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APRILIA RS125 Complete Workshop Repair Manual 2006-2013

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Model Variant: Sport Production (SP) Generation Generation Years: 2006-2013 👋 Introduction Market Position Market Segment: Lightweight sportbike, popular for entry-level riders, track days, and urban commuting due to its agile handling and sporty aesthetics. Competitive Analysis Competitors: Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125 (though some later models may overlap), Kawasaki Ninja 125. Key Features Design Philosophy: Emphasizes aggressive styling, sporty ergonomics, and performance-oriented components typically found on larger Aprilia sportbikes. Target Audience: Enthusiasts seeking a capable 125cc motorcycle with a premium feel and performance that punches above its weight class, suitable for learning and intermediate riding. 📋 Manual Details Coverage Areas Engine Coverage: Comprehensive coverage of all engine components, including top-end, bottom-end, lubrication, cooling, and fuel/ignition systems. Transmission Coverage: Detailed procedures for clutch, gearbox, and final drive maintenance and repair. Chassis Coverage: Complete coverage of frame, suspension (front and rear), steering, and wheel components. Electrical System Coverage: In-depth information on wiring diagrams, lighting, ignition, charging system, and starter motor. Bodywork Coverage: Instructions for fairing removal/installation, seat, fuel tank, and minor body panel adjustments. Page Count Page Count Estimated: Refer to actual manual for exact count, typically 300-500+ pages for a comprehensive service manual. Manual Type Manual Type: Workshop Service & Repair Manual Language Language: English (primary, with potential for other languages depending on source) Format Format: Digital Download (PDF, potentially ePub or similar for device compatibility) 📖 Manual Coverage Systems Covered Engine Systems: 2-stroke Rotax 125cc engine (e.g., Rotax 122 E4, Rotax 123, depending on specific variant within the model years), including cylinder, piston, crankshaft, con-rod, reed valve assembly, carburetor tuning (Dell'Orto PHBH series), exhaust system analysis, and cooling system (liquid cooling). Fuel System: Carburetor identification, jetting specifications, float bowl adjustment, fuel delivery system, fuel filter, and fuel tank maintenance. Ignition System: CDI ignition system, spark plug selection and gap, ignition timing procedures, stator and coil testing. Transmission And Drivetrain: 6-speed sequential gearbox, clutch operation (wet multi-plate), clutch cable adjustment, gearbox oil type and capacity, chain and sprockets maintenance and replacement. Suspension And Steering: Front telescopic forks (e.g., Marzocchi or Paioli depending on specification), rear monoshock absorber, swingarm inspection, steering head bearing maintenance, fork oil type and level, rear shock absorber adjustment. Braking System: Front and rear disc brakes (e.g., Brembo components), brake fluid specifications (DOT 4), bleeding procedures, pad and disc wear inspection, caliper maintenance. Electrical System: Complete wiring diagrams, battery specifications (e.g., YTX7L-BS or similar), charging system (stator, rectifier/regulator), lighting circuits (headlight, taillight, indicators), instrument cluster functionality. Procedures Included Routine Maintenance: Oil changes, filter replacements (air and oil if applicable to variant), chain lubrication and adjustment, brake adjustments, tire pressure checks, spark plug replacement. Engine Rebuild: Top-end rebuild (piston, rings, cylinder), bottom-end rebuild (crankshaft, bearings, seals), valve clearance adjustment (if applicable to specific engine variant, though typically fixed on 2-strokes), decarbonization procedures. Troubleshooting: Diagnostic charts for common starting issues, running problems, electrical faults, and braking system irregularities. Component Replacement: Step-by-step guides for replacing major components such as clutch plates, gearbox parts, suspension components, brake calipers, and electrical parts. Assembly Disassembly: Detailed instructions for the removal and reinstallation of all major motorcycle systems and components. Technical Depth Depth Level: Comprehensive, covering everything from basic user maintenance to full engine and chassis overhauls. Includes torque specifications, clearances, and detailed diagnostic procedures. