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Aprilia RS 125 2006-2012 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Model Variant: Full Fairing Sportbike Codes Production Years Covered: 2006, 2007, 2008, 2009, 2010, 2011, 2012 👋 Introduction Market Position Motorcycle Segment: Lightweight sportbike, popular in Europe for its performance and style, often a gateway to larger sportbikes. Competitive Analysis Key Competitors: Yamaha YZF-R125, Honda CBR125R, Kawasaki Ninja 125. Key Features Performance Focus: Known for its potent 2-stroke engine, offering lively acceleration and a sporty riding experience. Design Heritage: Shares styling cues with Aprilia's larger RSV Mille models, giving it an aggressive and premium look. Target Audience Rider Profile: New riders, younger enthusiasts, and experienced riders looking for an agile and engaging street or track day machine. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual Page Count: 225 Language: English Format: PDF 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage of the Rotax 125cc 2-stroke engine, including disassembly, assembly, timing, cooling system, lubrication, and performance tuning. Fuel System: Detailed information on the carburetor (likely Dell'Orto PHBH or similar), fuel pump, fuel lines, and filter maintenance and adjustment. Ignition System: Diagnosis and repair of the CDI ignition system, including stator, coil, spark plug specifications, and timing. Cooling System: Procedure for coolant flush, radiator maintenance, fan operation, and thermostat replacement. Transmission: Step-by-step guide for clutch operation, gear shifting mechanism, gearbox disassembly and reassembly, and transmission oil specifications. Chassis: In-depth coverage of frame components, suspension (front forks and rear shock absorber), steering system, and wheel bearing service. Brakes: Front and rear brake system maintenance, including caliper service, disc replacement, brake fluid flush, and bleeding procedures. Electrical System: Wiring diagrams, troubleshooting for lighting, battery, starter, and instrument panel issues. Bodywork: Fairing removal and installation, seat, fuel tank, and other body panel service. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, brake pad inspection, tire pressure checks, spark plug replacement. Troubleshooting: Diagnostic trees and common problem-solving techniques for engine performance, electrical faults, and starting issues. Major Repairs: Engine rebuild, gearbox overhaul, suspension fork service, carburetor tuning and rebuild. Wiring Diagrams: Detailed electrical schematics for easy troubleshooting and component identification. Torque Specifications: Precise torque values for all critical fasteners to ensure correct assembly and prevent damage. Technical Depth Depth Level: Comprehensive, covering everything from basic user maintenance to advanced engine overhauls and electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable if properly scanned, allowing for quick information retrieval. Print Quality Quality Description: High-resolution scans ensuring clear text and diagrams for ease of use. Binding Type Binding Type Description: Not applicable (Digital PDF) Paper Type Paper Type Description: Not applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, single-cylinder Displacement: 125 cc Bore X Stroke: 54 mm x 54.5 mm Valve Train: Reed valve induction, Aprilias's electronic power valve (APCS - Aprilia Controlled Performance System). Performance Horsepower: Approximately 30-33 HP (varies by market and specific model year due to emissions). Torque: Approximately 20-22 Nm (15-16 lb-ft). Fuel System Carburetor: Dell'Orto PHBH 28 (or similar 28mm constant velocity carburetor). Fuel Type: Unleaded gasoline with appropriate 2-stroke oil mixture (via separate oil injection system). Cooling System Cooling Method: Liquid-cooled with electric fan. 🔧 Transmission Standard Transmission Type: 6-speed manual sequential gearbox. Clutch Type: Wet, multi-plate, cable-actuated. Features Gear Ratios: Specific gear ratios are detailed within the manual for each gear. Final Drive: Chain drive. 📐 Dimensions Exterior Length: Approximately 1,950 mm (76.8 in). Width: Approximately 720 mm (28.3 in) at handlebars. Height: Approximately 1,150 mm (45.3 in) at windscreen. Weights Dry Weight: Approximately 120-125 kg (264-275 lbs). Fuel Capacity: Approximately 13 liters (3.4 US gal). Seat Height: Approximately 810 mm (31.9 in). 