Aprilia RS125 RS 125 2006 Factory Service Repair Manual

www.serviceaprilia.com workshopmanual RS 125 1300 6 00/2006-03 8104976 UK

INTRODUCTION 0-1 RS125 INTRODUCTION 0

INTRODUCTION 0 - 2 RS125 SUMMARY 0.1. INTRODUCTION ............................................................................................................................................. 3 0.1.1. FOREWORD .......................................................................................................................................... 3 0.1.2. REFERENCE MANUALS ....................................................................................................................... 4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ..................................................................................... 5

INTRODUCTION 0-3 RS125 0.1. INTRODUCTION 0.1.1. FOREWORD This manual provides the information required for normal servicing. This publication is intended for use by aprilia Dealers and their qualified mechanics; many concepts have been omitted on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been included in this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair procedures. Without such familiarity, repairs and checks could be ineffective and even hazardous. Since the repair and vehicle check instructions are not exhaustive, special care must be taken to avoid damage and injury. Piaggio & C. S.p.A. undertakes to constantly improve the design of its products and the relevant literature to ensure maximum customer satisfaction. The main technical modifications and changes in repair procedures are communicated to all aprilia dealers and agencies worldwide. Such modifications will be entered in subsequent editions of the manual. Should you need assistance or clarifications about the inspection and repair procedures, please contact the aprilia SERVICE DEPT., they will be glad to give you any information on the matter, or supply you with any detail on updates and technical changes applied to the vehicle. Piaggio & C. S.p.A. reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual. All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted, are reserved in all countries. Third parties’ products are only mentioned for information purposes, and constitute no engagement. Piaggio & C. S.p.A. is not liable in any way for the performance or use of these products. First edition: March 2006 Produced and printed by: VALLEY FORGE DECA Ravenna , Modena, Torino DECA s.r.l. Registered Main Office Via Vincenzo Giardini, 11 48022 Lugo (RA) - Italy - Tel. 0545-216611 Fax 0545-216610 www.vftis.com deca@vftis.spx.com on behalf of: Piaggio & C. S.p.A. via G. Galilei, 1 - 30033 Noale (VE) - Italy Tel. +39  (0)41 58 29 111 Fax +39  (0)41 58 29 190 www.aprilia.com www.serviceaprilia.com

INTRODUCTION 0 - 4 RS125 0.1.2. REFERENCE MANUALS SPARE PARTS CATALOGUE aprilia part# (description) 3406 MANUALI ATTREZZI SPECIALI aprilia part# (description) 8202278 CHASSIS WORKSHOP MANUAL aprilia part# (description) 8104972 8104973 8104974 8104975 8104976 8CM0101 ENGINE TECHNICAL MANUAL aprilia part# (description) 8140880 8140883 8140881 8140882 8140884 8CM0027 OWNERS MANUALS aprilia part# (description) Model Year 1993 8102260 Model Year 1994 8102260 8102319 Model Year 1995 8102476 8102530 8102543 Model Year 1996 8102685 8102682 8102530 8102683 8102543 Model Year 1997 8102685 8102682 8102683 8102530 8102543 8102752 8102753 Model Year 1998 8102685 8102682 8102683 8102849 8102934 Model Year 1999 8102821 8102937 8102938 8102939 Model Year 2001 8202248 8102821 8102937 8102938 8102939 Model Year 2002 8104465 8104466 8104467 8104468 Model Year 2006 8104917 8104934 8104935

INTRODUCTION 0-5 RS125 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS # = number < = less than > = greater than ≤ = less than or equal to ≥ = more than or equal to ~ = approximately ∞ = infinity C = degrees Celsius (centigrade) F = degrees Fahrenheit – = plus or minus a.c = alternating current A = Ampere Ah = Ampere per hour API = American Petroleum Institute AT = high voltage AV/DC = Anti-Vibration Double Countershaft bar = pressure measurement unit (1 bar = 100 kPa) d.c. = direct current cc = cubic centimetres CO = carbon monoxide CPU = Central Processing Unit DIN = German industrial standards (Deutsche Industrie Norm) DOHC = Double Overhead Camshaft ECU = Electronic Control Unit rpm = revolutions per minute HC = unburnt hydrocarbons ISC = Idle Speed Control ISO = International Standardisation Organisation kg = kilograms kgm = kilograms per metre (1 kgm = 10 Nm) km = kilometres km/h = kilometres per hour kΩ = kiloOhm kPa = kiloPascal (1 kPa = 0.01 bar) KS = clutch side (from the German "Kupplungsseite") kW = kilowatt ℓ = litres LAP = racetrack lap LED = Light Emitting Diode LEFT SIDE = left side m/s = metres per second max = maximum mbar = millibar (1 mbar = 0.1 kPa) mi = miles MIN = minimum MPH = miles per hour MS = flywheel side (from the German "Magnetoseite") MΩ = MegaOhm N.A. = Not Available N.O.M.M. = Motor Octane Number N.O.R.M. = Research Octane Number Nm = Newton metre (1 Nm = 0.1 kgm) Ω = ohm PICK-UP = pick-up BDC = Bottom Dead Centre TDC = Top Dead Centre PPC = Pneumatic Power Clutch

INTRODUCTION 0 - 6 RS125 RIGHT SIDE = right side SAE = Society of Automotive Engineers TEST = diagnostic check T.B.E.I. = crown-head Allen screw T.C.E.I. = cheese-head Allen screw T.E. = hexagonal head T.P. = flat head screw TSI = Twin Spark Ignition UPSIDE- DOWN = inverted fork V = volt W = watt  = diameter

GENERAL INFORMATION 1-1 RS125 GENERAL INFORMATION 1

GENERAL INFORMATION 1 - 2 RS125 SUMMARY 1.1. GENERAL INFORMATION.............................................................................................................................. 3 1.1.1. CONVENTIONS USED IN THE MANUAL ............................................................................................. 3 1.1.2. SAFETY WARNINGS............................................................................................................................. 4 1.2. GENERAL RULES........................................................................................................................................... 5 1.2.1. BASIC SAFETY RULES......................................................................................................................... 5 1.3. DANGEROUS ELEMENTS ............................................................................................................................. 8 1.3.1. WARNINGS ........................................................................................................................................... 8 1.4. RUNNING-IN ................................................................................................................................................. 12 1.4.1. RUNNING-IN........................................................................................................................................ 12 1.5. VEHICLE IDENTIFICATION .......................................................................................................................... 13 1.5.1. POSITION OF THE SERIAL NUMBERS ............................................................................................. 13

GENERAL INFORMATION 1-3 RS125 1.1. GENERAL INFORMATION 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting the manual. • Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure. • The terms "right" and "left" are referred to the rider seated on the vehicle in the normal riding position. • Motorcycle operation and basic maintenance are covered in the "OWNER’S MANUAL". In this manual any variants are identified with these symbols: optional catalytic version Full Power version - all versions 250 cc version 200 cc version 125 cc version MP national certification SF European certification (EURO 3 limits) VERSION: Italy Greece Malaysia United Kingdom Holland Chile Austria Switzerland Croatia Portugal Denmark Australia Finland Japan United States of America Belgium Singapore Brazil Germany Slovenia South Africa France Israel New Zealand Spain South Korea Canada

Aprilia RS125 RS 125 2006 Factory Service Repair Manual

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