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Aprilia RS125 RS125 2009 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: 2009 Product Type: Service Repair Workshop Manual 👋 Introduction Market Position Segment: Lightweight sport motorcycle, competitive in the 125cc supersport class. Target Demographic: Young riders, commuters, and track day enthusiasts seeking performance and style. Competitive Analysis Key Competitors: Yamaha YZF-R125, Honda CBR125R, KTM RC 125. Key Features Design: Aggressive, race-inspired styling mirroring larger Aprilia sportbikes. Performance: Known for its potent 2-stroke engine performance (though this generation shifted to 4-stroke) and agile handling. Handling: Premium suspension components and chassis design contribute to excellent ride and handling characteristics. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service and repair instructions for the Aprilia RS125 (2009). Target Audience: Professional mechanics and experienced DIY enthusiasts. Page Count Estimated Pages: Variable, typically 300-500 pages for this level of detail. Manual Type Type: Workshop Manual / Service Manual / Repair Manual Language Primary Language: English Format File Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, including top-end (cylinder, piston, cylinder head), bottom-end (crankshaft, connecting rod, bearings), valve timing, carburetor servicing, and ignition system diagnostics. Fuel System: Fuel tank, fuel pump, fuel lines, carburetor (Dell'Orto PHBH 28 QD or similar), air filter assembly, and fuel injection system (if applicable). Cooling System: Radiator, coolant hoses, water pump, thermostat, and fan control system. Exhaust System: Exhaust manifold, catalytic converter (if equipped), muffler, and associated fittings. Transmission: Gearbox (6-speed sequential), clutch operation (cable-actuated wet multi-plate), gear shifting mechanism, and lubrication. Chassis: Frame (aluminium alloy twin-spar), steering head bearings, swingarm, rear shock absorber, and front forks (upside-down telescopic). Brakes: Front disc brake (radial-mount caliper), rear disc brake, brake fluid specifications, bleeding procedures, and pad replacement. Wheels And Tires: Wheel types (spoked or alloy), tire sizes, inflation pressures, and wheel bearing maintenance. Electrical System: Battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, tail light, indicators), horn, and wiring diagrams. Instrumentation: Dashboard layout, speedometer, tachometer, warning lights, and sensor diagnostics. Bodywork: Fairings, seat, fuel tank cover, fenders, and mounting hardware. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, chain adjustment, brake lever adjustment, and general inspection. Troubleshooting: Diagnostic flowcharts for common problems, symptom-based troubleshooting guides. Repair And Overhaul: Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly. Torque Specifications: Detailed torque values for all critical fasteners. Special Tools: Identification and usage of specialized tools required for specific procedures. Wiring Diagrams: Clear and detailed electrical wiring schematics. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds. Diagnostics: Advanced diagnostic procedures for electrical and mechanical systems. Rebuild Procedures: Detailed instructions for rebuilding major components. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content for quick information retrieval. Printability: Printable pages for easy reference in a workshop environment. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Physical Format: N/A (Digital Format) Paper Type Physical Format: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, single-cylinder, liquid-cooled Displacement: 124.2 cc Bore X Stroke: 58 mm x 47 mm Compression Ratio: Approximately 12.0:1 Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: Approximately 15 hp (limited by licensing regulations in some markets, actual may be higher). Torque: Approximate peak torque around 12 Nm (8.9 lb-ft) at 8,000 rpm. Fuel System Induction: Dell'Orto PHBH 28 QD carburetor (or similar electronic fuel injection system in some markets). Fuel Type: Unleaded gasoline, minimum 95 RON. Lubrication System: Wet sump, forced lubrication. Oil Type: API SG or higher, SAE 10W-40 semi-synthetic or synthetic motorcycle oil. 🔧 Transmission Standard Type: 6-speed sequential constant mesh Final Drive: Chain driven (520 pitch). Features Clutch: Wet multi-plate, cable-actuated. Gear Ratios: Specific ratios detailed in manual, typically optimized for sporty performance. Transmission Oil Type: API GL-4, SAE 80W/90 hypoid gear oil (or specified alternative). 📐 Dimensions Exterior Length: Approx. 1950 mm Width: Approx. 740 mm Height: Approx. 1135 mm Wheelbase: Approx. 1345 mm Seat Height: Approx. 810 mm Weights Dry Weight: Approx. 130 kg Curb Weight: Approx. 144 kg (with all fluids) Maximum Load: Typically rated for 1 rider + minimal luggage. Fuel Capacity Tank Capacity: Approx. 13 liters (including 3 liters reserve). 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycles are not subjected to standardized crash testing like cars). Active Features Braking System: High-performance hydraulic disc brakes front and rear, often with braided lines for improved feel. Suspension: Adjustable front forks and rear monoshock provide stability and control. Passive Features Lighting: Halogen headlight, LED tail light, and clear turn signals for visibility. Frame Construction: Robust aluminum alloy frame designed for rigidity and rider feedback. Tires: Sport-oriented tire compound and profile for grip. 💡 Technology Features Infotainment System: Basic instrumentation with analogue tachometer and digital speedometer, essential indicators. Features: Includes trip meter, odometer, fuel level warning light, engine check light, oil pressure warning light. Driver...
