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Aprilia RS125 RS 125 2009 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: 2009 Codes Model Code: AP06 👋 Introduction Market Position Segment: Lightweight Supersport / Performance Motorcycle Target Audience: Enthusiast riders, track day participants, DIY mechanics, and aspiring racers. Competitive Analysis Competitors 2009: Yamaha YZF-R125, Honda CBR125R, Kawasaki Ninja 125 (market dependent). Key Features Design Philosophy: Aggressive styling, race-inspired ergonomics, and a potent 2-stroke engine for its class. Engine Type Advantage: The 2-stroke engine provides a high power-to-weight ratio and characteristic 'ring-ding' sound, appealing to performance enthusiasts. Handling Characteristics: Renowned for its agile handling and capable chassis, making it a favorite for spirited riding and track use. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: Downloadable PDF Completeness: Complete official factory documentation 📖 Manual Coverage Systems Covered Engine: Detailed breakdown of the Rotax 125cc 2-stroke engine, including top-end, bottom-end, cooling system, lubrication, and fuel/air mixture. Fuel System: Carburetor tuning (Dell'Orto PHBH 28), fuel pump, fuel lines, and fuel tank maintenance. Ignition System: CDI ignition, spark plug specifications, timing adjustments, and troubleshooting. Transmission: 6-speed gearbox, clutch operation, linkage adjustments, and gearbox oil specifications. Frame And Suspension: Chassis inspection, frame integrity, front fork (upside-down) overhaul and adjustment, rear shock absorber specifications and maintenance. Brakes: Front and rear hydraulic brake systems, caliper maintenance, master cylinder overhaul, brake fluid type and bleeding procedures, rotor inspection. Electrical System: Wiring diagrams, battery maintenance, lighting system, starter motor, generator, fuses, relays, and instrument cluster diagnostics. Cooling System: Radiator, hoses, thermostat, coolant type, capacity, and bleeding procedures. Exhaust System: Exhaust pipe and silencer inspection, gasket replacement. Wheels And Tires: Wheel bearing maintenance, tire pressure recommendations, and tire replacement procedures. Bodywork And Fairings: Fairing removal and installation, seat, tank, and paneling components. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain lubrication and adjustment, brake checks, and bolt torque specifications. Troubleshooting: Systematic diagnostic guides for common performance issues, starting problems, electrical faults, and braking anomalies. Repair: Step-by-step instructions for engine rebuilds, gearbox repairs, suspension servicing, electrical component replacement, and bodywork repairs. Disassembly And Assembly: Complete instructions for stripping down and reassembling major components and systems. Wiring Diagrams: Detailed, high-resolution electrical schematics for the entire motorcycle. Torque Specifications: Precise torque values for all critical fasteners and bolts. Technical Depth Depth Level: Comprehensive Factory Level - Covers everything from basic fluid checks to complete engine and transmission rebuilds. Diagnostic Capability: Advanced diagnostic procedures and troubleshooting flowcharts for identifying and resolving complex issues. Special Tools: Lists and descriptions of required special tools for specific repair procedures. 📊 Manual Specifications File Format Format: PDF Searchable: Yes Printable: Yes Print Quality Resolution: High resolution for clear text and images Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke Single Cylinder Cooling: Liquid-cooled Displacement: 124.8 cc Bore X Stroke: 54 mm x 54.5 mm Compression Ratio: 12.4:1 Valvetrain: Reed valve induction, Aprilia Exhaust Power Valve (AEPV) Performance Horsepower: Approx. 30-33 hp (varies by market/derestriction) Torque: Approx. 20 Nm (varies by market/derestriction) Fuel System Carburetor: Dell'Orto PHBH 28 CD Fuel Type: Unleaded gasoline (min. 95 RON recommended) Oil Mixture: Separate oil injection system (premix or automatic injection) 🔧 Transmission Standard Type: 6-speed constant mesh Clutch: Wet multi-plate Final Drive: Chain drive (RK 520 series) Features Gear Ratios: Specific ratios detailed in manual Gearbox Oil Type: SAE 75W/90 or SAE 80W API GL-4 📐 Dimensions Exterior Length: Approx. 1945 mm Width: Approx. 760 mm (at handlebars) Height: Approx. 1065 mm (at seat) Wheelbase: Approx. 1345 mm Weights Dry Weight: Approx. 131 kg Wet Weight: Approx. 145 kg (with fluids) Max Load: Typically 180 kg (rider + luggage) Wheels And Tires Front Tire: 110/70-17 Rear Tire: 140/70-17 Wheel Bolt Pattern: N/A (Cast aluminum wheels) Front Brake Size: 320 mm Disc Rear Brake Size: 220 mm Disc 🛡️ Safety Features Ratings Crash Test Data: N/A for motorcycles; emphasis on design and component integrity for rider protection. Active Features Braking System: Powerful dual hydraulic disc front brake and single rear disc brake for effective stopping power. Suspension Stability: Upside-down front forks and adjustable rear monoshock contribute to stability during braking and cornering. Passive Features Chassis Design: Robust twin-spar aluminum frame designed for rigidity and predictable handling. Ergonomics: Sportbike riding position, though more forgiving than larger supersports, encouraging rider control. 💡 Technology Features Infotainment Infotainment System: Basic analog/digital instrument cluster with speedometer, tachometer, odometer, trip meter, and essential warning lights. Driver Assistance ABS: ABS was not standard on the 2009 RS125 model. Connectivity Connectivity Features: None; this is a performance-oriented motorcycle without modern connectivity features. 🔧 Maintenance Service Intervals Oil Change Engine: Every 5,000 km or annually, or as per manual recommendation based on usage. Air Filter Cleaning: Inspect every 5,000 km, clean or replace as needed. Spark Plug Replacement: Every 10,000 km or as per...
