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Aprilia RS125 RS 125 2006-2012 Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Model Code: RS 125 Market Segment: Sportbike / Supersport Generation Generation Code: Second Generation (often referred to by internal project names or chassis designations) 👋 Introduction Market Position Positioning: The Aprilia RS125 from 2006-2012 represented a premium entry-level sportbike, often targeted at younger riders or those seeking a stylish and performance-oriented lightweight motorcycle. It competed against other 125cc sportbikes from brands like Yamaha (YZF-R125), Honda (CBR125R), and KTM (RC125). Target Audience: Enthusiast riders who want to perform their own maintenance and repairs, or professional motorcycle technicians working on Aprilia RS125 models. Competitive Analysis Comparative Advantage: The RS125 was known for its aggressive styling, race-derived chassis, and potent two-stroke engine (depending on market homologation and year). This manual provides the detailed technical information necessary to maintain this performance. Key Features Features: This manual offers the complete official factory service repair information, presented in a digital PDF format for ease of access and use. It emphasizes its suitability for both DIY enthusiasts and professional mechanics, highlighting the detailed, step-by-step instructions and extensive visual aids. 📋 Manual Details Coverage Areas Model Years Covered: 2006, 2007, 2008, 2009, 2010, 2011, 2012 Page Count Estimated Page Count: Hundreds of pages (precise count not specified, but described as 'complete') Manual Type Type: Official Factory Service Repair Manual / Workshop Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Covered Systems: General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix Engine Components: Cylinder head, cylinder, piston, connecting rod, crankshaft, crankcase, power valve system, lubrication system (oil injection). Fuel And Ignition: Carburetor assembly, fuel tank, petcock, fuel lines, ignition system (CDI, stator, spark plug). Drivetrain: Clutch assembly, gearbox, shift drum and forks, chain and sprockets (final drive). Suspension And Steering: Front forks (disassembly, oil changes, seal replacement), rear shock absorber, steering head bearings, triple clamps. Brakes And Wheels: Brake caliper service, master cylinder service, brake line replacement, wheel bearing service, wheel mounting, tire replacement. Electrical System: Wiring diagrams, lighting system, battery maintenance, starter motor, charging system, instrument cluster. Procedures Included Included Procedures: Step-by-step instructions for service and repair, complete disassembly guidance, routine maintenance, component replacement, troubleshooting Routine Maintenance: Oil level checks, chain adjustment, tire pressure checks, air filter cleaning/replacement, coolant level checks, brake pad inspection. Component Overhaul: Engine rebuilds (top end, bottom end), carburetor overhaul, brake caliper and master cylinder rebuilds, suspension fork rebuilds. Troubleshooting: Diagnosing common starting problems, running issues, electrical faults, and performance deficiencies, often with specific diagnostic flowcharts or tables. Engine Disassembly Reassembly: Detailed instructions for complete engine removal, splitting crankcases, crankshaft and bearing replacement, piston and cylinder installation, and reassembly of all engine components. Technical Depth Depth: Comprehensive, covering all service and repair procedures from basic maintenance to complete disassembly and reassembly, suitable for DIY enthusiasts and experienced mechanics. Diagnostic Procedures: Includes detailed steps for diagnosing ignition, fuel delivery, and mechanical issues, likely featuring specifications for compression testing and electrical component resistance/voltage checks. Torque Specifications: Includes precise torque values for all critical fasteners, essential for proper engine, chassis, and component assembly. Illustrations Photos: Hundreds of photos and illustrations are included to visually guide the user through each repair and service procedure. 📊 Manual Specifications File Format Format Details: PDF, compatible with Adobe PDF Reader. Accessibility: Compatible with any Windows computer (desktop, laptop), smartphones, and tablets. Accessible via web browser on any device. Print Quality Printability: Printable (entire manual or specific pages), high-quality illustrations and photos. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 2-stroke, liquid-cooled (common for this era and model, though specific market variations might exist) Displacement: 124.8 cc (typically) Performance Horsepower Output: Variable by market and emissions regulations, typically around 15 hp (restricted) to over 30 hp (unrestricted/race version). This manual would cover the factory specifications for all variants. Torque Output: Specific torque figures would be detailed in the manual but generally align with the horsepower output for a 125cc 2-stroke performance engine. Fuel System Fuel Delivery: Carburetor (e.g., Dell'Orto PHBH 28 AS, or Mikuni VM26SS depending on specific year/market). Induction: Reed valve induction, often with a variable exhaust valve (Rotax 122/123 derivative). 🔧 Transmission Standard Type: 6-speed constant mesh Optional Optional Transmission: N/A (Standard 6-speed) Features Clutch Type: Wet multi-plate clutch 📐 Dimensions Exterior Length: Specific dimensions vary, but generally compact sportbike dimensions. Wheelbase: Approximately 1360 mm (53.5 in). Seat Height: Approximately 810 mm (31.9 in). Weights Dry Weight: Approximately 131 kg (289 lbs). Wet Weight: Approximately 147 kg (324 lbs) with fluids. 🛡️ Safety Features Ratings Safety Considerations: As a lightweight sportbike, rider skill and appropriate safety gear are paramount. The manual details all braking...