🛡️ Safety Features Ratings Safety Certification: CE compliant for European markets. Active Features Braking System: Hydraulic disc brakes front and rear. Typically a 320mm disc front and 240mm disc rear with twin-piston calipers. Tire Specifications: Front: 110/70-17, Rear: 150/60-17 (typical sizes, check manual for exact fitment). Passive Features Lighting: Halogen headlight, LED taillight, turn signals. 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature gauge, clock. Driver Assistance ABS: ABS was not standard on most European models during these years; check specific market options. Connectivity Connectivity Features: No integrated connectivity features like Bluetooth or smartphone integration. 🔧 Maintenance Service Intervals Oil Change Interval: Check manual; typically every 3,000-5,000 km or annually for transmission oil. Spark Plug Replacement: Check manual; typically every 5,000-8,000 km. Air Filter Cleaning: Check manual; recommended every 3,000 km or as needed. Coolant Flush: Check manual; typically every 2 years. Fluid Specifications Engine Oil Type: Motul 710 2T or similar high-quality JASO FD approved 2-stroke oil for premix/injection. Transmission oil: SAE 10W/40 API GL-4 or GL-5 (check manual for exact specification). Coolant Type: Ethylene glycol-based antifreeze, pre-mixed with distilled water (50/50 ratio). Brake Fluid Type: DOT 4...
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Aprilia RS 125 2006-2012 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Model Variant:
Full Fairing Sportbike
Codes
Production Years Covered:
2006, 2007, 2008, 2009, 2010, 2011, 2012
👋 Introduction
Market Position
Motorcycle Segment:
Lightweight sportbike, popular in Europe for its performance and style, often a gateway to larger sportbikes.
Competitive Analysis
Key Competitors:
Yamaha YZF-R125, Honda CBR125R, Kawasaki Ninja 125.
Key Features
Performance Focus:
Known for its potent 2-stroke engine, offering lively acceleration and a sporty riding experience.
Design Heritage:
Shares styling cues with Aprilia's larger RSV Mille models, giving it an aggressive and premium look.
Target Audience
Rider Profile:
New riders, younger enthusiasts, and experienced riders looking for an agile and engaging street or track day machine.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual
Page Count:
225
Language:
English
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive coverage of the Rotax 125cc 2-stroke engine, including disassembly, assembly, timing, cooling system, lubrication, and performance tuning.
Fuel System:
Detailed information on the carburetor (likely Dell'Orto PHBH or similar), fuel pump, fuel lines, and filter maintenance and adjustment.
Ignition System:
Diagnosis and repair of the CDI ignition system, including stator, coil, spark plug specifications, and timing.
Cooling System:
Procedure for coolant flush, radiator maintenance, fan operation, and thermostat replacement.
Transmission:
Step-by-step guide for clutch operation, gear shifting mechanism, gearbox disassembly and reassembly, and transmission oil specifications.
Chassis:
In-depth coverage of frame components, suspension (front forks and rear shock absorber), steering system, and wheel bearing service.
Brakes:
Front and rear brake system maintenance, including caliper service, disc replacement, brake fluid flush, and bleeding procedures.
Electrical System:
Wiring diagrams, troubleshooting for lighting, battery, starter, and instrument panel issues.
Bodywork:
Fairing removal and installation, seat, fuel tank, and other body panel service.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, brake pad inspection, tire pressure checks, spark plug replacement.
Troubleshooting:
Diagnostic trees and common problem-solving techniques for engine performance, electrical faults, and starting issues.
Major Repairs:
Engine rebuild, gearbox overhaul, suspension fork service, carburetor tuning and rebuild.
Wiring Diagrams:
Detailed electrical schematics for easy troubleshooting and component identification.
Torque Specifications:
Precise torque values for all critical fasteners to ensure correct assembly and prevent damage.
