APRILIA Habana 125 Manual Download Page 4

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use and maintenance Habana 50/125 - Habana Custom 50/125

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SAFE DRIVE ..................................................... 5

BASIC SAFETY RULES.................................. 6
CLOTHING ...................................................... 9
ACCESSORIES ............................................ 10
LOAD............................................................. 10

ARRANGEMENT
OF THE MAIN ELEMENTS

.............. 12

ARRANGEMENT
OF THE MAIN ELEMENTS

.............. 14

ARRANGEMENT OF THE CONTROLS /
INSTRUMENTS AND INDICATORS ............... 16

INSTRUMENT AND INDICATOR TABLE ..... 17

MAIN INDEPENDENT
CONTROLS

...................................... 18

CONTROLS ON THE LEFT SIDE
OF THE HANDLEBAR .................................. 18
CONTROLS ON THE RIGHT SIDE
OF THE HANDLEBAR .................................. 19

MAIN INDEPENDENT
CONTROLS

...................................... 20

CONTROLS ON THE LEFT SIDE
OF THE HANDLEBAR .................................. 20
CONTROLS ON THE RIGHT SIDE
OF THE HANDLEBAR .................................. 21
IGNITION SWITCH ....................................... 22
STEERING LOCK ......................................... 22

AUXILIARY EQUIPMENT ............................... 23

UNLOCKING / LOCKING THE SADDLE ...... 23
CRASH HELMET /
GLOVE COMPARTMENT ............................. 23
ANTI-THEFT HOOK ...................................... 23
TOOL KIT ...................................................... 24
BAG HOOK ................................................... 24
GLOVE COMPARTMENT ............................. 24

MAIN COMPONENTS ..................................... 25

FUEL ............................................................. 25
LUBRICANTS................................................ 26
BRAKE FLUID - recommendations ............... 27
FRONT BRAKE DISC ................................... 28
REAR DRUM BRAKE ................................... 29
TYRES .......................................................... 30
AUTOMATIC
LIGHT SWITCHING VERSION

............... 31

CATALYTIC SILENCER

........... 32

EXHAUST SILENCER .................................. 32

INSTRUCTIONS FOR USE ............................. 33

PRELIMINARY
CHECKING OPERATIONS........................... 33
STARTING .................................................... 34
DEPARTURE AND DRIVE............................ 37
RUNNING-IN ................................................. 39
STOPPING.................................................... 40
PARKING ...................................................... 41
POSITIONING THE VEHICLE
ON THE STAND............................................ 42
SUGGESTIONS TO PREVENT THEFT ....... 42

MAINTENANCE .............................................. 43

REGULAR SERVICE
INTERVALS CHART

...................... 44

REGULAR SERVICE
INTERVALS CHART

...................... 46

IDENTIFICATION DATA ............................... 48
CHECKING THE ENGINE OIL LEVEL
AND TOPPING UP

......................... 49

AIR CLEANER

................................ 50

AIR CLEANER

................................ 51

CHECKING THE BRAKE PAD WEAR.......... 52
CHECKING THE SHOE WEAR .................... 53
INSPECTING THE FRONT
AND REAR SUSPENSIONS......................... 53
CHECKING THE STEERING........................ 54
CHECKING
THE ENGINE FULCRUM AXIS..................... 54
REMOVING THE FRONT COVER ............... 55
REMOVING
THE LOWER HANDLEBAR COVER  ........... 56
REMOVING
THE HEADLIGHT METAL RING .................. 56
PARTIAL REMOVAL
OF THE UPPER HANDLEBAR COVER  ...... 57
REMOVING THE REAR-VIEW MIRRORS ... 58
PARTIAL REMOVAL
OF THE DASHBOARD  ................................ 58
REMOVING THE CENTRAL
INSPECTION COVER................................... 59
REMOVING THE RIGHT AND LEFT
INSPECTION COVERS ................................ 59
REMOVING
THE BATTERY COVER

................. 59

CHECHING THE STAND .............................. 60
CHECKING THE SWITCHES ....................... 60
IDLING ADJUSTMENT ................................. 61

ADJUSTING
THE ACCELERATOR CONTROL................. 62
SPARK PLUG ............................................... 62
BATTERY ..................................................... 64
LONG INACTIVITY OF THE BATTERY ....... 64
CHECKING AND CLEANING
THE TERMINALS ......................................... 65
REMOVING THE BATTERY

.......... 65

REMOVING THE BATTERY

.......... 66

CHECKING THE ELECTROLYTE LEVEL .... 66
RECHARGING THE BATTERY .................... 67
INSTALLING THE BATTERY

......... 67

INSTALLING THE BATTERY

......... 67

CHANGING THE FUSES.............................. 68
ADJUSTING
THE VERTICAL HEADLIGHT BEAM ............ 69
BULBS........................................................... 69
CHANGING
THE HEADLIGHT BULBS

...................... 70

CHANGING
THE HEADLIGHT BULBS

...................... 71

CHANGING
THE HEADLIGHT BULBS

...................... 72

CHANGING
THE HEADLIGHT BULBS

...................... 73

CHANGING THE FRONT AND REAR
DIRECTION INDICATOR BULBS ................. 74
CHANGING
THE DASHBOARD BULBS

............ 75

CHANGING THE DASHBOARD BULBS ..... 76
CHANGING THE REAR LIGHT BULB .......... 77
CHANGING
THE NUMBER PLATE BULB

......... 78

TRANSPORT................................................... 78

DRAINING THE FUEL TANK ........................ 79

CLEANING ...................................................... 80

LONG PERIODS OF INACTIVITY ................ 81

TECHNICAL DATA ......................................... 82

LUBRICANT CHART

...................... 86

LUBRICANT CHART

...................... 87

Importers .................................................. 90-91
WIRING DIAGRAM Habana 50..................... 92
WIRING DIAGRAM - Habana 50

...... 94

WIRING DIAGRAM Habana Custom 50 ....... 96
WIRING DIAGRAM Habana 125................... 98
WIRING DIAGRAM Habana Custom 125 ... 100

Summary of Contents for Habana 125

Page 1: ......