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Aprilia RS125 RS 125 2006-2012 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Model Code:
RS 125
Market Segment:
Sportbike / Supersport
Generation
Generation Code:
Second Generation (often referred to by internal project names or chassis designations)
👋 Introduction
Market Position
Positioning:
The Aprilia RS125 from 2006-2012 represented a premium entry-level sportbike, often targeted at younger riders or those seeking a stylish and performance-oriented lightweight motorcycle. It competed against other 125cc sportbikes from brands like Yamaha (YZF-R125), Honda (CBR125R), and KTM (RC125).
Target Audience:
Enthusiast riders who want to perform their own maintenance and repairs, or professional motorcycle technicians working on Aprilia RS125 models.
Competitive Analysis
Comparative Advantage:
The RS125 was known for its aggressive styling, race-derived chassis, and potent two-stroke engine (depending on market homologation and year). This manual provides the detailed technical information necessary to maintain this performance.
Key Features
Features:
This manual offers the complete official factory service repair information, presented in a digital PDF format for ease of access and use. It emphasizes its suitability for both DIY enthusiasts and professional mechanics, highlighting the detailed, step-by-step instructions and extensive visual aids.
📋 Manual Details
Coverage Areas
Model Years Covered:
2006, 2007, 2008, 2009, 2010, 2011, 2012
Page Count
Estimated Page Count:
Hundreds of pages (precise count not specified, but described as 'complete')
Manual Type
Type:
Official Factory Service Repair Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Covered Systems:
General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix
Engine Components:
Cylinder head, cylinder, piston, connecting rod, crankshaft, crankcase, power valve system, lubrication system (oil injection).
Fuel And Ignition:
Carburetor assembly, fuel tank, petcock, fuel lines, ignition system (CDI, stator, spark plug).
Drivetrain:
Clutch assembly, gearbox, shift drum and forks, chain and sprockets (final drive).
Suspension And Steering:
Front forks (disassembly, oil changes, seal replacement), rear shock absorber, steering head bearings, triple clamps.
Brakes And Wheels:
Brake caliper service, master cylinder service, brake line replacement, wheel bearing service, wheel mounting, tire replacement.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, starter motor, charging system, instrument cluster.
Procedures Included
Included Procedures:
Step-by-step instructions for service and repair, complete disassembly guidance, routine maintenance, component replacement, troubleshooting
Routine Maintenance:
Oil level checks, chain adjustment, tire pressure checks, air filter cleaning/replacement, coolant level checks, brake pad inspection.
Component Overhaul:
Engine rebuilds (top end, bottom end), carburetor overhaul, brake caliper and master cylinder rebuilds, suspension fork rebuilds.
Troubleshooting:
Diagnosing common starting problems, running issues, electrical faults, and performance deficiencies, often with specific diagnostic flowcharts or tables.
Engine Disassembly Reassembly:
Detailed instructions for complete engine removal, splitting crankcases, crankshaft and bearing replacement, piston and cylinder installation, and reassembly of all engine components.
Technical Depth
Depth:
Comprehensive, covering all service and repair procedures from basic maintenance to complete disassembly and reassembly, suitable for DIY enthusiasts and experienced mechanics.
Diagnostic Procedures:
Includes detailed steps for diagnosing ignition, fuel delivery, and mechanical issues, likely featuring specifications for compression testing and electrical component resistance/voltage checks.
Torque Specifications:
Includes precise torque values for all critical fasteners, essential for proper engine, chassis, and component assembly.
Illustrations Photos:
Hundreds of photos and illustrations are included to visually guide the user through each repair and service procedure.
