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Aprilia RS125 RS 125 2008 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: 2008 Codes Chassis Code: e4*2002/24*0320* 👋 Introduction Market Position Segment: Lightweight sportbike, often considered a step-up from smaller displacement commuters, popular for track days and spirited road riding. Competitive Analysis Competitors: Yamaha YZF-R125, Honda CBR125R, Kawasaki Ninja 125. Key Features Design: Aggressive, race-inspired styling, sharp lines, dual headlights, aerodynamic fairings, clip-on handlebars. Performance Oriented: High-revving two-stroke engine, capable chassis, potent brakes, and performance suspension components. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: PDF Download Page Count Pages: Hundreds (specific number not provided, indicative of comprehensive coverage) 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, and troubleshooting for Rotax 125cc two-stroke engine. Fuel System: Carburetor (Dell'Orto PHBH 28) adjustments, jetting, cleaning, and rebuild procedures. Fuel tank, lines, and pump inspection and maintenance. Ignition System: CDI ignition system testing, troubleshooting, and component replacement. Cooling System: Radiator, hoses, water pump, thermostat, and coolant fluid specifications and maintenance. Exhaust System: Expansion chamber, silencer, and catalytic converter inspection and service. Transmission: Six-speed gearbox, clutch operation, adjustment, and rebuild. Gearbox oil specifications and change intervals. Chassis Frame: Frame inspection, alignment checks, and component mounting. Suspension Front: Upside-down telescopic fork (Marzocchi 40mm), oil levels, seal replacement, and spring preload adjustments. Suspension Rear: Monoshock (Sachs), linkage system, shock absorber adjustments, and rebuild procedures. Brakes Front: Brembo dual-piston caliper, 320mm disc, brake fluid specifications, bleeding procedures, pad replacement, and caliper servicing. Brakes Rear: Brembo single-piston caliper, 220mm disc, brake fluid specifications, bleeding procedures, pad replacement, and caliper servicing. Wheels Tires: Wheel bearing inspection and replacement, tire pressure recommendations, and wheel removal/installation. Electrical System: Wiring diagrams, battery testing, charging system (stator, regulator/rectifier), lighting, horn, and starter motor. Bodywork Fairings: Fairing removal, installation, and repair. Seat, fuel tank, and associated trim components. Procedures Included Maintenance: Routine maintenance tasks, lubrication points, bolt torque specifications, and fluid checks. Troubleshooting: Diagnostic charts and procedures for common operational issues and malfunctions. Repair: Step-by-step instructions for component repair and replacement across all vehicle systems. Rebuilds: Detailed procedures for engine and transmission complete rebuilds. Adjustments: Carburetor, clutch, throttle cable, and suspension adjustments. Technical Depth Depth Level: Comprehensive, from basic servicing to complete engine/transmission overhauls and electrical system diagnostics. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable (standard for factory PDFs). Print Quality Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital Download - PDF) Paper Type Type: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder, reed valve induction. Displacement: 124.8 cc (7.62 cubic inches) Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 12.0:1 (approximate, subject to specific tuning variations) Performance Horsepower: Approx. 30-33 HP (depending on market restrictions and tuning) Torque: Approx. 2.2 kgf-m (16.0 lb-ft) at ~8000 rpm Fuel System Carburetor: Dell'Orto PHBH 28 (with automatic oil mixing system) Fuel Type: Unleaded gasoline, minimum 95 RON (octane rating). Oil Mixture: Two-stroke engine oil injection system (separate oil reservoir). Lubrication Engine Oil Type: API TC-rated two-stroke synthetic or semi-synthetic oil (specific recommendations in manual). 🔧 Transmission Standard Type: 6-speed constant mesh sequential gearbox. Features Clutch: Wet multi-plate clutch, hydraulically operated. Gear Ratios: Specific ratios detailed in the manual for each gear. Final Drive: Chain drive (O-ring sealed chain). Transmission Oil Oil Type: Gear oil SAE 75W/90 API GL-4 or GL-5 (manual specifies exact type and capacity). 📐 Dimensions Exterior Length: Approx. 2030 mm (79.9 in) Width: Approx. 760 mm (29.9 in) Height: Approx. 1060 mm (41.7 in) Seat Height: Approx. 810 mm (31.9 in) Wheelbase: Approx. 1375 mm (54.1 in) Weights Dry Weight: Approx. 131 kg (288.8 lbs) Curb Weight: Approx. 