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Aprilia RS125 2006 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RS125 Year: 2006 Codes Vin Prefix: ZAPG07100 👋 Introduction Market Position Market Segment: High-performance lightweight sportbike Target Audience: Enthusiasts, aspiring racers, and riders...
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Type: Motorcycle
Vendor:
Sku: 558080
Aprilia RS125 2006 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RS125
Year:
2006
Codes
Vin Prefix:
ZAPG07100
👋 Introduction
Market Position
Market Segment:
High-performance lightweight sportbike
Target Audience:
Enthusiasts, aspiring racers, and riders seeking a premium 125cc experience
Competitive Analysis
Key Competitors:
Yamaha YZF-R125, Cagiva Mito 125, Honda CBR125R
Key Features
Performance Heritage:
Derived from Aprilia's extensive racing experience, particularly in the 125cc Grand Prix class.
Styling:
Aggressive, track-inspired fairing design and ergonomics
Engine Technology:
Renowned Rotax 122 engine, known for its potent 2-stroke performance in the 125cc segment.
Chassis Components:
Premium suspension (e.g., Marzocchi forks) and braking components (e.g., Brembo calipers) typically found on larger bikes.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
Digital (likely PDF)
Page Count:
Estimated 300-400 pages (typical for this model and year)
📖 Manual Coverage
Systems Covered
Engine:
2-stroke single-cylinder Rotax 122
Fuel System:
Carburetor (Dell'Orto PHBH 28 QD), Reed valve intake, Automatic oil injection
Ignition System:
Electronic ignition (CDI)
Cooling System:
Liquid-cooled
Transmission:
6-speed constant mesh gearbox
Clutch:
Wet multi-plate
Frame:
Aluminum alloy twin-spar
Suspension Front:
Upside-down telescopic fork (Marzocchi or Paoli, depending on specific build)
Suspension Rear:
Monoshock with adjustable preload and rebound damping (Sachs or similar)
Brakes Front:
Single hydraulic disc with multi-piston caliper (Brembo or Grimeca)
Brakes Rear:
Single hydraulic disc with single-piston caliper
Wheels Tires:
Alloy wheels, typical sizes: Front 17", Rear 17"
Electrical System:
12V DC system, battery, alternator, lighting, starter motor, instrumentation
Exhaust System:
2-stroke exhaust manifold and silencer, often with expansion chamber design
Procedures Included
Maintenance:
Regular servicing, oil changes, filter replacements, spark plug checks, chain adjustment
Disassembly Assembly:
Complete engine teardown and reassembly, gearbox, clutch, suspension components, wheels, brakes
Repair:
Engine internal repairs (piston, cylinder, crankshaft, bearings), gearbox repairs, brake caliper rebuilds, fork seal replacement
Troubleshooting:
Diagnostic procedures for common issues, electrical system faults, engine performance problems
Adjustments:
Carburetor tuning, ignition timing checks, chain tension, suspension setup
Installation:
Component replacement procedures (e.g., brake pads, exhaust system)
Technical Depth
Depth:
Comprehensive, covering routine maintenance to full engine rebuilds and chassis repairs.
Diagnostics:
Includes detailed troubleshooting guides and diagnostic flowcharts.
Specifications:
Provides all necessary torque values, clearances, fluid capacities, and component tolerances.
📊 Manual Specifications
File Format
File Type:
Digital (PDF)
Searchability:
Text-searchable for quick information retrieval
Printability:
Printable for workshop use
Print Quality
Image Resolution:
High-resolution diagrams and illustrations
Binding Type
Binding:
Not applicable for digital format; however, if printed, would typically be spiral-bound or comb-bound for ease of use.
Paper Type
Paper:
Not applicable for digital format; however, factory originals are printed on durable paper suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, single-cylinder, liquid-cooled, reed valve induction
Bore X Stroke:
54 mm x 54.5 mm
Displacement:
124.8 cc
Compression Ratio:
Approx. 12.2:1
Power Output:
Approx. 30-34 hp (depending on market restrictions, e.g., learner regulations)
Torque Output:
Approx. 22-24 Nm
Performance
Top Speed:
Approx. 150-160 km/h (subject to rider weight, conditions, and rider skill)
Fuel System
Carburetor Model:
Dell'Orto PHBH 28 QD
Fuel Type:
Unleaded gasoline (minimum 95 RON)
Oil System:
Automatic 2-stroke oil injection system
Oil Type Injection:
High-quality 2-stroke synthetic oil (refer to manual for specific API/JASO grades)
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Clutch Type:
Wet, multi-plate, cable-actuated
Features
Gear Ratios:
Specific ratios detailed in the manual, designed for sporty performance.
Final Drive:
Chain drive, typically 16T front and 48T rear sprockets (stock)
Transmission Oil:
Gear oil (e.g., SAE 80W/90)
📐 Dimensions
Exterior
Length:
Approx. 1990 mm
Width:
Approx. 730 mm (at handlebars)
Height:
Approx. 1145 mm (at seat)
Wheelbase:
Approx. 1375 mm
Weights
Dry Weight:
Approx. 131 kg
Wet Weight:
Approx. 143 kg (with all fluids)
Max Load:
Typically 180-200 kg (rider and passenger combined)
Fuel Tank Capacity:
7.5 Liters (including 1.5 Liter reserve)
🛡️ Safety Features
Ratings
Safety Classification:
Motorcycle safety standards (country-specific)
Active Features
Braking System:
Powerful front and rear disc brakes for reliable stopping power.
Tires:
Sport-oriented tires for good grip and handling.
Passive Features
Frame Design:
Stiff aluminum alloy frame for stable handling characteristics.
Lighting:
Full front and rear lighting system for visibility.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable for this model; basic analog instrumentation.
Instrumentation
Instrument Cluster:
Analog tachometer, speedometer, fuel gauge, coolant temperature warning light, neutral indicator, turn signal indicators, high beam indicator.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Check/top-up 2-stroke oil as needed; gearbox oil change typically every 6,000-10,000 km.
Spark Plug Replacement:
Approx. every 5,000-8,000 km, or as per manual recommendations.
Air Filter Cleaning:
Regular inspection and cleaning/replacement, typically every 3,000-6,000 km.
Chain Maintenance:
Lubricate and adjust chain every 500-1,000 km.
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze coolant (50/50 mix with distilled water)
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Fork Oil Type:
Specific weight and type of fork oil (e.g., SAE 5W or 7.5W, refer to manual for exact specification and fill level).
Known Issues
Common Problems:
Carburetor jetting sensitivity to atmospheric changes, exhaust valve operation (often needs cleaning/adjustment), clutch wear with aggressive use, occasional electrical gremlins (especially after modifications).
2 Stroke Specific Maintenance:
Proper pre-mix ratio or oil injection system functioning is critical. Carbon buildup in the exhaust port and power valve is common and requires periodic cleaning.
📚 Vehicle History
Brand Heritage
Brand Origin:
Aprilia is an Italian motorcycle manufacturer with a strong racing pedigree, founded in 1945.
Model Evolution
Rs125 Lineage:
The RS125 has been a dominant force in the 125cc sportbike category since its introduction, evolving through various iterations with engine and chassis updates.
2006 Model Updates:
The 2006 model typically featured refinements to the engine management, chassis, and styling compared to earlier versions.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Awards And Accolades:
The RS125 line has consistently received positive reviews and accolades for its performance, handling, and track-inspired design within the 125cc segment.
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