Page 2: ...ven death aCAUTION Indicates a potential hazard which may result in minor personal injury or dam age to the vehicle NOTE The word NOTE in this manual precedes important information or instruc tions 4 The operations preceded by this symbol must be repeated also on the opposite side of the vehicle If not expressly indicated otherwise for the reassembly of the units repeat the disas sembly operations...

Page 3: ...ons The user of the vehicle in these countries must contact an aprilia Official Dealer to have the non homologated components re placed with others homologated for use in the country in question carry out the required periodical inspec tions NOTE Soon after purchasing the vehi cle write down the identification data indi cated on the SPARE PARTS IDENTIFICA TION LABEL in the table here below The lab...

Page 4: ...WEAR 52 CHECKING THE SHOE WEAR 53 INSPECTING THE FRONT AND REAR SUSPENSIONS 53 CHECKING THE STEERING 54 CHECKING THE ENGINE FULCRUM AXIS 54 REMOVING THE FRONT COVER 55 REMOVING THE LOWER HANDLEBAR COVER 56 REMOVING THE HEADLIGHT METAL RING 56 PARTIAL REMOVAL OF THE UPPER HANDLEBAR COVER 57 REMOVING THE REAR VIEW MIRRORS 58 PARTIAL REMOVAL OF THE DASHBOARD 58 REMOVING THE CENTRAL INSPECTION COVER 5...

Page 5: ...safe drive ...

Page 6: ...e vehicle by driv ing it first in areas with low traffic and or pri vate areas The use of medicins alcohol and drugs or psychotropic substances notably increases the risk of accidents Be sure that you are in good psychophysi cal conditions and fit for driving and pay particular attention to physical weariness and drowsiness Most road accidents are caused by the driver s lack of experience NEVER le...

Page 7: ...el speeding etc and give due consideration to the road surface visibility and other driv ing conditions Avoid obstacles that could damage the ve hicle or make you lose control Avoid riding in the slipstream created by preceding vehicles in order to increase your speed Always keep both hands on the handlebars and both feet on the footboard or on the footrests in the correct driving posture Avoid st...

Page 8: ...e frame handlebars suspen sions safety parts and all the devices that you cannot check by yourself Always remember to report any malfunc tion to the technicians to help them in their work Never use the vehicle when the amount of damage it has suffered endangers your safety Never change the position inclination or colour of number plate direction indica tors lights and horns Any modification of the...

Page 9: ...al of original components can com promise vehicle performance levels and safety or even make it illegal We recommend respecting all regulations and national and local provisions regarding the equipment of the vehicle In particular avoid all modifications that in crease the vehicle s performance levels or alter its original characteristics Never race with other vehicles Avoid off road driving 4 Bef...

Page 10: ...imes during an emergency Big fairings and windshields installed on the vehicle may produce aerodynamic forc es that affect the stability of the vehicle es pecially when riding at high speed Make sure that the equipment is well fas tened to the vehicle and not dangerous during driving Do not install electrical de vices and do not modify those already ex isting to avoid electrical overloads be cause...

Page 11: ...icle sides because they could hit peo ple or obstacles making you lose control of the vehicle Do not carry any bag if it is not tightly se cured to the vehicle Do not carry bags which protrude too much from the luggage rack or which cover the lights horn or indicators Do not carry animals or children on the glove compartment or on the luggage rack Do not exceed the maximum load allowed for each si...

Page 12: ... w v 9 1 Left rear view mirror w not provided in the U version 2 Left inspection cover 3 Central inspection cover 4 Glove compartment 5 Battery 6 Fuse carrier 7 Passenger grab rail 8 Saddle lock 9 Air cleaner 10 Kick starter 11 Centre stand 12 Side stand 13 Spark plug ...

Page 13: ...troke oil tank plug 3 Fuel tank plug 4 Ignition switch steering lock 5 Bag hook 6 Right inspection cover 7 Right rear view mirror w in the countries where required 8 Brake fluid reservoir front brake 9 Horn 10 Fuel tank 11 Anti theft hook for the aprilia Body Guard armored cable 12 2 stroke oil tank ...

Page 14: ...9 1 Left rear view mirror 2 Glove compartment 3 Left inspection cover 4 Central inspection cover 5 Passenger left footrest 6 Air cleaner 7 Passenger grab rail 8 Saddle lock 9 Kick starter 10 Centre stand 11 Engine oil filler cap 12 Engine oil level sight glass 13 Side stand ...

Page 15: ... 2 Right inspection cover 3 Fuel tank plug 4 Ignition switch steering lock 5 Bag hook 6 Fuse carrier 7 Right rear view mirror 8 Brake fluid reservoir front brake 9 Horn 10 Fuel tank 11 Anti theft hook for the aprilia Body Guard armored cable 12 Spark plug 13 Passenger right footrest 14 Battery ...