Technical Depth
Depth Level:
Comprehensive, covering everything from basic user maintenance to advanced engine overhauls and electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable if properly scanned, allowing for quick information retrieval.
Print Quality
Quality Description:
High-resolution scans ensuring clear text and diagrams for ease of use.
Binding Type
Binding Type Description:
Not applicable (Digital PDF)
Paper Type
Paper Type Description:
Not applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
125 cc
Bore X Stroke:
54 mm x 54.5 mm
Valve Train:
Reed valve induction, Aprilias's electronic power valve (APCS - Aprilia Controlled Performance System).
Performance
Horsepower:
Approximately 30-33 HP (varies by market and specific model year due to emissions).
Torque:
Approximately 20-22 Nm (15-16 lb-ft).
Fuel System
Carburetor:
Dell'Orto PHBH 28 (or similar 28mm constant velocity carburetor).
Fuel Type:
Unleaded gasoline with appropriate 2-stroke oil mixture (via separate oil injection system).
Cooling System
Cooling Method:
Liquid-cooled with electric fan.
🔧 Transmission
Standard
Transmission Type:
6-speed manual sequential gearbox.
Clutch Type:
Wet, multi-plate, cable-actuated.
Features
Gear Ratios:
Specific gear ratios are detailed within the manual for each gear.
Final Drive:
Chain drive.
📐 Dimensions
Exterior
Length:
Approximately 1,950 mm (76.8 in).
Width:
Approximately 720 mm (28.3 in) at handlebars.
Height:
Approximately 1,150 mm (45.3 in) at windscreen.
Weights
Dry Weight:
Approximately 120-125 kg (264-275 lbs).
Fuel Capacity:
Approximately 13 liters (3.4 US gal).
Seat Height:
Approximately 810 mm (31.9 in).
🛡️ Safety Features
Ratings
Safety Certification:
CE compliant for European markets.
Active Features
Braking System:
Hydraulic disc brakes front and rear. Typically a 320mm disc front and 240mm disc rear with twin-piston calipers.
Tire Specifications:
Front: 110/70-17, Rear: 150/60-17 (typical sizes, check manual for exact fitment).
Passive Features
Lighting:
Halogen headlight, LED taillight, turn signals.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature gauge, clock.
Driver Assistance
ABS:
ABS was not standard on most European models during these years; check specific market options.
Connectivity
Connectivity Features:
No integrated connectivity features like Bluetooth or smartphone integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Check manual; typically every 3,000-5,000 km or annually for transmission oil.
Spark Plug Replacement:
Check manual; typically every 5,000-8,000 km.
Air Filter Cleaning:
Check manual; recommended every 3,000 km or as needed.
Coolant Flush:
Check manual; typically every 2 years.
Fluid Specifications
Engine Oil Type:
Motul 710 2T or similar high-quality JASO FD approved 2-stroke oil for premix/injection. Transmission oil: SAE 10W/40 API GL-4 or GL-5 (check manual for exact specification).
Coolant Type:
Ethylene glycol-based antifreeze, pre-mixed with distilled water (50/50 ratio).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Known Issues
Common Problems:
Carburetor jetting issues, power valve sticking due to carbon buildup, premature clutch wear if ridden aggressively, radiator leaks.
Two Stroke Specific Care:
Requires proper oil/fuel mixture (if premixed) or ensuring the oil injection system is functional and filled. Regular decarbonization of the exhaust port and power valve is crucial.
📚 Vehicle History
Brand Heritage
Aprilia History:
Aprilia is an Italian motorcycle manufacturer with a strong racing heritage, particularly in smaller displacement classes.
Model Evolution
Rs 125 Legacy:
The RS 125 has a long and successful lineage, tracing its roots back to the iconic RS 125 GP race bikes.
Production
Manufacturing Location:
Italy.
🏆 Awards & Recognition
Recognitions
Awards And Accolades:
The RS 125 platform has historically been praised for its racing pedigree and sporty handling, often winning comparisons in its class.
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