) Bore X Stroke: Typically around 54 mm x 54.5 mm (specific to the 2006 onwards model, needs verification) Power Output: Around 15 kW (20.4 hp) at 10,500 rpm (may vary by region and licensing laws) Torque: Around 12.5 Nm (9.2 lb-ft) at 10,000 rpm (may vary by region) Performance Cooling Method: Liquid-cooled with radiator and fan Reed Valve System: V-Force or similar design for improved intake efficiency Fuel System Carburetor Model: Dell'Orto PHBH 28 (common for this generation, specific model number to be confirmed in manual) Fuel Delivery: Gravity feed from tank via fuel pump (if equipped) or direct gravity feed, mixed with 2-stroke oil Oil Mixing: Automatic 2-stroke oil injection system 🔧 Transmission Standard Type: 6-speed constant mesh Optional Variant: N/A (standard for the RS125) Features Clutch Type: Wet, multi-plate Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1950 mm Width: Approx. 720 mm Height: Approx. 1140 mm Wheelbase: Approx. 1375 mm Weights Dry Weight: Approx. 131 kg (varies with spec) Fuel Capacity: Approx. 12 liters 🛡️ Safety Features Ratings Crash Test Data: Not applicable for motorcycles in the same manner as cars. Focus is on engineering design and rider protection features. Active Features Braking System: Front: Single Disc with 4-piston radial caliper (Brembo or similar), Rear: Single Disc with 2-piston caliper. Braided brake lines often fitted. Tire Specifications: Front: 110/70-17, Rear: 150/60-17 (typical, manual will specify) Passive Features Lighting: Halogen headlight, LED taillight (post-2008 models) and indicators. Frame Structure: Aluminum alloy twin-spar frame for rigidity and lightweight construction. 💡 Technology Features Infotainment Dashboard: Analog tachometer, digital speedometer, odometer,...
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APRILIA RS125 Service Repair Workshop Manual 2006 Onward
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Year Covered:
2006 onwards
Codes
Product Code:
APRILIA-RS125-2006-SM
👋 Introduction
Market Position
Target Audience:
Aprilia RS125 owners, independent repair shops, motorcycle enthusiasts with DIY capabilities
Competitive Analysis
Advantage Over Alternatives:
Claims to be the 'Best Manual Available' and 'Complete Manual - No Missing Pages', suggesting superior detail and accuracy compared to cheaper, incomplete alternatives. Emphasis on 'Do it Right the First Time'.
Key Features
Completeness:
Advertised as a 'Complete Manual - No Missing Pages', assuring users of full coverage.
Customer Satisfaction:
Guaranteed customer satisfaction, indicating a focus on quality and support.
Quality Assurance:
Explicitly contrasts with 'cheap, incomplete, inferior manuals', highlighting a commitment to high standards.
📋 Manual Details
Coverage Areas
Primary Focus:
Service, Repair, Workshop
Geographic Coverage:
Global (based on Aprilia's standard market distribution)
Page Count
Estimated Page Count:
Comprehensive (advertised as complete, typical for this type of manual would be 300-500+ pages)
Manual Type
Type:
Workshop Manual / Service Manual / Repair Manual
Language
Language:
Likely English (standard for international sales, but verification recommended)
Format
Format:
Digital (PDF implied by sales platform, possibility of print-on-demand)
📖 Manual Coverage
Systems Covered
Engine:
Complete disassembly, assembly, tuning, troubleshooting, component diagnostics (cylinder, piston, crank, bearings, reed valve, exhaust, cooling system)
Fuel System:
Carburetor (Dell'Orto PHBH series, jetting, float height, idle adjustment), fuel pump, fuel lines, fuel tank maintenance
Ignition System:
CDI unit, spark plug selection and gap, stator and rotor troubleshooting, wiring diagrams
Transmission:
Clutch (operation, adjustment, friction plates), gearbox (gear selection, ratios, maintenance, inspection), chain drive maintenance
Chassis Frame:
Frame inspection, geometry, steering head bearings, swingarm bearings, rear shock absorber mounting
Suspension:
Front forks (dismantling, oil change, spring replacement, seal replacement, damping adjustment), rear shock absorber (adjustment, overhaul)
Brakes:
Front and rear brake systems (caliper overhaul, pad replacement, fluid flush and bleed, master cylinder maintenance, rotor inspection)
Electrical System:
Wiring diagrams (color-coded), lighting system, battery maintenance, charging system, starter motor, switchgear, instrumentation
Cooling System:
Liquid cooling system, radiator, water pump, thermostat, coolant specifications and capacity
Bodywork:
Fairing removal and installation, seat, fuel tank, body panel component identification and repair
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks, tire pressure, brake fluid checks
Troubleshooting:
Diagnostic flowcharts, common problems and solutions, electrical fault finding
Engine Rebuild:
Complete engine overhaul procedures, torque specifications, piston ring gap, cylinder honing
Suspension Overhaul:
Fork seal replacement, shock absorber rebuild, steering bearing adjustment
Brake System Maintenance:
Brake bleeding, caliper rebuild, master cylinder overhaul
Electrical Diagnostics:
Wiring diagram interpretation, component testing, fault diagnosis
Technical Depth
Level Of Detail:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts
Diagnostic Capabilities:
Advanced diagnostics for engine performance, electrical systems, and mechanical components
Special Tool Requirements:
Likely specifies required special tools for specific procedures (e.g., flywheel puller, clutch holder)
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format) - typically optimized for searchability and printability
Print Quality
Image Resolution:
High resolution for clear diagrams, schematics, and photographs
Binding Type
Physical Manual Binding:
If printed, likely spiral-bound or saddle-stitched for lay-flat usability in a workshop environment
Paper Type
Physical Manual Paper:
If printed, typically on durable, coated paper to resist grease and shop wear
⚙️ Engine Specifications
Primary Engine
Type:
Two-stroke, single-cylinder, liquid-cooled
Displacement:
124.8 cc (approx.)