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format), optimized for digital viewing and printing. Searchable text functionality is typically included in high-quality digital manuals. Print Quality Print Quality: High-resolution digital reproduction of original factory service information. Ensures clarity of diagrams, illustrations, and text. Binding Type Binding Type: N/A (Digital Download - no physical binding) Paper Type Paper Type: N/A (Digital Download - no physical paper type) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, two-stroke, single-cylinder, reed-valve inducted Displacement: 124.2 cc (7.58 cu in) Bore X Stroke: 54 mm x 54.5 mm (2.13 in x 2.15 in) Compression Ratio: Typically around 8.4:1 to 12.0:1 depending on specific variant and tuning. Valvetrain: Reed valve induction Cooling System: Liquid-cooled Performance Horsepower: Approximately 15 hp (11 kW) at 8,000 rpm (limited for A1 license category in Europe), potentially higher in unrestricted race configurations. Torque: Approximately 12 Nm (8.9 lb-ft) at 7,000 rpm Fuel System Carburetor: Dell'Orto PHBH 28 (typically), sometimes PHVA 28 variants depending on emission regulations and model year. Fuel Type: Unleaded gasoline, minimum 95 RON recommended. Lubrication Oil System: Automatic oil injection for pre-mix lubrication, separate oil reservoir. 🔧 Transmission Standard Transmission Type: 6-speed manual sequential gearbox Clutch: Wet, multi-plate Final Drive: Chain drive Features Gear Ratios: Specific ratios vary, but typically offer a wide range for performance and usability. Gearbox Oil Type: API GL-4, SAE 75W/90 or 80W/90 gear oil. Specific Aprilia recommendation should be consulted in the manual. Gearbox Oil Capacity: Refer to manual for exact capacity,...
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APRILIA RS125 Complete Workshop Repair Manual 2006-2013
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Model Variant:
Sport Production (SP)
Generation
Generation Years:
2006-2013
👋 Introduction
Market Position
Market Segment:
Lightweight sportbike, popular for entry-level riders, track days, and urban commuting due to its agile handling and sporty aesthetics.
Competitive Analysis
Competitors:
Yamaha YZF-R125, Honda CBR125R, Suzuki GSX-R125 (though some later models may overlap), Kawasaki Ninja 125.
Key Features
Design Philosophy:
Emphasizes aggressive styling, sporty ergonomics, and performance-oriented components typically found on larger Aprilia sportbikes.
Target Audience:
Enthusiasts seeking a capable 125cc motorcycle with a premium feel and performance that punches above its weight class, suitable for learning and intermediate riding.
📋 Manual Details
Coverage Areas
Engine Coverage:
Comprehensive coverage of all engine components, including top-end, bottom-end, lubrication, cooling, and fuel/ignition systems.
Transmission Coverage:
Detailed procedures for clutch, gearbox, and final drive maintenance and repair.
Chassis Coverage:
Complete coverage of frame, suspension (front and rear), steering, and wheel components.
Electrical System Coverage:
In-depth information on wiring diagrams, lighting, ignition, charging system, and starter motor.
Bodywork Coverage:
Instructions for fairing removal/installation, seat, fuel tank, and minor body panel adjustments.
Page Count
Page Count Estimated:
Refer to actual manual for exact count, typically 300-500+ pages for a comprehensive service manual.
Manual Type
Manual Type:
Workshop Service & Repair Manual
Language
Language:
English (primary, with potential for other languages depending on source)
Format
Format:
Digital Download (PDF, potentially ePub or similar for device compatibility)
📖 Manual Coverage
Systems Covered
Engine Systems:
2-stroke Rotax 125cc engine (e.g., Rotax 122 E4, Rotax 123, depending on specific variant within the model years), including cylinder, piston, crankshaft, con-rod, reed valve assembly, carburetor tuning (Dell'Orto PHBH series), exhaust system analysis, and cooling system (liquid cooling).