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Aprilia RS125 RS125 2009 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Year:
2009
Product Type:
Service Repair Workshop Manual
👋 Introduction
Market Position
Segment:
Lightweight sport motorcycle, competitive in the 125cc supersport class.
Target Demographic:
Young riders, commuters, and track day enthusiasts seeking performance and style.
Competitive Analysis
Key Competitors:
Yamaha YZF-R125, Honda CBR125R, KTM RC 125.
Key Features
Design:
Aggressive, race-inspired styling mirroring larger Aprilia sportbikes.
Performance:
Known for its potent 2-stroke engine performance (though this generation shifted to 4-stroke) and agile handling.
Handling:
Premium suspension components and chassis design contribute to excellent ride and handling characteristics.
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive service and repair instructions for the Aprilia RS125 (2009).
Target Audience:
Professional mechanics and experienced DIY enthusiasts.
Page Count
Estimated Pages:
Variable, typically 300-500 pages for this level of detail.
Manual Type
Type:
Workshop Manual / Service Manual / Repair Manual
Language
Primary Language:
English
Format
File Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, including top-end (cylinder, piston, cylinder head), bottom-end (crankshaft, connecting rod, bearings), valve timing, carburetor servicing, and ignition system diagnostics.
Fuel System:
Fuel tank, fuel pump, fuel lines, carburetor (Dell'Orto PHBH 28 QD or similar), air filter assembly, and fuel injection system (if applicable).
Cooling System:
Radiator, coolant hoses, water pump, thermostat, and fan control system.
Exhaust System:
Exhaust manifold, catalytic converter (if equipped), muffler, and associated fittings.
Transmission:
Gearbox (6-speed sequential), clutch operation (cable-actuated wet multi-plate), gear shifting mechanism, and lubrication.
Chassis:
Frame (aluminium alloy twin-spar), steering head bearings, swingarm, rear shock absorber, and front forks (upside-down telescopic).
Brakes:
Front disc brake (radial-mount caliper), rear disc brake, brake fluid specifications, bleeding procedures, and pad replacement.
Wheels And Tires:
Wheel types (spoked or alloy), tire sizes, inflation pressures, and wheel bearing maintenance.
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, tail light, indicators), horn, and wiring diagrams.
Instrumentation:
Dashboard layout, speedometer, tachometer, warning lights, and sensor diagnostics.
Bodywork:
Fairings, seat, fuel tank cover, fenders, and mounting hardware.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain adjustment, brake lever adjustment, and general inspection.
Troubleshooting:
Diagnostic flowcharts for common problems, symptom-based troubleshooting guides.
Repair And Overhaul:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly.
Torque Specifications:
Detailed torque values for all critical fasteners.
Special Tools:
Identification and usage of specialized tools required for specific procedures.
Wiring Diagrams:
Clear and detailed electrical wiring schematics.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds.
Diagnostics:
Advanced diagnostic procedures for electrical and mechanical systems.
Rebuild Procedures:
Detailed instructions for rebuilding major components.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content for quick information retrieval.
Printability:
Printable pages for easy reference in a workshop environment.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Physical Format:
N/A (Digital Format)
Paper Type
Physical Format:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Type:
Four-stroke, single-cylinder, liquid-cooled
Displacement:
124.2 cc
Bore X Stroke:
58 mm x 47 mm
Compression Ratio:
Approximately 12.0:1
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Approximately 15 hp (limited by licensing regulations in some markets, actual may be higher).
Torque:
Approximate peak torque around 12 Nm (8.9 lb-ft) at 8,000 rpm.
Fuel System
Induction:
Dell'Orto PHBH 28 QD carburetor (or similar electronic fuel injection system in some markets).
