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2006 Aprilia RS125 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: 2006 Codes Internal Code: RS125-2006-SM 👋 Introduction Market Position Target Audience: DIY enthusiasts and experienced motorcycle mechanics alike, providing accessible and detailed repair information for the 2006 Aprilia RS125. Competitive Analysis Advantage: Provides factory-level detail for a relatively niche high-performance sportbike, offering a cost-effective alternative to dealership service. Key Features Clarity And Detail: Easy-to-read text sections complemented by top-quality diagrams and exploded views for efficient and accurate repairs. Completeness: Covers every single detail of the machine, based on complete disassembly, ensuring no aspect of repair or maintenance is overlooked. 📋 Manual Details Coverage Areas Primary Coverage: Full Service, Repair, Maintenance, Diagnostics, Troubleshooting Page Count Estimated Pages: High (exact number not specified, but described as 'complete' and 'every single detail') Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Management: Complete engine disassembly, assembly, tuning, and component analysis Fuel System: Carburetor system (Mikuni TM28), fuel pump, fuel lines, fuel tank Cooling System: Radiator, water pump, thermostat, coolant passages, fan Lubrication System: Oil pump, oil filter, oil passages, lubrication schedules Chassis And Suspension: Front forks (USD Marzocchi), rear shock absorber (Sachs), swingarm, steering head, wheel bearings Electrical System: Ignition system, lighting, battery, charging system, wiring diagrams, starter motor Braking System: Front and rear brake systems (disc brakes), hydraulic lines, calipers, master cylinders, pad replacement Exhaust System: Exhaust manifold, muffler, associated components Bodywork: Fairings, seat, fuel tank, tail section, panel removal and installation Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, brake fluid checks, tire pressure checks, spark plug replacement Engine Rebuild: Complete engine disassembly, piston, cylinder, crankshaft, and gearbox rebuild procedures Troubleshooting: Diagnostic guides for common problems, symptom-based troubleshooting trees Component Replacement: Detailed instructions for replacing all major and minor components Wiring Diagrams: Comprehensive electrical schematics for troubleshooting and repairs Torque Specifications: Crucial torque values for all fasteners and critical engine components Technical Depth Depth: Comprehensive: Covers everything from basic maintenance and adjustments to complete engine and chassis rebuilds, including detailed diagnostics. 📊 Manual Specifications File Format Format: PDF Compatibility: All versions of Windows & Mac Requirements: Adobe PDF Reader & WinZip Print Quality Printability: All pages are printable Binding Type Binding: Digital (No physical binding) Paper Type Paper Type: N/A (Digital format) Delivery Delivery Method: Instant Download ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder, liquid-cooled, reed valve induction Displacement: 124.8 cc (approx.) Bore X Stroke: 54 mm x 54.5 mm (typical for this model) Compression Ratio: Approx. 12.5:1 (varies slightly by variant) Performance Horsepower: Approx. 30-33 HP (claimed, depending on market and derestriction) Torque: Approx. 20-22 Nm (claimed) Fuel System Carburetor: Mikuni TM28-1 flat slide carburetor (common specification) Fuel Type: Unleaded gasoline (minimum 95 octane recommended), 2-stroke oil injection system Lubrication Oil Type: High-quality 2-stroke synthetic oil Ignition Ignition System: Digital electronic ignition (CDI) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet multi-plate clutch Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 1955 mm Width: Approx. 700 mm Height: Approx. 1150 mm Weights Dry Weight: Approx. 120-125 kg (varies by market) Fuel Tank Capacity: Approx. 12 Liters Wheels And Tires Front Tire Size: 110/70-17 Rear Tire Size: 150/60-17 Wheel Type: Alloy wheels 🛡️ Safety Features Active Features Braking System Front: Single 320mm disc with 4-piston radial caliper (e.g., Nissin or Brembo, depending on market) Braking System Rear: Single 220mm disc with 2-piston caliper Passive Features Lighting: Halogen headlight, LED taillight 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature gauge, and warning lights. Driver Assistance No Electronic Aids: As a 2006 125cc sportbike, typically lacks electronic rider aids like ABS, traction control, or ride modes. Focus is on mechanical performance and rider input. Connectivity No Connectivity: No Bluetooth or smartphone integration present on this model year. 🔧 Maintenance Service Intervals Oil Change Interval: Recommended every 2000-3000 km or annually (refer to manual for specific engine oil type and capacity). Spark Plug Replacement: Typically every 6000-8000 km (specific plug type and gap provided in manual). Air Filter Cleaning: Recommended every 3000-5000 km, depending on riding conditions. Chain Lubrication And Adjustment: Frequent checks recommended, adjust slack per manual specifications. Fluid Specifications Coolant: Ethylene glycol-based antifreeze, mixed with distilled water (typically 50/50 ratio). Brake Fluid: DOT 4 or DOT 5.1 (verify specific requirement in manual). Known Issues Power Valve System: The Rotax 123 engine's power valve system (A.E.S. - Aprilia Exhaust System) can accumulate carbon deposits, potentially affecting performance and requiring regular cleaning/maintenance. The manual details its inspection and cleaning. Carburetor Tuning: Due to its 2-stroke nature and performance focus, carburetor jetting and adjustment can be sensitive to altitude and atmospheric changes. The manual provides guidance on tuning. Top End Wear: Like many high-performance 2-stroke engines, regular top-end inspections...
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2006 Aprilia RS125 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Year:
2006
Codes
Internal Code:
RS125-2006-SM
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts and experienced motorcycle mechanics alike, providing accessible and detailed repair information for the 2006 Aprilia RS125.
Competitive Analysis
Advantage:
Provides factory-level detail for a relatively niche high-performance sportbike, offering a cost-effective alternative to dealership service.