Page 16: ...controls on the right side of the handlebar 7 Ignition switch steering lock n m s 8 Speedometer 8 Speedometer km h scale only 9 Total kilometres odometer 10 Green low beam and parking light warning light p 11 Blue high beam warning light a 12 Fuel level indicator g 13 Green direction indicator warning light c 14 Amber low fuel warning light g 15 w v Red 2 stroke oil reserve warning light j 15 x u ...

Page 17: ...mes on every time the ignition switch is brought to position n and the engine is not running thus testing the correct operation of the bulb If during this phase the lamp does not turn on it must be replaced The warning light must go off when the engine is running If the warning light comes on during the normal running of the engine this means that the oil pres sure in the circuit is insufficient I...

Page 18: ...tion o if the dimmer switch is in position a the high beam comes on while if it is in po sition b the low beam comes on 2 DIMMER SWITCH a b _ When it is in position b the parking lights the dashboard light and the low beam are always on When it is in position a the high beam comes on NOTE The lights can be switched off only by stopping the engine 3 DIRECTION INDICATOR SWITCH c To indicate the turn...

Page 19: ...ow beam are on The high beam can be operated by means of the dimmer switch a b 1a ENGINE STOP SWITCH n m in the countries where required aCAUTION Do not operate the engine stop switch n m in running conditions This is a safety or emergency switch With the switch in po sition n it is possible to start the engine the engine can be stopped by moving the switch to position m aCAUTION With stopped engi...

Page 20: ...osition A a independently of the position of the light switch o p NOTE When the dimmer switch is released the high beam signaller is disconnected 2 DIMMER SWITCH a b a _ J When it is in position b the parking lights the dashboard light and the low beam are always on When it is in position a the high beam comes on The high beam signaller is operated by pressing the dimmer switch a b a to position A...

Page 21: ...rd light and the low beam are on The high beam can be operated by means of the dimmer switch a b a 2 ENGINE STOP SWITCH n m aCAUTION Do not operate the engine stop switch n m in running conditions This is a safety or emergency switch With the switch in po sition n it is possible to start the engine the engine can be stopped by moving the switch to position m aCAUTION With stopped engine and igniti...

Page 22: ...position s in running conditions in order to avoid losing control of the vehicle OPERATION To lock the steering Turn the handlebar completely leftwards Turn the key to position m Press the key and rotate it to position s Extract the key Position Function Key removal s Steering lock The steering is locked It is neither possible to start the en gine nor to switch on the lights It is possible to remo...

Page 23: ...r have to carry the crash helmet or other objects with you eve ry time you park the vehicle The compartment is positioned under the saddle and can contain a JET helmet To reach it Raise the saddle 2 see beside UN LOCKING LOCKING THE SADDLE NOTE Position the helmet with the opening facing downwards as indicated in the figure aWARNING Do not load the crash helmet glove compartment too much Maximum a...

Page 24: ...e n 1 3 mm hexagon spanner n 1 4 mm hexagon spanner aWARNING Do not hang excessively bulky bags or parcels to the hook as this may seri ously compromise the manoeuvrability of the vehicle or the movement of your feet The bag hook 2 is positioned under the front part of the saddle Max allowed weight 1 5 kg 6 0 24 4 It is placed under the handlebar on the in ner part of the shield To reach it Introd...

Page 25: ... petrol expands under the heat of the sun and due to the effects of sun ra diation never fill the tank to the brim Screw the cap carefully after refuelling Avoid any contact of the fuel with the skin and the inhalation of vapours do not swallow fuel or pour it from a recep tacle into another by means of a tube DO NOT DISPOSE OF FUEL IN THE EN VIRONMENT KEEP AWAY FROM CHILDREN w v Use only premium ...

Page 26: ... for the lubrication of the engine see p 86 LUBRIFICANT CHART w v The reserve is indicated by the coming on of the 2 stroke oil reserve warning light j positioned on the dashboard see p 16 and 17 ARRANGEMENT OF THE CONTROLS INSTRUMENTS AND INDI CATORS aCAUTION The use of the vehicle without 2 stroke oil causes serious damages to the en gine If you run out of oil in the 2 stroke oil tank or if the ...

Page 27: ... mi x u Have the transmission oil level checked every 12000 km 7500 mi It is necessary to have the transmission oil changed after the first 1000 km 625 mi and successively every 24000 km 15000 mi To check the oil level and to change the oil contact an aprilia Official Dealer 2 5 RECOMMENDATIONS aWARNING Sudden resistance or clearance prob lems on the brake lever may be due to troubles in the hydra...

Page 28: ...uid level in the res ervoir 1 and the pad wear see p 52 CHECKING THE BRAKE PAD WEAR aWARNING Do not use the vehicle if the braking system leaks fluid CHECKING To check the brake fluid level proceed as follows NOTE Position the vehicle on firm and flat ground Position the vehicle on the centre stand Rotate the handlebar so that the fluid contained in the brake reservoir is paral lel to the MIN mark...

Page 29: ...ust be about 10 mm To adjust the clearance proceed as fol lows Force the spring 1 to reach the seat 2 of the threaded rod Lock the rotation of the threaded rod by acting on the appropriate seat 2 with a spanner Act on the adjuster 3 Put on the brake repeatedly and make sure that the wheel turns freely after the brake has been released Check the braking efficiency aCAUTION w v The fact that the adj...