Bore X Stroke:
Typically around 54 mm x 54.5 mm (specific to the 2006 onwards model, needs verification)
Power Output:
Around 15 kW (20.4 hp) at 10,500 rpm (may vary by region and licensing laws)
Torque:
Around 12.5 Nm (9.2 lb-ft) at 10,000 rpm (may vary by region)
Performance
Cooling Method:
Liquid-cooled with radiator and fan
Reed Valve System:
V-Force or similar design for improved intake efficiency
Fuel System
Carburetor Model:
Dell'Orto PHBH 28 (common for this generation, specific model number to be confirmed in manual)
Fuel Delivery:
Gravity feed from tank via fuel pump (if equipped) or direct gravity feed, mixed with 2-stroke oil
Oil Mixing:
Automatic 2-stroke oil injection system
🔧 Transmission
Standard
Type:
6-speed constant mesh
Optional
Variant:
N/A (standard for the RS125)
Features
Clutch Type:
Wet, multi-plate
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 1950 mm
Width:
Approx. 720 mm
Height:
Approx. 1140 mm
Wheelbase:
Approx. 1375 mm
Weights
Dry Weight:
Approx. 131 kg (varies with spec)
Fuel Capacity:
Approx. 12 liters
🛡️ Safety Features
Ratings
Crash Test Data:
Not applicable for motorcycles in the same manner as cars. Focus is on engineering design and rider protection features.
Active Features
Braking System:
Front: Single Disc with 4-piston radial caliper (Brembo or similar), Rear: Single Disc with 2-piston caliper. Braided brake lines often fitted.
Tire Specifications:
Front: 110/70-17, Rear: 150/60-17 (typical, manual will specify)
Passive Features
Lighting:
Halogen headlight, LED taillight (post-2008 models) and indicators.
Frame Structure:
Aluminum alloy twin-spar frame for rigidity and lightweight construction.
💡 Technology Features
Infotainment
Dashboard:
Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature warning light, neutral indicator.
Driver Assistance
ABS:
ABS was not standard on most RS125 models of this era; manual will confirm if available as an option or standard on specific sub-models.
Connectivity
Connectivity Features:
N/A (No modern connectivity features like Bluetooth or smartphone integration).
🔧 Maintenance
Service Intervals
Oil Change Engine:
Recommended every 3,000-5,000 km or annually (refer to manual for precise interval and 2T oil type)
Spark Plug Check:
Every 3,000-5,000 km
Chain Adjustment:
Every 1,000-2,000 km, or as needed based on slack
Brake Fluid Flush:
Every 2 years (DOT 4 recommended)
Coolant Change:
Every 2-3 years or as per manual
Fluid Specifications
Engine Oil:
Fully synthetic 2-stroke premix oil (e.g., Motul 7100 2T, Castrol Power 1 Racing 2T) - manual will specify API TC/TC++ or JASO FD/FE rating.
Transmission Oil:
SAE 75W/80 or 85W/90 Gear Oil (e.g., Motul Gear 300 75W-90) - capacity approx. 0.8-1.0 liters.
Coolant:
Ethylene glycol-based coolant mixed with distilled water (50/50 ratio recommended), with anti-corrosion additives.
Brake Fluid:
DOT 4
Known Issues
Carburetor Fouling:
Can occur with short rides or incorrect jetting, requiring cleaning and proper setup.
Power Valve Sticking:
The exhaust power valve can carbon up and seize, impacting engine performance; requires periodic cleaning.
Engine Seizure:
Can happen with insufficient oil mixture or overheating, especially under sustained high RPMs.
Electrical Gremlins:
Wiring loom degradation or faulty connectors can lead to intermittent electrical issues.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia is renowned for its sport motorcycles, particularly in the smaller displacement categories, with a strong racing heritage.
Model Evolution
Rs125 Lineage:
The RS125 has been a flagship model for Aprilia in the 125cc sportbike segment for decades, evolving in styling and technology, but maintaining its performance-oriented character.
Production
Manufacturing Origin:
Italy (Noale, Venice)
Key Generation Updates:
The 2006 onwards generation introduced updated styling, often with a single-sided swingarm on higher-spec models and improved chassis components compared to earlier versions.
🏆 Awards & Recognition
Recognitions
Motorcycle Awards:
The Aprilia RS125 has historically received numerous accolades in its class for performance and handling, often winning '125cc Bike of the Year' awards.
Ratings
Performance Reviews:
Consistently praised for its track-like handling and exhilarating two-stroke performance, making it a favorite for track days and spirited riding.
Certifications
Manual Certification:
Not applicable for a third-party manual. However, its comprehensiveness and accuracy are implicitly certified by customer satisfaction guarantees and professional reputation.
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