142 kg (313.1 lbs) (with all fluids) Fuel Capacity: 13 liters (3.4 US gal) Oil Tank Capacity: 1.3 liters (0.34 US gal) 🛡️ Safety Features Ratings Crash Test Results: Not applicable for motorcycles in typical automotive safety rating standards. Active Features Braking System: Powerful Brembo hydraulic disc brakes front and rear, providing excellent stopping power. Lighting: Dual halogen headlights for improved nighttime visibility. Passive Features Frame Design: Sturdy aluminum alloy perimeter frame designed for high rigidity and stability. Ergonomics: Sportbike riding position, clip-on handlebars, and rear-set footpegs contributing to rider control. 💡 Technology Features Infotainment Dashboard: Digital-analog instrument cluster with speedometer, tachometer, fuel gauge, odometer, trip meter, and warning lights. Driver Assistance ABS: ABS was not a standard feature on the 2008 RS125 model, but this manual would detail brake system maintenance if equipped with aftermarket ABS. Connectivity Connectivity Features: N/A (no modern connectivity features like Bluetooth or smartphone integration on this model). 🔧 Maintenance Service Intervals Oil Change Transmission: Every 6,000 km or 1 year (refer to manual for exact interval and procedure). Spark Plug Replacement: Recommended every 5,000 - 7,000 km (refer to manual for specific plug...
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Aprilia RS125 RS 125 2008 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Year:
2008
Codes
Chassis Code:
e4*2002/24*0320*
👋 Introduction
Market Position
Segment:
Lightweight sportbike, often considered a step-up from smaller displacement commuters, popular for track days and spirited road riding.
Competitive Analysis
Competitors:
Yamaha YZF-R125, Honda CBR125R, Kawasaki Ninja 125.
Key Features
Design:
Aggressive, race-inspired styling, sharp lines, dual headlights, aerodynamic fairings, clip-on handlebars.
Performance Oriented:
High-revving two-stroke engine, capable chassis, potent brakes, and performance suspension components.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
PDF Download
Page Count
Pages:
Hundreds (specific number not provided, indicative of comprehensive coverage)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, tuning, and troubleshooting for Rotax 125cc two-stroke engine.
Fuel System:
Carburetor (Dell'Orto PHBH 28) adjustments, jetting, cleaning, and rebuild procedures. Fuel tank, lines, and pump inspection and maintenance.
Ignition System:
CDI ignition system testing, troubleshooting, and component replacement.
Cooling System:
Radiator, hoses, water pump, thermostat, and coolant fluid specifications and maintenance.
Exhaust System:
Expansion chamber, silencer, and catalytic converter inspection and service.
Transmission:
Six-speed gearbox, clutch operation, adjustment, and rebuild. Gearbox oil specifications and change intervals.
Chassis Frame:
Frame inspection, alignment checks, and component mounting.
Suspension Front:
Upside-down telescopic fork (Marzocchi 40mm), oil levels, seal replacement, and spring preload adjustments.
Suspension Rear:
Monoshock (Sachs), linkage system, shock absorber adjustments, and rebuild procedures.
Brakes Front:
Brembo dual-piston caliper, 320mm disc, brake fluid specifications, bleeding procedures, pad replacement, and caliper servicing.
Brakes Rear:
Brembo single-piston caliper, 220mm disc, brake fluid specifications, bleeding procedures, pad replacement, and caliper servicing.
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, and wheel removal/installation.
Electrical System:
Wiring diagrams, battery testing, charging system (stator, regulator/rectifier), lighting, horn, and starter motor.
Bodywork Fairings:
Fairing removal, installation, and repair. Seat, fuel tank, and associated trim components.
Procedures Included
Maintenance:
Routine maintenance tasks, lubrication points, bolt torque specifications, and fluid checks.
Troubleshooting:
Diagnostic charts and procedures for common operational issues and malfunctions.
Repair:
Step-by-step instructions for component repair and replacement across all vehicle systems.
Rebuilds:
Detailed procedures for engine and transmission complete rebuilds.
Adjustments:
Carburetor, clutch, throttle cable, and suspension adjustments.
Technical Depth
Depth Level:
Comprehensive, from basic servicing to complete engine/transmission overhauls and electrical system diagnostics.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable (standard for factory PDFs).
Print Quality
Quality:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital Download - PDF)
Paper Type
Type:
N/A (Digital Download - PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, two-stroke, single-cylinder, reed valve induction.