Page 30: ...braking the tyres could even get out of the rims Further the vehicle could skid while turning Check the surface and the wear of the tyres since tyres in bad conditions can impair both the grip and the controlla bility of the vehicle Some types of tyres homologated for this vehicle are provided with wear indi cators There are several kinds of wear indica tors For more information on how to check th...

Page 31: ... or by a qualified tyre repairer If the tyres are new they may still be covered with a slippery film drive care fully for the first miles Do not oil the tyres with unsuitable fluids MINIMUM TREAD DEPTH LIMIT 3 front 1 5 mm 3 mm rear 1 5 mm 3 mm 54 4 4 37 4 6 23 _ The vehicles provided with the Automatic Switch on Device can be immediately rec ognized since the lights come automatical ly on as soon...

Page 32: ...ods in which the engine runs at rel atively high rpm even if only for a few sec onds but rather frequently What has been stated above assumes par ticular importance for the cold starting of the engine in this case in order to reach a rpm regime sufficient to enable the prim ing of the catalytic reaction just make sure that the temperature of the thermal unit has reached at least 50 C which gen era...

Page 33: ...erator Make sure that it works smoothly and that it is possible to open and close it completely in all steering positions If necessary adjust and or lubricate it 62 w v 2 stroke oil Check and top up if necessary 26 x u engine oil Check and top up if necessary 27 49 Wheel tyres Check the tyre surface the inflation pressure wear and tear and any damage 30 Brake levers Make sure that they work smooth...

Page 34: ... re mains on until the engine starts Lock at least one wheel by pulling a brake lever 5 If this operation is not carried out the start relay receives no current and there fore the engine does not start NOTE After a long period of inactivity carry out the operations described at see p 36 STARTING AFTER A LONG PERI OD OF INACTIVITY NOTE To avoid the excessive wear of the battery do not keep the star...

Page 35: ...icle with insufficient engine oil in order to avoid damaging the engine components Do not accelerate and pull the brake le vers at the same time until you move off To leave see p 37 DEPARTURE AND DRIVE KICK START For the kick start proceed as follows Position the vehicle on the centre stand Move to the left side of the vehicle Make sure that the light switch 1 is in position Make sure that the dim...

Page 36: ...starts Release the throttle grip 7 If the idling is unstable twist the throttle grip 7 slightly and frequently If the engine does not start Wait a few seconds and repeat the START ING WITH COLD ENGINE procedure If necessary remove the spark plug see p 62 SPARK PLUG and make sure that it is not wet If the spark plug is wet clean and dry it Before reinstalling it NOTE Put a clean cloth on the cylind...

Page 37: ...sts are folded While riding keep your hands on the grips and your feet on the footrests NEVER RIDE IN ANY POSITION OTHER THAN THOSE INDICATED If you drive with a passenger instruct him her so that he she does not create problems during manouvres Before leaving make sure that the stand stands is are completely up To leave Release the throttle grip Pos A put on the rear brake then move the vehicle d...

Page 38: ... use of the engine to keep the vehi cle at a halt may cause the overheating of the speed variator Before beginning to turn slow down or brake driving at moderate and constant speed or accelerating slightly avoid braking at the last moment it would be very easy to skid If the brakes are operated continuously on downhill stretches the friction mate rial may overheat thus reducing the braking efficie...

Page 39: ...ee p 26 w v 2 STROKE OIL 25 aWARNING w v After the first 500 km 312 mi carry out the checking operations indi cated in the column After running in of the REGULAR SERVICE INTERVALS CHART w v see p 44 in order to avoid hurting yourself or other people and or damaging the vehicle aWARNING x u After the first 1000 km 625 mi carry out the checking operations indi cated in the column After running in of...

Page 40: ... and after the running in 0 100 km 0 62 mi During the first 100 km 62 mi put on the brakes with caution and avoid sharp and prolonged brakings This ensures the cor rect bedding in of the friction material of the pads on the brake disc and of the shoes on the rear wheel drum 0 300 km 0 187 mi Do not keep the throttle grip open more than one half for long stretches 500 1000 km 312 625 mi During the ...

Page 41: ... not sit on the vehicle when the stand is down Stop the vehicle see p 40 STOPPING Move the engine stop switch 1 to posi tion m for the countries where re quired aCAUTION With stopped engine and ignition switch in position n the battery may run down Rotate the key 2 and move the ignition switch 3 to position m Position the vehicle on the stand see p 42 POSITIONING THE VEHICLE ON THE STAND NOTE It i...

Page 42: ... ground Steer the handlebar completely left wards aWARNING Make sure that the vehicle is stable 35 34 3 4 02 6 4 4 4 NEVER leave the ignition key inserted and always use the steering lock Park the vehicle in a safe place possibly in a garage or a protected place If possible use the appropriate aprilia Body Guard armored cable or an ad ditional anti theft device Make sure that all documents are in ...

Page 43: ...ts of the vehicle with your mouth the components are not edible and some of them are noxious or even toxic aCAUTION If not expressly indicated otherwise for the reassembly of the units repeat the disassembly operations in reverse or der In case any maintenance operation has to be carried out it is advisable to use latex gloves Normally the routine maintenance opera tions can be performed by the us...

Page 44: ...se the vehi cle in rainy and dusty areas or on uneven ground Component After running in 500 km 312 mi Every 4000 km 2500 mi or 12 months Every 8000 km 5000 mi or 24 months Battery Terminal fastening Electrolyte level Spark plug Carburettor idling Air cleaner Accelerator operation Brake locking operation Light systems Stop light switches Brake fluid 2 stroke oil every 500 km 312 mi Headlight beam d...