Fuel System:
Carburetor identification, jetting specifications, float bowl adjustment, fuel delivery system, fuel filter, and fuel tank maintenance.
Ignition System:
CDI ignition system, spark plug selection and gap, ignition timing procedures, stator and coil testing.
Transmission And Drivetrain:
6-speed sequential gearbox, clutch operation (wet multi-plate), clutch cable adjustment, gearbox oil type and capacity, chain and sprockets maintenance and replacement.
Suspension And Steering:
Front telescopic forks (e.g., Marzocchi or Paioli depending on specification), rear monoshock absorber, swingarm inspection, steering head bearing maintenance, fork oil type and level, rear shock absorber adjustment.
Braking System:
Front and rear disc brakes (e.g., Brembo components), brake fluid specifications (DOT 4), bleeding procedures, pad and disc wear inspection, caliper maintenance.
Electrical System:
Complete wiring diagrams, battery specifications (e.g., YTX7L-BS or similar), charging system (stator, rectifier/regulator), lighting circuits (headlight, taillight, indicators), instrument cluster functionality.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (air and oil if applicable to variant), chain lubrication and adjustment, brake adjustments, tire pressure checks, spark plug replacement.
Engine Rebuild:
Top-end rebuild (piston, rings, cylinder), bottom-end rebuild (crankshaft, bearings, seals), valve clearance adjustment (if applicable to specific engine variant, though typically fixed on 2-strokes), decarbonization procedures.
Troubleshooting:
Diagnostic charts for common starting issues, running problems, electrical faults, and braking system irregularities.
Component Replacement:
Step-by-step guides for replacing major components such as clutch plates, gearbox parts, suspension components, brake calipers, and electrical parts.
Assembly Disassembly:
Detailed instructions for the removal and reinstallation of all major motorcycle systems and components.
Technical Depth
Depth Level:
Comprehensive, covering everything from basic user maintenance to full engine and chassis overhauls. Includes torque specifications, clearances, and detailed diagnostic procedures.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format), optimized for digital viewing and printing. Searchable text functionality is typically included in high-quality digital manuals.
Print Quality
Print Quality:
High-resolution digital reproduction of original factory service information. Ensures clarity of diagrams, illustrations, and text.
Binding Type
Binding Type:
N/A (Digital Download - no physical binding)
Paper Type
Paper Type:
N/A (Digital Download - no physical paper type)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, two-stroke, single-cylinder, reed-valve inducted
Displacement:
124.2 cc (7.58 cu in)
Bore X Stroke:
54 mm x 54.5 mm (2.13 in x 2.15 in)
Compression Ratio:
Typically around 8.4:1 to 12.0:1 depending on specific variant and tuning.
Valvetrain:
Reed valve induction
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approximately 15 hp (11 kW) at 8,000 rpm (limited for A1 license category in Europe), potentially higher in unrestricted race configurations.
Torque:
Approximately 12 Nm (8.9 lb-ft) at 7,000 rpm
Fuel System
Carburetor:
Dell'Orto PHBH 28 (typically), sometimes PHVA 28 variants depending on emission regulations and model year.
Fuel Type:
Unleaded gasoline, minimum 95 RON recommended.
Lubrication
Oil System:
Automatic oil injection for pre-mix lubrication, separate oil reservoir.
🔧 Transmission
Standard
Transmission Type:
6-speed manual sequential gearbox
Clutch:
Wet, multi-plate
Final Drive:
Chain drive
Features
Gear Ratios:
Specific ratios vary, but typically offer a wide range for performance and usability.
Gearbox Oil Type:
API GL-4, SAE 75W/90 or 80W/90 gear oil. Specific Aprilia recommendation should be consulted in the manual.
Gearbox Oil Capacity:
Refer to manual for exact capacity, typically around 1.0-1.2 liters.
