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Aprilia RS 125 2006-2012 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS 125 Model Variant: Full Faired Sportbike Applicable Years: 2006, 2007, 2008, 2009, 2010, 2011, 2012 Codes Engine Code: Rotax 122 (Varying specifics based on sub-model/market) 👋 Introduction Market Position Market Segment: Lightweight Supersport / Entry-Level Performance Motorcycle Target Audience: New riders seeking sporty styling and performance, experienced riders looking for a nimble and track-capable machine. Competitive Analysis Key Competitors: Yamaha YZF-R125, Honda CBR125R, Kawasaki Ninja 125 (depending on market availability and specific model years). Key Features Design Philosophy: Aggressive, race-inspired styling mimicking larger Aprilia sportbikes, lightweight chassis for agility. Performance Focus: Emphasis on handling, braking, and a rev-happy two-stroke engine (in earlier versions of the platform, though later models might have transitioned to 4-stroke). This manual likely covers the later iterations, potentially with 4-stroke engines depending on exact year variants. *Correction: The Rotax 122 is a 2-stroke engine.* Manual Purpose: To provide detailed technical guidance for the repair, maintenance, and servicing of the Aprilia RS 125 models from 2006-2012, ensuring optimal performance and longevity. 📋 Manual Details Coverage Areas Manual Language: English (Presumed primary language of this edition) Manual Format: PDF Manual Type: Workshop Repair Service Manual Page Count Estimated Page Count: Refer to actual PDF for precise count, typically 300-600 pages for comprehensive workshop manuals. 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, inspection, and repair of the Rotax 122 engine, including top-end (cylinder, piston, rings), bottom-end (crankshaft, connecting rod, bearings), cylinder head, and cooling system. Fuel System: Carburetor (likely Dell'Orto PHBH or similar) tuning, cleaning, overhaul, fuel pump, fuel lines, and fuel tank maintenance. Ignition System: CDI unit, spark plug, stator, rotor, and wiring diagnostics. Transmission: 6-speed gearbox, clutch assembly (wet multi-plate), gear selection mechanism, lubrication, and troubleshooting. Cooling System: Radiator, water pump, thermostat, hoses, and coolant specifications. Exhaust System: Expansion chamber, muffler, and associated fittings maintenance and inspection. Chassis: Frame inspection, alignment, and repair considerations. Front Suspension: Telescopic front forks (e.g., Marzocchi or Paioli), oil change, seal replacement, spring inspection, and damping adjustments. Rear Suspension: Monoshock rear suspension, linkage maintenance, shock absorber servicing, and adjustment procedures. Brakes Front: Hydraulic disc brake system, caliper overhaul, master cylinder servicing, brake pad replacement, fluid flush and bleeding, and rotor inspection. Brakes Rear: Hydraulic disc brake system, caliper overhaul, master cylinder servicing, brake pad replacement, fluid flush and bleeding, and rotor inspection. Wheels Tires: Wheel bearing inspection and replacement, rim maintenance, tire mounting and balancing, and recommended tire pressures. Electrical System: Wiring diagrams, battery maintenance, lighting systems (headlight, tail light, indicators), horn, starter motor, and fuse box diagnostics. Instrumentation: Speedometer, tachometer, coolant temperature gauge, and warning lights operation and troubleshooting. Bodywork: Fairing removal and installation, seat, fuel tank, and associated paneling. Procedures Included Maintenance: Scheduled maintenance tasks, lubrication points, filter replacements (air, oil if applicable), chain adjustment, and general upkeep. Troubleshooting: Diagnostic procedures for common problems, electrical fault finding, engine performance issues, and mechanical failures. Repair: Step-by-step instructions for component removal, repair, reassembly, and adjustment. Overhaul: Complete engine rebuilds, carburetor overhauls, and suspension unit servicing. Diagnostics: Guidance on identifying the root cause of malfunctions using systematic testing. Technical Depth Depth: Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers full disassembly, repair, and reassembly with detailed diagrams and specifications. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Likely text-searchable if produced from original digital sources, enabling quick access to information. Print Quality: Dependent on the original source, but typically aims for clarity of text and diagrams for printing. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, single-cylinder, Reed-valve induction Bore X Stroke: 54 mm x 54.5 mm (Typical for Rotax 122) Displacement: 124.8 cc Compression Ratio: Approx. 12.0:1 (Varies with sub-model) Power Output Hp: Approx. 33-34 HP (claimed, may vary by market regulations and specific year) Torque Nm: Approx. 22-23 Nm (Varies) Lubrication: Autolube (separate oil injection system) Fuel System Carburetor Type: Dell'Orto PHBH 28 or similar 28mm flat-slide carburetor Fuel Type: Unleaded gasoline, minimum 95 RON (Octane rating) Fuel Delivery: Gravity feed with vacuum operated fuel tap 🔧 Transmission Standard Type: 6-speed constant mesh Clutch Type: Wet, multi-plate Features Gear Ratios: Specific ratios will be detailed in the manual, critical for performance tuning. Final Drive: Chain drive (e.g., 16/40 tooth sprockets typical) Transmission Fluid: Typically a high-quality 10W-40 or 15W-50 motorcycle specific engine oil, capacity approx. 0.8 - 1.0 liters. Refer to manual for precise specification and part number. 📐 Dimensions Exterior Length: Approx. 1945 mm (Varies slightly by year) Width: Approx. 760 mm (Varies slightly by year) Height: Approx. 1135 mm (Varies slightly by year) Weights Dry Weight: Approx. 140 kg (Varies) Wet Weight: Approx. 155 kg (Varies, with fluids) Fuel Tank Capacity: Approx. 12 liters Seat Height: Approx....