Page 45: ...be bearings and steering slack Wheel bearings Brake discs Piston rings every 12000 km 7500 mi General running of the vehicle Braking systems brake discs Electric start transmission pin greasing Rear brake cam pin greasing Brake fluid every 2 years Exhaust silencer exhaust terminal Mixer accelerator operation Transmission oil every 12000 km 7500 mi Rear pulley pins every 12000 km 7500 mi Front shoc...

Page 46: ... vehi cle in rainy and dusty areas or on uneven ground Component After run ning in 1000 km 625 mi Every 6000 km 3750 mi or 12 months Every 12000 km 7500 mi or 24 months Battery Terminal fastening Spark plug Carburettor idling Air cleaner Accelerator operation Brake locking operation Light systems Stop light switches Brake fluid Engine oil at every start Headlight beam direction operation Spark plu...

Page 47: ...n cables and controls Variator belt Steering tube bearings and steering slack Wheel bearings Brake discs Engine oil filter every 3000 km 1875 mi General running of the vehicle Valve clearance every 18000 km 11250 mi Speed change gear grease Braking systems Brake fluid every 2 years Exhaust silencer exhaust terminal Engine oil every 3000 km 1875 mi Transmission oil every 12000 km 7500 mi every 2400...

Page 48: ...evere penal and administrative sanctions In par ticular the alteration of the frame number results in the immediate invalidity of the guarantee FRAME NUMBER The frame number is stamped on the cen tral tube of the frame To be able to read it it is necessary to remove the cover 1 NOTE The cover 1 can be inserted in one direction only The part provided with the two tangs 2 is the lower part Frame no ...

Page 49: ...il level Check the oil level through the appropri ate sight glass 1 MAX maximum level MIN minimum level The difference between MAX and MIN is about 300 cm The level is correct when the oil almost reaches the MAX mark aCAUTION Never exceed the MAX mark nor leave the oil below the MIN mark in order to avoid serious damage to the engine If necessary provide for topping up TOPPING UP Unscrew and remov...

Page 50: ...to remove it from the vehicle REMOVAL Position the vehicle on the centre stand Unscrew and remove the four screws 1 Rotate the start pedal 2 completely and keep it down Withdraw the complete filter 3 from be low and remove it CLEANING Separate the grid 4 from the support 5 Remove the filtering element 6 aWARNING Do not use petrol or inflammable sol vents to wash the filtering element in order to a...

Page 51: ...VAL Position the vehicle on the centre stand Unscrew and remove the four screws 1 aCAUTION Pay attention to the correct position of the lower cover 2 and the filtering ele ment 4 in such a way as to be able to reposition them correctly Withdraw the lower cover 2 from below and take the gasket 3 Withdraw the filtering element 4 CLEANING aWARNING Do not use petrol or inflammable sol vents to wash th...

Page 52: ...ly before every trip To carry out a rapid checking of the wear of the front pads proceed as follows Position the vehicle on the centre stand Remove the brake caliper cover 1 Carry out a visual check between brake disc and pads aWARNING The excessive wear of the friction mate rial would cause the contact of the pad metal support with the disc with conse quent metallic noise and production of sparks...

Page 53: ...ar brake shoe wear indicator 3 aWARNING If the rear brake shoe wear indicator 3 is positioned on or beyond the lower reference tooth 5 contact an APRILIA Official Dealer who will provide for re placing the rear brake shoes 30 4 4 2 4 2 2 3530 3 3 Carefully read p 43 MAINTENANCE Check the tightening of all the components and the functionality of the articulations of the front and rear suspensions a...

Page 54: ...ection of travel NOTE Do not shake the fork excesively otherwise you may take in consideration the movement of the stand thus observing an incorrect slack Repeat the previous operation more than once If you find that there is a considerable slack contact your aprilia Official Dealer to restore the optimal steering condi tions 4 5 25 8 3 Carefully read p 43 MAINTENANCE Periodically check the slack ...

Page 55: ... and or their seats Handle the plastic and painted compo nents with care and avoid scraping or damaging them Release the couplings 3 and 4 from their seats and remove the two collars 5 and 6 Unscrew and remove the two lower screws 7 v u Remove the grille 8 Unscrew and remove the upper screw 9 taking the washer NOTE To release the front cover 10 from the side couplings carry out the fol lowing oper...

Page 56: ...and painted compo nents with care and avoid scraping or damaging them Move the lower handlebar cover 6 carefully downwards Unscrew and remove the screw 7 aCAUTION Proceed with care Do not force the electric wires Partially remove the reflector 8 releas ing the seat 9 from the pin 10 NOTE Upon reassembly make sure that the reflector 8 the seat 9 and the pin 10 are in the correct position 2 6 4 4 4 ...

Page 57: ... COVER w x Remove the rear view mirrors see p 58 REMOVING THE REAR VIEW MIR RORS Raise the rubber ring 1 releasing it from the odometer control coupling 2 aCAUTION Proceed with care Do not damage the tangs and or their seats Release the odometer control coupling 2 from its seat on the dashboard by means of a spanner aCAUTION The upper handlebar cover 3 com plete with switches instruments and in di...

Page 58: ...p 43 MAINTENANCE Unscrew and remove the three nuts 5 aCAUTION Proceed with care Do not force the electric wires Handle the plastic and painted compo nents with care and avoid scraping or damaging them Partially remove the dashboard 6 At this point proceed as follows to reach the dashboard bulbs Unscrew and remove the two screws 7 Remove the upper cover 8 Remove the glass element 9 with its support...

