APRILIA SR 125 - 1999 Manual Download

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use and maintenance

SR 50 - SR 125 - SR 150

OPERATIONS TO BE CARRIED OUT BY
THE

APRILIA

Official Dealer.

Key

= check and clean, adjust, lubricate or

change, if necessary;

= clean;

= change;

= adjust.

NOTE

Carry out the maintenance opera-

tions more frequently if you use the vehicle
in rainy and dusty areas or on uneven
ground.

Component

After running-in

[1000 km (625 mi)]

Every 4000 km

(2500 mi) or 12

months

Every 8000 km

(5000 mi) or 24

months

Rear shock absorber

–

Transmission cables and controls

–

Cylinder/Piston

every 12000 km (7500 mi):

Mixer belt

every 30000 km (18750 mi):

Speed change gear belt and roller
shoes

every 12000 km (7500 mi):

Steering tube bearings and steering
slack

–

Wheel bearings

–

Brake discs

–

Piston rings

every 12000 km (7500 mi):

General running of the vehicle

–

Braking systems

–

Cylinder cooling system

every 20000 km (12500 mi):

(outside cleaning)

Gas cable splitter greasing

every 12000 km (7500 mi):

Brake fluid

every 2 years:

Mixer/accelerator operation

–

Fork oil and oil seal

every 12000 km (7500 mi):

Transmission oil

every 12000 km

(7500 mi):

Wheels/tyres and inflation pressure

–

Nut, bolt, screw tightening

–

2 stroke oil reserve warning light

–

Fuel pipe

–

every 4 years:

Braking system pipe

–

every 4 years:

Mixer oil pipe

every 4 years:

Clutch wear

–

Rear brake shoe wear

every 2000 km (1250 mi):

Summary of Contents for SR 125 - 1999

Page 1: ......

Page 2: ...r 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 in reverse order The terms right and left are referred to the rider sea...

Page 3: ...he 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 label is...

Page 4: ...HECKING THE SHOE WEAR 51 CHECKING THE STEERING 52 CHECKING THE ENGINE FULCRUM AXIS 52 REMOVING THE COVER SUPPORT ELEMENT 53 REMOVING THE FRONT COVER 53 REMOVING THE LOWER HANDLEBAR COVER 54 PARTIAL REMOVAL OF THE UPPER HANDLEBAR COVER 54 REMOVING THE RIGHT AND LEFT INSPECTION COVERS 55 INSTALLING THE REAR MUDGUARD EXTENSION 56 REMOVING THE NUMBER PLATE SUPPORT 56 INSTALLING THE REAR MUDGUARD EXTEN...

Page 5: ...safe drive ...

Page 6: ...le 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 lend the ...

Page 7: ...ing 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 standing u...

Page 8: ...lebars 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 vehicle wil...

Page 9: ...iginal 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 Before star...

Page 10: ...ring 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 the ve...

Page 11: ...es 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 side bag W...

Page 12: ...ntenance SR 50 SR 125 SR 150 22 4 4 43 9 1 Coolant expansion tank plug 1 2 Bag hook 3 Battery tool kit compartment cover 4 Fuel tank 5 Fuel tank plug 6 Saddle lock 7 Kick starter 8 Air cleaner 9 Left inspection cover ...

Page 13: ...SR 150 9 1 2 stroke oil tank plug 2 2 stroke oil tank 3 Ignition switch steering lock 4 Right inspection cover 5 Fuse carrier 6 Horn 7 Battery 8 Lower shield cover 9 Anti theft hook for the aprilia Body Guard armored cable 10 Centre stand ...

Page 14: ...nce SR 50 SR 125 SR 150 22 4 4 43 9 1 Bag hook 2 Battery tool kit compartment cover 3 Fuel tank 4 Fuel tank plug 5 Saddle lock 6 Air cleaner 7 Kick starter 8 Passenger left footrest 9 Fuse carrier 10 Left inspection cover ...

Page 15: ...stroke oil tank 3 Crash helmet glove compartment 4 Ignition switch steering lock 5 Right inspection cover 6 Brake fluid reservoir front brake 7 Horn 8 Battery 9 Spark plug 10 Anti theft hook for the aprilia Body Guard armored cable 11 Centre stand 12 Passenger right footrest ...

Page 16: ...t brake lever 8 Electrical controls on the right side of the handlebar 9 Ignition switch steering lock n m s 10 Fuel level indicator g 11 Speedometer 12 Total kilometres odometer 13 Coolant temperature indicator h 1 14 Green direction indicator warning light c 15 Red 2 stroke oil reserve warning light j 16 Green low beam warning light b 16a Blue high beam warning light a C K _ 17 Blue high beam wa...

