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...
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).
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.
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.