Page 59: ...ic and painted compo nents with care and avoid scraping or damaging them Lift the saddle see p 23 UNLOCKING LOCKING THE SADDLE Unscrew and remove the upper screw 3 Unscrew and remove the side screw 4 Remove the side inspection cover 5 NOTE Upon reassemby correctly fit the seats in the appropriate tangs 2 6 4 44 29 6 2 w v NOTE Position the vehicle on firm and flat ground Position the vehicle on th...

Page 60: ...t rotate freely if neces sary grease the joint see p 86 LUBRI CANT CHART w v or p 87 LU BRICANT CHART x u 4 37 4 3 Carefully read p 43 MAINTENANCE The vehicle is provided with two switches Stoplight switch on the rear brake con trol lever 3 Stoplight switch on the front brake con trol lever 4 To reach the switches proceed as follows w x Partially remove the upper han dlebar cover see p 57 PARTIAL ...

Page 61: ...spark plug cable aWARNING Before proceeding make sure that the room in which you are working is prop erly ventilated Start the engine The minimum speed of the engine idling must be about 1600 200 rpm in this case the engine does not make the rear wheel rotate If necessary Remove the left inspection cover see p 59 REMOVING THE RIGHT AND LEFT INSPECTION COVERS w v Act on the adjusting screw 1 positi...

Page 62: ...ndlebar does not mod ify the engine idling rpm and that the throttle grip returns smoothly and auto matically to its original position after being released 30 2 0 5 Carefully read p 43 MAINTENANCE w v Check the spark plug after the first 500 km 312 mi successively every 4000 km 2500 mi change it every 8000 km 5000 mi x u Check the spark plug after the first 1000 km 625 mi successively every 6000 k...

Page 63: ... has crackings on the in sulating material corroded electrodes or excessive deposits it must be changed Check the spark plug gap with a thick ness gauge The gap must be w v 0 6 0 7 mm x u 0 7 0 8 mm if necessary adjust it carefully bending the earth electrode Make sure that the washer is in good conditions With the washer on screw the spark plug by hand in order not to damage the thread Tighten th...

Page 64: ... milk of magnesia or vegetable oil and consult a doctor with out delay The battery gives off explosive gases keep it away from flames sparks ciga rettes and any other source of heat During the recharging or the use make sure that the room is properly ventilated and avoid inhaling the gases released during the recharging KEEP AWAY FROM CHILDREN Do not incline the vehicle too much in order to avoid ...

Page 65: ...on Reconnect first the positive red and then the negative cable Cover the terminals with special grease or Vaseline After these operations w v Put back the battery cover see p 59 REMOVING THE BATTERY COVER w v x u Put back the battery see p 67 INSTALLING THE BATTERY x u 2 6 4 44 29 w v Carefully read p 64 BATTERY Remove the battery cover see p 59 REMOVING THE BATTERY COVER w v Make sure that the i...

Page 66: ...withdrawing it from behind COMPLETE REMOVAL Disconnect first the negative cable and then the positive cable red Position the battery 2 on a flat surface in a cool and dry place aWARNING After removal the battery must be stored in a safe place and kept away from children 4 42 94 6 w v Carefully read p 64 BATTERY Remove the battery from its compart ment see beside REMOVING THE BATTERY w v Make sure ...

Page 67: ...e recharger since the battery continues to produce gas for a short lapse of time 34 4 44 29 w v Carefully read p 64 BATTERY Remove the battery cover see see p 59 REMOVING THE BATTERY COVER w v Put the battery in its container Connect the breather pipe aCAUTION Always connect the battery breather pipe to prevent the sulphuric acid va pours from corroding the electric sys tem painted parts rubber el...

Page 68: ...on cover see p 59 REMOVING THE RIGHT AND LEFT INSPECTION COV ERS Extract the fuses one by one and check if the filament is broken Before replacing a fuse try to find out the cause of the trouble if possible Then replace the damaged fuse with a new one having the same amperage NOTE If you use one of the spare fuses put a new fuse in the appropriate seat w v Put back the battery cover see p 59 REMOV...

Page 69: ...follows Loosen the nut 2 Adjust the inclination of the headlight 3 Tighten the nut 2 Make sure that the nut 2 is tightened correctly Make sure that the headlight 3 is direct ed correctly 5 3 Carefully read p 43 MAINTENANCE aWARNING Risk of fire Keep fuel and other flammable sub stances away from the electrical com ponents aCAUTION Before changing a bulb position the ve hicle on the centre stand mo...

Page 70: ...eed as fol lows PARKING LIGHT BULB aCAUTION Do not pull the electric cables to extract the bulb socket Grasp the parking light bulb socket 4 pull it and remove it from its seat Withdraw the parking light bulb 1 and replace it with a new one of the same type LOW HIGH BEAM BULB Rotate the bulb socket 5 anticlockwise and extract it Press the bulb 2 moderately and rotate it anticlockwise Extract the b...

Page 71: ...t the bulb socket Grasp the parking light bulb socket 4 pull it and remove it from its seat Withdraw the parking light bulb 1 and re place it with a new one of the same type LOW HIGH BEAM BULB HALOGEN aCAUTION To extract the bulb electric connector do not pull its electric wires Grasp the bulb electric connector 5 pull it and disconnect it from the bulb 6 Release the clip 7 that holds the bulb 6 E...