Page 17: ...eter It indicates the driving speed Low beam warning light b It comes on when the headlight is in low beam position High beam warning light C K _ a It comes on when the headlight in high beam position High beam warning light a It comes on when the headlight in high beam position Low fuel warning light g It comes on when the quantity of fuel left in the tank is about 2 L Fuel level indicator g It i...

Page 18: ...ever downwards To disconnect the cold start bring the lever to its initial posi tion 3 DIRECTION INDICATOR SWITCH c To indicate the turn to the left move the switch to the left to indicate the turn to the right move the switch to the right To turn off the direction indicator press the switch 4 DIMMER SWITCH a b in the countries where the engine stop switch is required m n When it is in position b ...

Page 19: ...n the dimmer switch is in position b the low beam and the parking lights are on when it is in position a the high beam and the parking lights are on NOTE The lights can be switched off only by stopping the engine 1c 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 ...

Page 20: ...on is pressed 2 DIMMER SWITCH a b _ not provided When the light switch is in position 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 3 DIRECTION INDICATOR SWITCH c To indicate the turn to the left move the switch to the left to indicate the turn to the right move the switch to the right To turn off the direction indicator press th...

Page 21: ...hts and the dash board light are on when the switch is in position o the parking lights the dashboard light and the low beam are on The high beam can be operated by means of the dimmer switch a b 1a 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 2 START PUSH BUTTON r When the start p...

Page 22: ...ehicle OPERATION To lock the steering Turn the handlebar completely leftwards Turn the key 1 to position m and press it Release the key NOTE Turn the key and steer the han dlebar at the same time Rotate the key 1 anticlockwise left wards steer the handlebar slowly until the key 1 reaches position s Extract the key Position Function Key removal s Steering lock The steering is locked It is neither p...

Page 23: ...nger have to carry the crash helmet or other objects with you eve ry time you park the vehicle The compart ment is positioned under the saddle 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 allowed weight 2 5 kg 4 4 ...

Page 24: ...nner shield Max allowed weight 1 5 kg 2 2 5 5 2 84 3 The rear mudguard extension 5 is provid ed as standard equipment and can be in stalled if the vehicle is used on wet roads since it reduces the reach of the water spray caused by the rear wheel NOTE The rear mudguard extension 5 complete with screws and relevant nuts is supplied as standard equipment and is housed in the crash helmet glove compa...

Page 25: ... 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 Use only premium grade petrol 4 Stars U in con...

Page 26: ...p 84 x LUBRICANT CHART or p 85 z LUBRICANT CHART 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 INDICATORS 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 2 stroke oil pipe ...

Page 27: ...ssively every 12000 km 7500 mi or every 24 months 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 hydraulic system For any doubt regarding the perfect functioning of the braking system and in case you are not able to carry out the usual checking ope...

Page 28: ... coupling Period ically check the brake fluid level in the res ervoir 1 and the pad wear see p 51 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 MIN minimum level Position the vehicle on the centre stand Rotate the handlebar so that the fluid c...

Page 29: ...ING If the adjuster 1 can be screwed up completely this means that the brake shoes are worn out In this case see p 51 CHECKING THE SHOE WEAR NOTE The heating of the brake shoes caused by the braking action may modify the clearance between the friction material and the drum For this reason it is advisa ble to check the clearance even with the shoes at operating temperature Carry out a trial run ope...

Page 30: ...ations are to be performed it is advisable to use la tex gloves Have the coolant changed by an APRILIA Official Dealer The coolant is made up of 50 water and 50 antifreeze This mixture is ideal for most running tem peratures and ensures good protection against corrosion It is advisable to keep the same mixture also in the hot season since in this way losses due to evaporation are reduced and it is...

Page 31: ...conds in order to release any residual pressure Unscrew and remove the cap 1 aWARNING The coolant is noxious do not swallow it if the coolant gets in contact with the skin or the eyes it can cause serious ir ritations Do not use your fingers or any other ob ject to check if there is enough coolant aCAUTION While topping up never exceed the MAX level otherwise the fluid will flow out of the tank wh...

Page 32: ...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 the wear c...

Page 33: ...m 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 as the engine is started For this reason the light switch has been replaced with a dimmer switch b a The lights can be switched off only by stop ping the engine Before starting the vehicle make sure that the dimmer switch is in position ...

Page 34: ...ich 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 erally occur...