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Aprilia RS125 RS 125 2009 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Year:
2009
Codes
Model Code:
AP06
👋 Introduction
Market Position
Segment:
Lightweight Supersport / Performance Motorcycle
Target Audience:
Enthusiast riders, track day participants, DIY mechanics, and aspiring racers.
Competitive Analysis
Competitors 2009:
Yamaha YZF-R125, Honda CBR125R, Kawasaki Ninja 125 (market dependent).
Key Features
Design Philosophy:
Aggressive styling, race-inspired ergonomics, and a potent 2-stroke engine for its class.
Engine Type Advantage:
The 2-stroke engine provides a high power-to-weight ratio and characteristic 'ring-ding' sound, appealing to performance enthusiasts.
Handling Characteristics:
Renowned for its agile handling and capable chassis, making it a favorite for spirited riding and track use.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
Downloadable PDF
Completeness:
Complete official factory documentation
📖 Manual Coverage
Systems Covered
Engine:
Detailed breakdown of the Rotax 125cc 2-stroke engine, including top-end, bottom-end, cooling system, lubrication, and fuel/air mixture.
Fuel System:
Carburetor tuning (Dell'Orto PHBH 28), fuel pump, fuel lines, and fuel tank maintenance.
Ignition System:
CDI ignition, spark plug specifications, timing adjustments, and troubleshooting.
Transmission:
6-speed gearbox, clutch operation, linkage adjustments, and gearbox oil specifications.
Frame And Suspension:
Chassis inspection, frame integrity, front fork (upside-down) overhaul and adjustment, rear shock absorber specifications and maintenance.
Brakes:
Front and rear hydraulic brake systems, caliper maintenance, master cylinder overhaul, brake fluid type and bleeding procedures, rotor inspection.
Electrical System:
Wiring diagrams, battery maintenance, lighting system, starter motor, generator, fuses, relays, and instrument cluster diagnostics.
Cooling System:
Radiator, hoses, thermostat, coolant type, capacity, and bleeding procedures.
Exhaust System:
Exhaust pipe and silencer inspection, gasket replacement.
Wheels And Tires:
Wheel bearing maintenance, tire pressure recommendations, and tire replacement procedures.
Bodywork And Fairings:
Fairing removal and installation, seat, tank, and paneling components.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain lubrication and adjustment, brake checks, and bolt torque specifications.
Troubleshooting:
Systematic diagnostic guides for common performance issues, starting problems, electrical faults, and braking anomalies.
Repair:
Step-by-step instructions for engine rebuilds, gearbox repairs, suspension servicing, electrical component replacement, and bodywork repairs.
Disassembly And Assembly:
Complete instructions for stripping down and reassembling major components and systems.
Wiring Diagrams:
Detailed, high-resolution electrical schematics for the entire motorcycle.
Torque Specifications:
Precise torque values for all critical fasteners and bolts.
Technical Depth
Depth Level:
Comprehensive Factory Level - Covers everything from basic fluid checks to complete engine and transmission rebuilds.
Diagnostic Capability:
Advanced diagnostic procedures and troubleshooting flowcharts for identifying and resolving complex issues.
Special Tools:
Lists and descriptions of required special tools for specific repair procedures.