Fuel Type:
Unleaded gasoline, minimum 95 RON.
Lubrication
System:
Wet sump, forced lubrication.
Oil Type:
API SG or higher, SAE 10W-40 semi-synthetic or synthetic motorcycle oil.
🔧 Transmission
Standard
Type:
6-speed sequential constant mesh
Final Drive:
Chain driven (520 pitch).
Features
Clutch:
Wet multi-plate, cable-actuated.
Gear Ratios:
Specific ratios detailed in manual, typically optimized for sporty performance.
Transmission Oil Type:
API GL-4, SAE 80W/90 hypoid gear oil (or specified alternative).
📐 Dimensions
Exterior
Length:
Approx. 1950 mm
Width:
Approx. 740 mm
Height:
Approx. 1135 mm
Wheelbase:
Approx. 1345 mm
Seat Height:
Approx. 810 mm
Weights
Dry Weight:
Approx. 130 kg
Curb Weight:
Approx. 144 kg (with all fluids)
Maximum Load:
Typically rated for 1 rider + minimal luggage.
Fuel Capacity
Tank Capacity:
Approx. 13 liters (including 3 liters reserve).
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycles are not subjected to standardized crash testing like cars).
Active Features
Braking System:
High-performance hydraulic disc brakes front and rear, often with braided lines for improved feel.
Suspension:
Adjustable front forks and rear monoshock provide stability and control.
Passive Features
Lighting:
Halogen headlight, LED tail light, and clear turn signals for visibility.
Frame Construction:
Robust aluminum alloy frame designed for rigidity and rider feedback.
Tires:
Sport-oriented tire compound and profile for grip.
💡 Technology Features
Infotainment
System:
Basic instrumentation with analogue tachometer and digital speedometer, essential indicators.
Features:
Includes trip meter, odometer, fuel level warning light, engine check light, oil pressure warning light.
Driver Assistance
ABS:
Not typically equipped on this model year of the RS125.
Traction Control:
Not equipped.
Connectivity
System:
No electronic connectivity features (Bluetooth, smartphone integration).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 - 5,000 km or annually, whichever comes first.
Oil Filter Replacement:
At every oil change.
Spark Plug Check/Replacement:
Every 5,000 - 8,000 km, depending on usage and plug type.
Air Filter Cleaning/Replacement:
Inspect every 3,000 km, clean or replace as needed.
Chain Cleaning And Lubrication:
Every 500 km and after riding in wet conditions.
Brake Fluid Change:
Every 2 years, or as per manual recommendations.
Coolant Change:
Every 2-3 years.
Fluid Specifications
Engine Oil:
SAE 10W-40 API SG or higher (Semi-synthetic or Synthetic)
Brake Fluid:
DOT 4
Coolant:
Ethylene glycol based coolant with anti-corrosion additives (50/50 mix with distilled water).
Transmission Oil:
SAE 80W/90 API GL-4 hypoid gear oil
Known Issues
Electrical Gremlins:
Occasional issues with the charging system (regulator/rectifier) or wiring harness connections due to vibration and exposure.
Carburetor Adjustment:
Carburetors require periodic cleaning and precise adjustment for optimal performance, especially after prolonged storage or exposure to contaminants.
Suspension Wear:
Fork seals and rear shock absorber may require rebuilding or replacement over time, typical for performance motorcycles.
Clutch Wear:
Clutch plates can wear out with aggressive use, leading to slipping or difficulty engaging gears.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian motorcycle manufacturer known for its racing heritage and high-performance sportbikes.
Model Evolution
Previous Generations:
The RS125 has a long history, originally featuring a potent 2-stroke engine, which was highly successful in its class. The 2009 model represents a transition or continuation with a 4-stroke engine to meet emissions standards and broaden appeal.
Key Changes For 2009:
While the exact specifications can vary by market, 2009 models generally featured updated styling, often transitioning to a 4-stroke engine (replacing the iconic 2-stroke Rotax engine in many regions) to comply with stricter emission regulations.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Racing Pedigree:
Aprilia has a strong history in motorcycle racing, particularly in the 125cc Grand Prix class, which influences the design and performance of the RS125 road model.
Ratings
Editorial Reviews:
Generally praised for its sharp handling, strong engine performance for its class, and premium feel.
Certifications
Emissions Compliance:
Designed to meet European emissions standards relevant for the 2009 model year.
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