📊 Manual Specifications
File Format
Format Details:
PDF, compatible with Adobe PDF Reader.
Accessibility:
Compatible with any Windows computer (desktop, laptop), smartphones, and tablets. Accessible via web browser on any device.
Print Quality
Printability:
Printable (entire manual or specific pages), high-quality illustrations and photos.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 2-stroke, liquid-cooled (common for this era and model, though specific market variations might exist)
Displacement:
124.8 cc (typically)
Performance
Horsepower Output:
Variable by market and emissions regulations, typically around 15 hp (restricted) to over 30 hp (unrestricted/race version). This manual would cover the factory specifications for all variants.
Torque Output:
Specific torque figures would be detailed in the manual but generally align with the horsepower output for a 125cc 2-stroke performance engine.
Fuel System
Fuel Delivery:
Carburetor (e.g., Dell'Orto PHBH 28 AS, or Mikuni VM26SS depending on specific year/market).
Induction:
Reed valve induction, often with a variable exhaust valve (Rotax 122/123 derivative).
🔧 Transmission
Standard
Type:
6-speed constant mesh
Optional
Optional Transmission:
N/A (Standard 6-speed)
Features
Clutch Type:
Wet multi-plate clutch
📐 Dimensions
Exterior
Length:
Specific dimensions vary, but generally compact sportbike dimensions.
Wheelbase:
Approximately 1360 mm (53.5 in).
Seat Height:
Approximately 810 mm (31.9 in).
Weights
Dry Weight:
Approximately 131 kg (289 lbs).
Wet Weight:
Approximately 147 kg (324 lbs) with fluids.
🛡️ Safety Features
Ratings
Safety Considerations:
As a lightweight sportbike, rider skill and appropriate safety gear are paramount. The manual details all braking and suspension components critical for safe operation.
Active Features
Braking System:
Front: Single disc with a radial-mount 4-piston caliper (e.g., Brembo); Rear: Single disc with a 1-piston caliper. ABS was not typically a factory option on this model in these years.
Passive Features
Chassis Design:
Steel twin-spar frame, designed for rigidity and sporty handling.
💡 Technology Features
Infotainment
Display Features:
Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature gauge, basic indicator lights (neutral, turn signals, oil level, etc.).
Driver Assistance
Assistance Systems:
N/A (No electronic rider aids like ABS, traction control, or ride modes typical of modern motorcycles).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time intervals; typically 3,000-5,000 km (1,800-3,000 miles) for synthetics. Engine oil for the gearbox is separate from the 2-stroke mix.
Spark Plug Replacement:
Refer to manual; typically every 5,000-10,000 km (3,000-6,000 miles), depending on plug type and usage.
Engine Top End Rebuild:
Recommended between 10,000-20,000 km (6,000-12,000 miles) for optimal performance and reliability, depending on usage and maintenance. Manual will specify exact intervals and procedures.
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water. Refer to manual for specific Aprilia or equivalent specification.
Gearbox Oil:
API GL-4 or GL-5, SAE 75W/90 or 80W/90 gear oil. Refer to manual for exact viscosity and capacity.
2 Stroke Oil:
High-quality 2-stroke synthetic oil formulated for high-performance liquid-cooled engines. Always use an oil compatible with the oil injection system.
Brake Fluid:
DOT 4 or DOT 5.1. Refer to manual for specific Aprilia recommendation and change intervals.
Known Issues
Common Wear Items:
Clutch wear, 2-stroke exhaust port carbon buildup, carburetor jetting adjustments, rear shock absorber wear, electrical connector integrity.
Common Performance Issues:
Carburetor synchronization, reed valve wear impacting performance, exhaust system carbon fouling, potential power valve issues if not maintained.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia has a strong racing heritage, particularly in smaller displacement classes. The RS125 nameplate has been a significant model for the brand, consistently offering a taste of true supersport performance in the lightweight category.
Model Evolution
Evolution Summary:
The RS125 underwent several design updates and engine revisions throughout its production life. The 2006-2012 models represent a later iteration of the classic Rotax-engined RS125, featuring updated styling and chassis components compared to earlier generations.
Key Updates 2006-2012:
Facelifted bodywork, potential revisions to engine management or exhaust for emissions, improved suspension components compared to earlier generations.
Production
Manufacturing Origin:
Italy
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