Page 35: ...and that it is possible to open and close it completely in all steering positions If necessary adjust and or lubricate it 63 2 stroke oil Check and or top up if necessary 26 Wheel tyres Check the tyre surface the inflation pressure wear and tear and any damage 32 33 Brake levers Make sure that they work smoothly If necessary lubricate the articulations 27 28 29 Steering Make sure that the steering...

Page 36: ...ty carry out the operations described at p 37 STARTING AFTER A LONG PERIOD OF INACTIVITY NOTE To avoid the excessive wear of the battery do not keep the start push but ton r pressed for more than five sec onds If the engine does not start within this lapse of time wait ten seconds and press the start push button r again Press the start push button r 7 with out accelerating then release it as soon ...

Page 37: ... letting the engine spin over with completely open throttle 9 Pos A STARTING WITH COLD ENGINE When the room temperature is low near or below 0 C it may be difficult to start the engine at the first attempt In this case Rotate the cold start lever e 10 downwards Press the start push button r 7 and at the same time rotate the throttle grip 9 moderately If the engine starts Release the throttle grip ...

Page 38: ...hen move the vehicle down the stand Get on the vehicle keeping at least one foot on the ground in order not to lose balance Adjust the inclination of the rear view mirrors correctly aWARNING With the vehicle at rest try to get ac quainted with the use of the rear view mirrors To leave release the brake lever and ac celerate by gently rotating the throttle grip Pos B the vehicle will start mov ing ...

Page 39: ...el grip snow ice mud etc drive slowly avoiding sudden brakings or manoeu vres that could make you lose grip and fall down Pay the utmost attention to any obsta cle or variation of the road surface Uneven roads rails manhole covers indications painted on the road surface building site metal plates become rather slippery by rain For this reason all these obstacles have to be carefully avoided drivin...

Page 40: ... grip open more than three fourths for long stretches 25 aWARNING After the first 1000 km 625 mi carry out the checking operations indicated in the column after running in of the REGULAR SERVICE INTERVALS CHART see p 46 in order to avoid hurt ing yourself or other people and or dam aging the vehicle The running in of the engine is primary to ensure its correct functioning and its correct functioni...

Page 41: ...Do not leave the vehicle unattended when the engine is on or the key is in serted into the ignition switch Do not sit on the vehicle when the stand is down Stop the vehicle see beside STOP PING 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 ...

Page 42: ...bly 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 order and the road tax has been paid Write down your personal data and tele phone number in the space provided in this page to facilitate the identification of the owner in case of finding after theft SURNAME NAME ADDRESS TELE...

Page 43: ...he 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 user how ...

Page 44: ...u use the vehicle 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 system Stop light switches Brake fluid 2 stroke oil every 500 km 312 mi Headlight beam ...

Page 45: ... rings every 12000 km 7500 mi Accelerator operation Mixer General running of the vehicle Braking systems brake discs Cylinder cooling system every 20000 km 12500 mi outside cleaning Rear brake cam pin greasing t Brake fluid every 2 years Coolant q every 2000 km 1250 mi every 2 years Fork oil and oil seal every 12000 km 7500 mi Transmission oil every 12000 km 7500 mi or 2 years Rear pulley pins eve...

Page 46: ...e frequently if you use the vehicle in rainy and dusty areas or on uneven ground Component After running in 1000 km 625 mi Every 4000 km 2500 mi or 12 months Every 8000 km 5000 mi or 24 months Battery Terminal fastening Spark plug Carburettor idling Air cleaner Accelerator operation Brake locking operation Light system Stop light switches Brake fluid 2 stroke oil every 500 km 312 mi Headlight beam...

Page 47: ...y 30000 km 18750 mi Speed change gear belt and roller shoes every 12000 km 7500 mi Steering tube bearings and steering slack Wheel bearings Brake discs Piston rings every 12000 km 7500 mi General running of the vehicle Braking systems Cylinder cooling system every 20000 km 12500 mi outside cleaning Gas cable splitter greasing every 12000 km 7500 mi Brake fluid every 2 years Mixer accelerator opera...

Page 48: ...ear brake ad juster ENGINE NUMBER The engine number is stamped on the low er support of the rear shock absorber Engine no ENGINE NUMBER The engine number is stamped on the rear side near the rear brake adjuster Engine no 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 dire...