Page 72: ... To change the bulbs proceed as follows PARKING LIGHT BULB aCAUTION Do not pull the electric cables to extract the bulb socket Grasp the parking light bulb socket 4 pull it and remove it from its seat Withdraw the parking light bulb 1 and re place it with a new one of the same type LOW HIGH BEAM BULB Rotate the bulb socket 5 anticlockwise and extract it Press the bulb 2 moderately and rotate it an...

Page 73: ...e electric cables to extract the bulb socket Grasp the parking light bulb socket 4 pull it and remove it from its seat Withdraw the parking light bulb 1 and re place it with a new one of the same type LOW HIGH BEAM BULB HALOGEN aCAUTION To extract the bulb electric connector do not pull its electric wires Grasp the bulb electric connector 5 pull it and disconnect it from the bulb 6 Release the cli...

Page 74: ...he transparent colourless type Unscrew and remove the screw 6 NOTE When removing the coloured screen proceed with care in order not to break the tang Rotate the coloured screen 5 towards the inside until releasing the tang 7 then remove it NOTE Upon reassembly correctly insert the tang 7 in the appropriate seat Press the bulb 8 slightly and rotate it anticlockwise Extract the bulb from its seat NO...

Page 75: ...lace it with one of the same type DASHBOARD LIGHTING BULBS NOTE To change the two bulbs of the upper part of the dashboard it is sufficient to remove the lower handlebar cover Remove the lower handlebar cover see p 56 REMOVING THE LOWER HAN DLEBAR COVER w x NOTE Extract the bulb sockets one by one in such a way as to avoid positioning them incorrectly during the reassembly Extract the bulb socket ...

Page 76: ...ly during the reassembly Extract the relative bulb socket Extract the bulb and replace it with one of the same type DASHBOARD LIGHTING BULBS NOTE Extract the bulb sockets one by one in such a way as to avoid positioning them incorrectly during the reassembly Extract the bulb socket of the dashboard part in which there has been a light de crease Extract the bulb and replace it with one of the same ...

Page 77: ...The lower part has shaped profile aCAUTION Upon reassembly tighten the two screws 1 moderately and carefully to avoid damaging the protection screen Press the bulb 3 slightly and rotate it anticlockwise Extract the bulb from its seat NOTE Insert the bulb in the bulb socket making the two bulb pins coincide with the relevant guides on the socket Correctly install a new bulb of the same type w v NOT...

Page 78: ... Correctly install a new bulb of the same type aCAUTION Upon reassembly position the electric cable correctly in the appropriate grooved seat on the right side of the light unit 2 42 30 24 aWARNING Before transporting the vehicle it is necessary to empty the fuel tank and the carburettor completely see p 79 DRAINING THE FUEL TANK making sure that both are completely dry During transport the vehicl...

Page 79: ...e tank and put it on the ground on the left side of the vehicle Remove the fillercap Empty the fuel tank by means of a manu al pump or a similar system aWARNING After draining the tank put back the fill er cap in the correct position Put back the filler cap To drain the carburettor completely proceed as follows Remove the left inspection cover see p 59 REMOVING THE RIGHT AND LEFT INSPECTION COVERS...

Page 80: ...the painted surfaces use a low pressure water jet carefully wet the dirty parts remove mud and filth with a soft car sponge impregnat ed with a lot of water and shampoo 2 4 parts of shampoo in water Then rinse with plenty of water and dry with chamois leather To clean the outer parts of the engine use a degreaser brushes and wipers aCAUTION Polish with silicone wax only after hav ing carefully was...

Page 81: ...ATTERY w v and p 66 REMOVING THE BATTERY x u Wash and dry the vehicle see p 80 CLEANING Polish the painted surfaces with wax Inflate the tyres see p 30 TYRES By means of a suitable support position the vehicle so that both tyres are raised from the ground Place the vehicle in an unheated not hu mid room away from sunlight with mini mum temperature variations Position and tie a plastic bag on the f...

Page 82: ... 140 mm 85 mm Weight ready for starting 97 kg 115 kg ENGINE Model M222 Type 2 stroke with controlled ignition 4 stroke with controlled ignition Number of valves 2 Number of cylinders horizontal one cylinder Total displacement 49 38 cm 124 0 cm Bore stroke 41 0 mm 37 4 mm 57 0 mm 48 6 mm Compression ratio 11 3 0 5 1 10 8 0 5 1 Starting electric kick starter Clutch centrifugal Change gear automatic ...

Page 83: ...2 stroke oil reserve 0 4L Engine oil engine oil change only Ò 850 cm Seats 1 2 in the countries where this is allowed n 2 Vehicle max load driver luggage 105 kg 105 kg Vehicle max load driver passenger luggage 180 kg in the countries where this is allowed 180 kg CARBURETTOR Model KEIHIN PWS 12 MIKUNI BS 24 Choke tube Ø12 mm Ø22 mm FUEL SUPPLY Fuel Premium grade petrol 4 Stars U according to the DI...

Page 84: ...r drum brake Ø120 mm with mechanic transmission drum brake Ø140 mm with mechanic transmission WHEELS Type alloy Front 3 00 x 12 Rear 3 50 x 10 TYRES Type tubeless Front 120 70 12 51J 120 70 12 51P Rear 130 70 10 59J 130 70 10 59P STANDARD INFLATION PRESSURE Front 170 kPa 1 7 bar Rear 190 kPa 1 9 bar INFLATION PRESSURE WITH PASSENGER w v where drive with passenger is allowed Front 190 kPa 1 9 bar 1...