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Aprilia RS 125 2006-2012 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS 125
Model Variant:
Full Faired Sportbike
Applicable Years:
2006, 2007, 2008, 2009, 2010, 2011, 2012
Codes
Engine Code:
Rotax 122 (Varying specifics based on sub-model/market)
👋 Introduction
Market Position
Market Segment:
Lightweight Supersport / Entry-Level Performance Motorcycle
Target Audience:
New riders seeking sporty styling and performance, experienced riders looking for a nimble and track-capable machine.
Competitive Analysis
Key Competitors:
Yamaha YZF-R125, Honda CBR125R, Kawasaki Ninja 125 (depending on market availability and specific model years).
Key Features
Design Philosophy:
Aggressive, race-inspired styling mimicking larger Aprilia sportbikes, lightweight chassis for agility.
Performance Focus:
Emphasis on handling, braking, and a rev-happy two-stroke engine (in earlier versions of the platform, though later models might have transitioned to 4-stroke). This manual likely covers the later iterations, potentially with 4-stroke engines depending on exact year variants. *Correction: The Rotax 122 is a 2-stroke engine.*
Manual Purpose:
To provide detailed technical guidance for the repair, maintenance, and servicing of the Aprilia RS 125 models from 2006-2012, ensuring optimal performance and longevity.
📋 Manual Details
Coverage Areas
Manual Language:
English (Presumed primary language of this edition)
Manual Format:
PDF
Manual Type:
Workshop Repair Service Manual
Page Count
Estimated Page Count:
Refer to actual PDF for precise count, typically 300-600 pages for comprehensive workshop manuals.
📖 Manual Coverage
Systems Covered
Engine:
Detailed disassembly, assembly, inspection, and repair of the Rotax 122 engine, including top-end (cylinder, piston, rings), bottom-end (crankshaft, connecting rod, bearings), cylinder head, and cooling system.
Fuel System:
Carburetor (likely Dell'Orto PHBH or similar) tuning, cleaning, overhaul, fuel pump, fuel lines, and fuel tank maintenance.
Ignition System:
CDI unit, spark plug, stator, rotor, and wiring diagnostics.
Transmission:
6-speed gearbox, clutch assembly (wet multi-plate), gear selection mechanism, lubrication, and troubleshooting.
Cooling System:
Radiator, water pump, thermostat, hoses, and coolant specifications.
Exhaust System:
Expansion chamber, muffler, and associated fittings maintenance and inspection.
Chassis:
Frame inspection, alignment, and repair considerations.
Front Suspension:
Telescopic front forks (e.g., Marzocchi or Paioli), oil change, seal replacement, spring inspection, and damping adjustments.
Rear Suspension:
Monoshock rear suspension, linkage maintenance, shock absorber servicing, and adjustment procedures.
Brakes Front:
Hydraulic disc brake system, caliper overhaul, master cylinder servicing, brake pad replacement, fluid flush and bleeding, and rotor inspection.
Brakes Rear:
Hydraulic disc brake system, caliper overhaul, master cylinder servicing, brake pad replacement, fluid flush and bleeding, and rotor inspection.
Wheels Tires:
Wheel bearing inspection and replacement, rim maintenance, tire mounting and balancing, and recommended tire pressures.
Electrical System:
Wiring diagrams, battery maintenance, lighting systems (headlight, tail light, indicators), horn, starter motor, and fuse box diagnostics.
Instrumentation:
Speedometer, tachometer, coolant temperature gauge, and warning lights operation and troubleshooting.
Bodywork:
Fairing removal and installation, seat, fuel tank, and associated paneling.
Procedures Included
Maintenance:
Scheduled maintenance tasks, lubrication points, filter replacements (air, oil if applicable), chain adjustment, and general upkeep.
Troubleshooting:
Diagnostic procedures for common problems, electrical fault finding, engine performance issues, and mechanical failures.
Repair:
Step-by-step instructions for component removal, repair, reassembly, and adjustment.
Overhaul:
Complete engine rebuilds, carburetor overhauls, and suspension unit servicing.
Diagnostics:
Guidance on identifying the root cause of malfunctions using systematic testing.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers full disassembly, repair, and reassembly with detailed diagrams and specifications.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Likely text-searchable if produced from original digital sources, enabling quick access to information.