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Yes
Printable:
Yes
Print Quality
Resolution:
High resolution for clear text and images
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-Stroke Single Cylinder
Cooling:
Liquid-cooled
Displacement:
124.8 cc
Bore X Stroke:
54 mm x 54.5 mm
Compression Ratio:
12.4:1
Valvetrain:
Reed valve induction, Aprilia Exhaust Power Valve (AEPV)
Performance
Horsepower:
Approx. 30-33 hp (varies by market/derestriction)
Torque:
Approx. 20 Nm (varies by market/derestriction)
Fuel System
Carburetor:
Dell'Orto PHBH 28 CD
Fuel Type:
Unleaded gasoline (min. 95 RON recommended)
Oil Mixture:
Separate oil injection system (premix or automatic injection)
🔧 Transmission
Standard
Type:
6-speed constant mesh
Clutch:
Wet multi-plate
Final Drive:
Chain drive (RK 520 series)
Features
Gear Ratios:
Specific ratios detailed in manual
Gearbox Oil Type:
SAE 75W/90 or SAE 80W API GL-4
📐 Dimensions
Exterior
Length:
Approx. 1945 mm
Width:
Approx. 760 mm (at handlebars)
Height:
Approx. 1065 mm (at seat)
Wheelbase:
Approx. 1345 mm
Weights
Dry Weight:
Approx. 131 kg
Wet Weight:
Approx. 145 kg (with fluids)
Max Load:
Typically 180 kg (rider + luggage)
Wheels And Tires
Front Tire:
110/70-17
Rear Tire:
140/70-17
Wheel Bolt Pattern:
N/A (Cast aluminum wheels)
Front Brake Size:
320 mm Disc
Rear Brake Size:
220 mm Disc
🛡️ Safety Features
Ratings
Crash Test Data:
N/A for motorcycles; emphasis on design and component integrity for rider protection.
Active Features
Braking System:
Powerful dual hydraulic disc front brake and single rear disc brake for effective stopping power.
Suspension Stability:
Upside-down front forks and adjustable rear monoshock contribute to stability during braking and cornering.
Passive Features
Chassis Design:
Robust twin-spar aluminum frame designed for rigidity and predictable handling.
Ergonomics:
Sportbike riding position, though more forgiving than larger supersports, encouraging rider control.
💡 Technology Features
Infotainment
Infotainment System:
Basic analog/digital instrument cluster with speedometer, tachometer, odometer, trip meter, and essential warning lights.
Driver Assistance
ABS:
ABS was not standard on the 2009 RS125 model.
Connectivity
Connectivity Features:
None; this is a performance-oriented motorcycle without modern connectivity features.
🔧 Maintenance
Service Intervals
Oil Change Engine:
Every 5,000 km or annually, or as per manual recommendation based on usage.
Air Filter Cleaning:
Inspect every 5,000 km, clean or replace as needed.
Spark Plug Replacement:
Every 10,000 km or as per manual recommendation.
Chain Lubrication:
Every 1,000 km and after washing or riding in rain.
Fluid Specifications
Engine Oil Type:
2-stroke specific pre-mix oil (e.g., Motul 7100 2T, Castrol TTS) or specific Aprilia 2-stroke injector oil.
Coolant Type:
Ethylene glycol-based antifreeze coolant (50% mix with distilled water).
Brake Fluid Type:
DOT 4
Gearbox Oil Specification:
SAE 75W/90 or SAE 80W API GL-4
Known Issues
Power Valve Sticking:
Common issue on 2-stroke engines; carbon buildup can cause the exhaust power valve to stick, affecting performance. Regular cleaning is essential.
Carburetor Tuning Sensitivity:
The Dell'Orto carburetor can be sensitive to altitude and atmospheric changes, often requiring adjustments for optimal performance.
Clutch Wear:
Aggressive riding can lead to faster clutch wear; the manual details inspection and adjustment procedures.
Electrical Connector Corrosion:
In certain climates, electrical connectors can be prone to corrosion, leading to intermittent electrical faults. The manual's wiring diagrams are crucial for diagnosis.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia has a rich history in motorcycle racing, particularly in the Grand Prix paddock, with numerous championships in smaller displacement classes.
Sportbike Focus:
The brand is renowned for its performance-oriented motorcycles, from small-displacement two-strokes to liter-class sportbikes.
Model Evolution
Rs125 Lineage:
The RS125 has been a cornerstone of Aprilia's lightweight sportbike offering for decades, evolving through various iterations and engine configurations.
Rotax Engine Use:
The reliable and potent Rotax 125cc two-stroke engine has been a staple in the RS125 and other Aprilia models, a testament to its performance.
Production
Production Period:
The RS125, including the 2009 model, was produced for many years, with significant updates and engine variants throughout its lifespan.
Manufacturing Location:
Primarily Italy
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