Page 85: ...t 12 V 115 W 12 V 100 W BULBS Low high beam 12 V 35 35 W Low high beam halogen 12 V 55 60 W H4 Front parking light 12 V 5 W 12 V 3 W Direction indicators 12 V 10 W Rear parking light stoplight number plate light 12 V 5 21 W Rear parking light stoplight 12 V 5 21 W Number plate light 12 V 3 W Dashboard light 12 V 2 W 12 V 1 2 W 12 V 1 2 W WARNING LIGHTS Low beam and parking light 12 V 1 2 W High be...

Page 86: ... and FORK 20W these can be mixed as indicated below SAE 10W 0F A 5W 67 of the volume 0F A 20W 33 of the volume or FORK 5W 67 of the volume FORK 20W 33 of the volume SAE 15W 0F A 5W 33 of the volume 0F A 20W 67 of the volume or FORK 5W 33 of the volume FORK 20W 67 of the volume Bearings and other lubrication points recommended 0AUTOGREASE MP or GREASE 30 As an alternative to the recommended product...

Page 87: ... with intermediate characteristics in comparison with the 0 F A 5W and 0 F A 20W or FORK 5W and FORK 20W these can be mixed as indicated below AE 10W 0F A 5W 67 of the volume 0F A 20W 33 of the volume or FORK 5W 67 of the volume FORK 20W 33 of the volume AE 15W 0F A 5W 33 of the volume 0F A 20W 67 of the volume or FORK 5W 33 of the volume FORK 20W 67 of the volume earings and other lubrication poi...

Page 88: ...88 4 3 2 5 30 2 0 243 9 use and maintenance Habana 50 125 Habana Custom 50 125 ...

Page 89: ...89 4 3 2 5 30 2 0 243 9 use and maintenance Habana 50 125 Habana Custom 50 125 ...

Page 90: ...90 use and maintenance Habana 50 125 Habana Custom 50 125 MPORTERS ...

Page 91: ...91 use and maintenance Habana 50 125 Habana Custom 50 125 MPORTERS ...

Page 92: ...92 use and maintenance Habana 50 125 Habana Custom 50 125 7 2 2 ABANA ...

Page 93: ...on 22 Blinking 23 Dashboard 24 Direction indicator warning light 25 2 stroke oil reserve warning light 26 Dashboard light 27 Fuel level instrument 28 Low fuel warning light 29 High beam warning light 30 Front parking light 31 Front right direction indicator 32 Front left direction indicator 33 Front light 34 Low high beam bulb 35 Horn 36 Pick up 37 Fuses 38 Multiple connectors 39 Rear parking ligh...

Page 94: ...94 use and maintenance Habana 50 125 Habana Custom 50 125 7 2 2 ABANA J ...

Page 95: ...ng 23 Dashboard 24 Direction indicator warning light 25 2 stroke oil reserve warning light 26 Dashboard light 27 Fuel level instrument 28 Low fuel warning light 29 High beam warning light 30 Front parking light 31 Front right direction indicator 32 Front left direction indicator 33 Front light 34 Low high beam bulb 35 Horn 36 Pick up 37 Fuses 38 Multiple connectors 39 Rear parking light stoplight ...

Page 96: ...96 use and maintenance Habana 50 125 Habana Custom 50 125 7 2 2 ABANA USTOM ...

Page 97: ...rol diode 21 Anti theft device installation point 22 Blinking 23 Dashboard 24 Direction indicator warning light 25 2 stroke oil reserve warning light 26 Dashboard light 27 Fuel level instrument 28 Low fuel warning light 29 High beam warning light 30 Front parking light 31 Front right direction indicator 32 Front left direction indicator 33 Front light 34 Low high beam bulb 35 Horn 36 Pick up 37 Fu...

Page 98: ...98 use and maintenance Habana 50 125 Habana Custom 50 125 7 2 2 ABANA ...

Page 99: ...sh button 22 Automatic starter 23 Dashboard 24 Direction indicator warning light 25 Engine oil pressure warning light 26 Dashboard light 27 Fuel level instrument 28 Low fuel warning light 29 High beam warning light 30 Front parking light 31 Front right direction indicator 32 Front left direction indicator 33 Front light 34 Low high beam bulb 35 Horn 36 Pick up 37 Fuses 38 Multiple connectors 39 Re...

Page 100: ...100 use and maintenance Habana 50 125 Habana Custom 50 125 7 2 2 ABANA USTOM ...

Page 101: ...control device 21 Anti theft device installation point 22 Automatic starter 23 Dashboard 24 Direction indicator warning light 25 Engine oil pressure warning light 26 Dashboard light 27 Fuel level instrument 28 Low fuel warning light 29 High beam warning light 30 Front parking light 31 Front right direction indicator 32 Front left direction indicator 33 Front light 34 Low high beam bulb 35 Horn 36 ...

Page 102: ...102 4 3 2 5 30 2 0 243 9 use and maintenance Habana 50 125 Habana Custom 50 125 ...

Page 103: ...103 4 3 2 5 30 2 0 243 9 use and maintenance Habana 50 125 Habana Custom 50 125 ...

Page 104: ... 125 aprilia s p a wishes to thank its customers for the purchase of this vehicle Do not dispose of oil fuel polluting substances and components in the envi ronment Do not keep the engine running if it isn t necessary Avoid disturbing noises Respect nature ...

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Summary of Contents for Habana 125

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APRILIA Habana 125, Manual, Page: 4 / 104

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Summary of Contents for Habana 125

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