Page 49: ...D COVER Remove the left inspection cover see p 55 REMOVING THE RIGHT AND LEFT INSPECTION COVERS Unscrew and remove the screw 1 tak ing the washer and the breather pipe ring 2 Unscrew and remove the screw 3 with the relevant washer Loosen the screw 4 of the air manifold clamp Grasp the air manifold in correspond ence with the clamp and pull it thus re moving the whole air cleaner casing CLEANING TH...

Page 50: ...ve it from the vehicle REMOVAL Position the vehicle on the centre stand Unscrew and remove the two screws 1 Unscrew and remove the seven screws 2 Remove the filter case cover 3 Remove the filtering element 4 Check filtering element 4 filter case gasket 5 and change them if necessary CLEANING aWARNING Do not use petrol or inflammable sol vents to wash the filtering element in order to avoid fires o...

Page 51: ...sc 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 from the caliper braking effi ciency safety and soundness of the disc would thus be negatively affected If the thickness of the friction material even of one pad only has reduced to about 1 5 mm replace both pads a...

Page 52: ... stable Shake the fork in the direction 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 MAINTENA...

Page 53: ... 6 2 Carefully read p 43 MAINTENANCE Remove the cover support element 2 see beside REMOVING THE COVER SUPPORT ELEMENT Rotate the handlebar completely un screw and remove the screws 3 taking the washers aCAUTION Proceed with care Do not damage the tangs and or their seats Handle the plastic and painted compo nents with care and avoid scraping or damaging them Remove the front cover 4 by pulling it ...

Page 54: ...dlebar in central position withdraw the lower handlebar cover 8 from the front and remove it 0 24 2 6 4 500 2 2 6 2 Carefully read p 43 MAINTENANCE Remove the rear view mirrors see p 61 REMOVING THE REAR VIEW MIR RORS Remove the lower handlebar cover see beside REMOVING THE LOWER HAN DLEBAR COVER Disconnect the two electric terminals 9 aCAUTION The upper handlebar cover 10 com plete with switches ...

Page 55: ...be re moved Unscrew and remove the screw 4 and the screw 5 of the rear part of the fair ing NOTE Upon reassembly fit the screw 5 with shorter diameter of the rear part of the fairing in the relevant seat Slightly raise the inspection cover 6 re lease it from the footrest and withdraw it sidewards NOTE Upon reassembly insert the rear part of the inspection cover in the rear part of the fairing maki...

Page 56: ...e relevant nuts 1 A C K _ Position the number plate light 4 and tighten the relevant nuts Insert the number plate light cable 3 in the two couplings Insert the screw 6 and tighten the rele vant nut 5 Make sure that the rear mudguard exten sion 7 is positioned correctly 2 6 4 5 2 0 4 3500 24 Carefully read p 43 MAINTENANCE Position the vehicle on the centre stand Unscrew and remove the number plate...

Page 57: ... point screwdriver press in correspondence with the marks in order to obtain the seat aWARNING Proceed with care Keep your hands away from the drilling axis Drill in correspondence with the three seats holes with diameter 5 Position the rear mudguard extension 5 correctly in its seat Insert the three screws 7 and screw the relevant nuts without tightening them Make sure that the rear mudguard exte...

Page 58: ...lb socket 3 as much as necessary to disconnect its two electric terminals 4 NOTE Upon reassembly make the bulb socket opening coincide with the seat of the screw 1 Unscrew the screw 5 and take the rele vant nut aCAUTION Handle with care Do not force the electric cables NOTE To remove the indicator support 6 withdraw the cables one by one Remove the indicator support 6 and withdraw it from the cabl...

Page 59: ...ection indicator replac ing the screw 5 with the screw 9 sup plied with this equipment see p 58 REMOVING THE WHOLE DIREC TION INDICATOR 2 6 4 7 2 3 6 2 Carefully read p 43 MAINTENANCE Position the vehicle on the centre stand aWARNING Before performing the operations de scribed below let the engine and the exhaust silencer cool down until they have reached room temperature in or der to avoid burns ...

Page 60: ...mat 2 Unscrew and remove the two fastening screws 3 of the bag hook Remove the bag hook 4 Unscrew and remove the screw 5 with the relevant washer Unscrew and remove the three screws 6 Unscrew and remove the screw 7 aCAUTION Proceed with care Do not damage the tangs and or their seats Handle the painted components with care and avoid scraping or damaging them Withdraw and remove the front inner shi...

Page 61: ...ut the following checks The springs 6 must not be damaged worn rusty or weakened The stand must rotate freely if neces sary grease the joint see p 84 x LU BRICANT CHART or p 85 z LU BRICANT CHART 4 37 4 3 Carefully read p 43 MAINTENANCE The vehicle is provided with two switches stoplight switch on the rear brake control lever 7 stoplight switch on the front brake con trol lever 8 To reach the swit...