Key Features
Clarity And Detail:
Easy-to-read text sections complemented by top-quality diagrams and exploded views for efficient and accurate repairs.
Completeness:
Covers every single detail of the machine, based on complete disassembly, ensuring no aspect of repair or maintenance is overlooked.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service, Repair, Maintenance, Diagnostics, Troubleshooting
Page Count
Estimated Pages:
High (exact number not specified, but described as 'complete' and 'every single detail')
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Management:
Complete engine disassembly, assembly, tuning, and component analysis
Fuel System:
Carburetor system (Mikuni TM28), fuel pump, fuel lines, fuel tank
Cooling System:
Radiator, water pump, thermostat, coolant passages, fan
Lubrication System:
Oil pump, oil filter, oil passages, lubrication schedules
Chassis And Suspension:
Front forks (USD Marzocchi), rear shock absorber (Sachs), swingarm, steering head, wheel bearings
Electrical System:
Ignition system, lighting, battery, charging system, wiring diagrams, starter motor
Braking System:
Front and rear brake systems (disc brakes), hydraulic lines, calipers, master cylinders, pad replacement
Exhaust System:
Exhaust manifold, muffler, associated components
Bodywork:
Fairings, seat, fuel tank, tail section, panel removal and installation
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, brake fluid checks, tire pressure checks, spark plug replacement
Engine Rebuild:
Complete engine disassembly, piston, cylinder, crankshaft, and gearbox rebuild procedures
Troubleshooting:
Diagnostic guides for common problems, symptom-based troubleshooting trees
Component Replacement:
Detailed instructions for replacing all major and minor components
Wiring Diagrams:
Comprehensive electrical schematics for troubleshooting and repairs
Torque Specifications:
Crucial torque values for all fasteners and critical engine components
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance and adjustments to complete engine and chassis rebuilds, including detailed diagnostics.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All versions of Windows & Mac
Requirements:
Adobe PDF Reader & WinZip
Print Quality
Printability:
All pages are printable
Binding Type
Binding:
Digital (No physical binding)
Paper Type
Paper Type:
N/A (Digital format)
Delivery
Delivery Method:
Instant Download
⚙️ Engine Specifications
Primary Engine
Engine Type:
Two-stroke, single-cylinder, liquid-cooled, reed valve induction
Displacement:
124.8 cc (approx.)
Bore X Stroke:
54 mm x 54.5 mm (typical for this model)
Compression Ratio:
Approx. 12.5:1 (varies slightly by variant)
Performance
Horsepower:
Approx. 30-33 HP (claimed, depending on market and derestriction)
Torque:
Approx. 20-22 Nm (claimed)
Fuel System
Carburetor:
Mikuni TM28-1 flat slide carburetor (common specification)
Fuel Type:
Unleaded gasoline (minimum 95 octane recommended), 2-stroke oil injection system
Lubrication
Oil Type:
High-quality 2-stroke synthetic oil
Ignition
Ignition System:
Digital electronic ignition (CDI)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Features
Clutch Type:
Wet multi-plate clutch
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 1955 mm
Width:
Approx. 700 mm
Height:
Approx. 1150 mm
Weights
Dry Weight:
Approx. 120-125 kg (varies by market)
Fuel Tank Capacity:
Approx. 12 Liters
Wheels And Tires
Front Tire Size:
110/70-17
Rear Tire Size:
150/60-17
Wheel Type:
Alloy wheels
🛡️ Safety Features
Active Features
Braking System Front:
Single 320mm disc with 4-piston radial caliper (e.g., Nissin or Brembo, depending on market)
Braking System Rear:
Single 220mm disc with 2-piston caliper
Passive Features
Lighting:
Halogen headlight, LED taillight
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature gauge, and warning lights.
Driver Assistance
No Electronic Aids:
As a 2006 125cc sportbike, typically lacks electronic rider aids like ABS, traction control, or ride modes. Focus is on mechanical performance and rider input.
Connectivity
No Connectivity:
No Bluetooth or smartphone integration present on this model year.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Recommended every 2000-3000 km or annually (refer to manual for specific engine oil type and capacity).
Spark Plug Replacement:
Typically every 6000-8000 km (specific plug type and gap provided in manual).
Air Filter Cleaning:
Recommended every 3000-5000 km, depending on riding conditions.
Chain Lubrication And Adjustment:
Frequent checks recommended, adjust slack per manual specifications.
Fluid Specifications
Coolant:
Ethylene glycol-based antifreeze, mixed with distilled water (typically 50/50 ratio).
Brake Fluid:
DOT 4 or DOT 5.1 (verify specific requirement in manual).
Known Issues
Power Valve System:
The Rotax 123 engine's power valve system (A.E.S. - Aprilia Exhaust System) can accumulate carbon deposits, potentially affecting performance and requiring regular cleaning/maintenance. The manual details its inspection and cleaning.
Carburetor Tuning:
Due to its 2-stroke nature and performance focus, carburetor jetting and adjustment can be sensitive to altitude and atmospheric changes. The manual provides guidance on tuning.
Top End Wear:
Like many high-performance 2-stroke engines, regular top-end inspections (piston and rings) are recommended to maintain optimal performance and prevent catastrophic failure. The manual details wear limits and replacement procedures.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its high-performance sport motorcycles, particularly in the smaller displacement categories.
Model Evolution
Rs125 Lineage:
The RS125 has a long and storied history as a dominant force in 125cc racing and a popular choice for young sportbike enthusiasts, evolving significantly since its inception.
Production
Production Era:
The RS125 model has been in continuous production for many years, with significant updates throughout its lifecycle, including the 2006 model which incorporated advancements in design and technology.
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