Print Quality:
Dependent on the original source, but typically aims for clarity of text and diagrams for printing.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Quality:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder, Reed-valve induction
Bore X Stroke:
54 mm x 54.5 mm (Typical for Rotax 122)
Displacement:
124.8 cc
Compression Ratio:
Approx. 12.0:1 (Varies with sub-model)
Power Output Hp:
Approx. 33-34 HP (claimed, may vary by market regulations and specific year)
Torque Nm:
Approx. 22-23 Nm (Varies)
Lubrication:
Autolube (separate oil injection system)
Fuel System
Carburetor Type:
Dell'Orto PHBH 28 or similar 28mm flat-slide carburetor
Fuel Type:
Unleaded gasoline, minimum 95 RON (Octane rating)
Fuel Delivery:
Gravity feed with vacuum operated fuel tap
🔧 Transmission
Standard
Type:
6-speed constant mesh
Clutch Type:
Wet, multi-plate
Features
Gear Ratios:
Specific ratios will be detailed in the manual, critical for performance tuning.
Final Drive:
Chain drive (e.g., 16/40 tooth sprockets typical)
Transmission Fluid:
Typically a high-quality 10W-40 or 15W-50 motorcycle specific engine oil, capacity approx. 0.8 - 1.0 liters. Refer to manual for precise specification and part number.
📐 Dimensions
Exterior
Length:
Approx. 1945 mm (Varies slightly by year)
Width:
Approx. 760 mm (Varies slightly by year)
Height:
Approx. 1135 mm (Varies slightly by year)
Weights
Dry Weight:
Approx. 140 kg (Varies)
Wet Weight:
Approx. 155 kg (Varies, with fluids)
Fuel Tank Capacity:
Approx. 12 liters
Seat Height:
Approx. 805 mm
🛡️ Safety Features
Ratings
Safety Certification:
CE, Euro 3 (for emissions standards applicable to model years)
Active Features
Braking System:
Powerful twin-piston front caliper and single-piston rear caliper for effective stopping power.
Tires:
Sport-oriented tires providing good grip in dry and moderate wet conditions.
Passive Features
Lighting:
Halogen headlight, LED tail light, and standard front/rear turn signals for visibility.
Frame Construction:
Sturdy aluminum twin-spar frame for stability and rigidity.
💡 Technology Features
Infotainment
Display Type:
Analog tachometer, digital speedometer (may vary by exact sub-model/year), coolant temperature warning light.
Driver Assistance
Electronic Aids:
None (typical for this class and era).
Connectivity
Connectivity Features:
None (typical for this class and era).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 km or annually. Refer to manual for exact specification.
Spark Plug Replacement:
Every 5,000-10,000 km, depending on type and usage. Manual will specify recommended plug type and gap.
Air Filter Cleaning Replacement:
Inspect every 5,000 km, clean or replace as needed. Crucial for 2-stroke engine health.
Chain Adjustment Lubrication:
Check and lubricate every 1,000 km, adjust tension as needed. Manual will provide specific slack measurement.
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water. Manual specifies Aprilia part number or equivalent.
Brake Fluid Type:
DOT 4 or DOT 5.1 (Check manual for exact specification). Requires regular flushing and replacement.
2 Stroke Oil Type:
High-quality, synthetic or semi-synthetic 2-stroke premix oil suitable for high-performance engines (e.g., Motul 7100 2T, Castrol Power 1 Racing 2T). Manual specifies Aprilia recommendations.
Known Issues
Power Valve Sticking:
Common in Rotax 2-stroke engines, can lead to poor performance. Requires periodic cleaning and lubrication as detailed in the manual.
Carburetor Jetting:
Can be sensitive to environmental changes (altitude, temperature) and requires proper jetting for optimal performance and engine longevity. Manual provides baseline settings.
Cylinder Wear:
Due to the nature of 2-stroke engines, cylinder and piston wear are critical. Regular monitoring and correct lubrication are essential. Manual details wear limits and inspection procedures.
Clutch Wear:
Clutch plates can wear over time with aggressive riding. Manual covers inspection and replacement.
📚 Vehicle History
Brand Heritage
Brand Origin:
Aprilia is an Italian manufacturer with a strong racing heritage, particularly in smaller displacement categories.
Model Evolution
Rs125 Legacy:
The RS 125 has a long-standing reputation as a potent and stylish 125cc sportbike, often seen as a stepping stone to larger motorcycles.
Engine Development:
The Rotax 122 engine, a mainstay for many years, was known for its robust design and tunable nature, often used in various racing applications.
Production
Production Period Covered:
2006-2012, representing a specific generation of the RS 125, likely with minor updates during this period.
🏆 Awards & Recognition
Recognitions
Performance Awards:
The RS 125 platform has historically received praise in motorcycle publications for its handling and performance relative to its displacement class.
Ratings
User Satisfaction:
Generally high among owners who appreciate its sporty character and handling capabilities, with an understanding of the maintenance required for a 2-stroke.
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