Displacement:
124.8 cc (7.62 cubic inches)
Bore X Stroke:
54 mm x 54.5 mm
Compression Ratio:
12.0:1 (approximate, subject to specific tuning variations)
Performance
Horsepower:
Approx. 30-33 HP (depending on market restrictions and tuning)
Torque:
Approx. 2.2 kgf-m (16.0 lb-ft) at ~8000 rpm
Fuel System
Carburetor:
Dell'Orto PHBH 28 (with automatic oil mixing system)
Fuel Type:
Unleaded gasoline, minimum 95 RON (octane rating).
Oil Mixture:
Two-stroke engine oil injection system (separate oil reservoir).
Lubrication
Engine Oil Type:
API TC-rated two-stroke synthetic or semi-synthetic oil (specific recommendations in manual).
🔧 Transmission
Standard
Type:
6-speed constant mesh sequential gearbox.
Features
Clutch:
Wet multi-plate clutch, hydraulically operated.
Gear Ratios:
Specific ratios detailed in the manual for each gear.
Final Drive:
Chain drive (O-ring sealed chain).
Transmission Oil
Oil Type:
Gear oil SAE 75W/90 API GL-4 or GL-5 (manual specifies exact type and capacity).
📐 Dimensions
Exterior
Length:
Approx. 2030 mm (79.9 in)
Width:
Approx. 760 mm (29.9 in)
Height:
Approx. 1060 mm (41.7 in)
Seat Height:
Approx. 810 mm (31.9 in)
Wheelbase:
Approx. 1375 mm (54.1 in)
Weights
Dry Weight:
Approx. 131 kg (288.8 lbs)
Curb Weight:
Approx. 142 kg (313.1 lbs) (with all fluids)
Fuel Capacity:
13 liters (3.4 US gal)
Oil Tank Capacity:
1.3 liters (0.34 US gal)
🛡️ Safety Features
Ratings
Crash Test Results:
Not applicable for motorcycles in typical automotive safety rating standards.
Active Features
Braking System:
Powerful Brembo hydraulic disc brakes front and rear, providing excellent stopping power.
Lighting:
Dual halogen headlights for improved nighttime visibility.
Passive Features
Frame Design:
Sturdy aluminum alloy perimeter frame designed for high rigidity and stability.
Ergonomics:
Sportbike riding position, clip-on handlebars, and rear-set footpegs contributing to rider control.
💡 Technology Features
Infotainment
Dashboard:
Digital-analog instrument cluster with speedometer, tachometer, fuel gauge, odometer, trip meter, and warning lights.
Driver Assistance
ABS:
ABS was not a standard feature on the 2008 RS125 model, but this manual would detail brake system maintenance if equipped with aftermarket ABS.
Connectivity
Connectivity Features:
N/A (no modern connectivity features like Bluetooth or smartphone integration on this model).
🔧 Maintenance
Service Intervals
Oil Change Transmission:
Every 6,000 km or 1 year (refer to manual for exact interval and procedure).
Spark Plug Replacement:
Recommended every 5,000 - 7,000 km (refer to manual for specific plug type and gap).
Air Filter Cleaning:
Regular inspection and cleaning or replacement as per manual recommendations (often based on riding conditions).
Chain Cleaning Lubrication:
Every 500-1000 km and after riding in wet conditions.
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze coolant (50% mixture with distilled water recommended).
Brake Fluid Type:
DOT 4 brake fluid.
Fork Oil Type:
Specific grade of suspension oil (e.g., SAE 10W), capacity per fork leg specified in manual.
Known Issues
Two Stroke Maintenance:
Two-stroke engines require diligent attention to lubrication, spark plug health, and exhaust port cleaning for optimal performance.
Carburetor Tuning:
Dell'Orto carburetors can require specific jetting and adjustment based on altitude, temperature, and exhaust modifications. Manual provides baseline settings.
Power Valve:
The exhaust power valve system needs regular cleaning and inspection for proper operation, which affects low-end torque and high-end power.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer with a strong racing heritage, particularly in smaller displacement classes.
Model Evolution
Rs125 Legacy:
The RS125 is a long-standing model in Aprilia's lineup, renowned for its performance and handling characteristics in the 125cc two-stroke segment.
2008 Updates:
The 2008 model typically featured refinements and minor updates from previous generations, building on the established platform.
Production
Production Period:
The RS125 has been in production for many years, with continuous updates to meet emissions and technological standards.
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