📐 Dimensions
Exterior
Length:
Approximately 1945 mm (76.6 in)
Width:
Approximately 710 mm (28.0 in)
Height:
Approximately 1135 mm (44.7 in)
Wheelbase:
Approximately 1345 mm (53.0 in)
Weights
Dry Weight:
Approximately 134 kg (295 lbs)
Wet Weight:
Approximately 145 kg (320 lbs) (with all fluids)
Fuel Capacity:
Approximately 12.5 liters (3.3 US gallons), including a 2-liter reserve.
🛡️ Safety Features
Ratings
Safety Standard:
Manufactured to meet European ABE (Allgemeine Betriebserlaubnis) standards for road legality.
Active Features
Braking System:
Dual disc front braking system (e.g., 320mm disc with 4-piston caliper), single disc rear braking system (e.g., 220mm disc with 2-piston caliper). ABS was not a standard feature on most variants of this model.
Passive Features
Lighting:
Halogen headlight, LED taillight and brake light, standard incandescent turn signals.
💡 Technology Features
Infotainment
Dashboard:
Digital/analog hybrid instrument cluster displaying speedometer, tachometer, odometer, trip meter, coolant temperature warning light, and neutral indicator.
Driver Assistance
ABS:
ABS was generally not a standard feature on this model. Some later or special editions might have offered it as an option.
Connectivity
Connectivity Features:
N/A (Basic motorcycle, no integrated connectivity features).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual; typically every 5,000-7,500 km (3,000-4,500 miles) for the gearbox oil. Engine oil changes are not applicable for a 2-stroke, but piston/ring checks might be recommended at higher mileages.
Spark Plug Replacement:
Refer to manual; typically every 5,000-10,000 km (3,000-6,000 miles) depending on riding conditions and spark plug type.
Chain Maintenance:
Lubricate and adjust chain every 1,000 km (600 miles) or as needed.
Brake Fluid Flush:
Recommended every 2 years, or as per manual.
Fluid Specifications
Engine Oil:
Specific 2-stroke synthetic or semi-synthetic oil injection blend, as recommended by Aprilia (e.g., Motul 7100 2T, Castrol Power 1 Racing 2T).
Cooling System Coolant:
Ethylene glycol-based antifreeze with corrosion inhibitors, mixed with distilled water (50/50 ratio). Refer to manual for specific coolant type.
Brake Fluid:
DOT 4
Known Issues
Common Wear Items:
Clutch plates, piston rings, exhaust valve (power valve) carbon buildup, fork seals, wheel bearings, and steering head bearings are common wear items on higher mileage examples.
Electrical Gremlins:
Some older models may experience issues with aging wiring harnesses or rectifier/regulators.
Carburetor Tuning:
The Dell'Orto carburetors can require periodic cleaning and adjustment, especially if the bike sits for extended periods or if fuel quality varies.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian motorcycle manufacturer known for its performance-oriented motorcycles, particularly in the racing and sportbike segments.
Model Evolution
Development Context:
The RS125 has a long lineage, evolving from earlier models to become a benchmark in the 125cc sportbike class, incorporating design cues and technology from Aprilia's Grand Prix racing efforts.
Notable Versions:
Various graphic schemes and minor updates were introduced throughout its production run. Special editions (e.g., Replica models honoring racers like Max Biaggi or Valentino Rossi) are also common.
Production
Manufacturing Location:
Italy
Production Span:
1992 - 2012 (with variations and updates within this period; 2006-2013 covers a significant portion of its later production).
🏆 Awards & Recognition
Recognitions
Racing Pedigree:
The RS125 has a strong racing heritage in the 125cc Grand Prix classes, contributing to its sporty image and performance capabilities.
Ratings
Review Consensus:
Consistently praised for its sharp handling, excellent chassis dynamics, and powerful (for its class) 2-stroke engine, making it a popular choice for aspiring racers and performance-minded riders.
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