Page 62: ...re 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 1800 100 rpm in this case the engine does not make the rear wheel rotate If necessary Act on the adjusting screw 1 positioned on the carburettor By SCREWING IT clockwise you in crease the engine rpm By UNSCREWING IT anticlockwise you decrease ...

Page 63: ...r see the figure Act on the adjusting screw 1 positioned on the carburettor By SCREWING IT clockwise you in crease the engine rpm By UNSCREWING IT anticlockwise you decrease the engine rpm Twist the throttle grip accelerating and decelerating a few times to make sure that it functions correctly and to check if the idling speed is constant NOTE If necessary contact your aprilia Official Dealer 534 ...

Page 64: ... cleaners for spark plugs with an iron wire and or a metal brush Energetically blow some air in order to prevent the removed residues from get ting into the engine If the spark plug has crackings on the in sulating material corroded electrodes or excessive deposits it must be changed Check the spark plug gap with a thickness gauge The gap must be 0 5 0 6 mm if neces sary adjust it carefully bendin...

Page 65: ...es Connect and disconnect the battery with the ignition switch in position m otherwise some components may be damaged Connect first the positive cable and then the negative cable Disconnect following the reverse order The electrolyte is corrosive Do not pour or spill it especially on the plastic parts ONLY FOR MAINTENANCE FREE BAT TERIES If this vehicle is equipped with a MAIN TENANCE FREE battery...

Page 66: ...special grease or Vaseline After these operations Put back the tool kit compartment 1 Put back the battery tool kit compart ment cover see p 24 BATTERY TOOL KIT COMPARTMENT 2 6 4 44 29 Carefully read p 65 BATTERY Remove the battery tool kit compartment cover see p 24 BATTERY TOOL KIT COMPARTMENT Remove the tool kit compartment 1 Make sure that the ignition switch is in position m Disconnect first ...

Page 67: ...grease or Vaseline Put back the tool kit compartment Put back the battery tool kit compartment cover see p 24 BATTERY TOOL KIT COMPARTMENT 4 42 94 6 ONLY FOR BATTERIES THAT NEED MAINTENANCE NOTE The following text is valid ONLY if the installed battery needs maintenance Carefully read p 65 BATTERY Remove the battery from its compart ment see p 66 REMOVING THE BAT TERY Make sure that the fluid leve...

Page 68: ...TION Reassemble the battery only 5 10 min utes after disconnecting the recharger since the battery continues to produce gas for a short lapse of time 2 2 4 44 29 ONLY FOR MAINTENANCE FREE BATTERIES Carefully read p 65 BATTERY NOTE Do not remove the battery plugs without plugs the battery may be damaged Remove the battery see p 66 REMOV ING THE BATTERY aWARNING During the recharging or the use make...

Page 69: ...RTMENT Remove the tool kit compartment 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 Put back the tool kit compartment Put back the battery tool kit compart...

Page 70: ...ct on the suit able screw 2 by means of a screwdriv er By TURNING IT CLOCKWISE you set the beam upwards By TURNING IT ANTICLOCKWISE you set the beam downwards 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 move the igni tion switch to p...

Page 71: ...king light bulb 7 one low high beam bulb 5 LOW HIGH BEAM BULB To change the bulb proceed as follows Remove the front inner shield see p 60 REMOVING THE FRONT INNER SHIELD Move the protection element 3 with your hands Rotate the bulb socket 4 anticlockwise and extract it Press the bulb 5 slightly and rotate it anticlockwise Extract the bulb 5 from its seat Correctly install a new bulb of the same t...

Page 72: ...W BEAM BULB Manually move the protection element 10 Withdraw the electric terminal 6 Release the check spring 7 positioned at the rear of the bulb socket Extract the bulb from its seat NOTE Insert the bulb in the bulb socket making the relevant positioning seats coin cide aCAUTION Do not press the bulb cable with the check spring 7 Correctly install a new bulb of the same type HIGH BEAM BULBS Manu...

Page 73: ...2 4 4 2 5 3 Carefully read p 70 BULBS Position the vehicle on the stand NOTE Before changing a bulb check the fuse see p 69 CHANGING THE FUSES Unscrew and remove the screw 4 NOTE While removing the protection screen proceed carefully in order not to break the cog Remove the protection screen 5 NOTE Upon reassembly correctly posi tion the protection screen in its seat Tighten the screw 4 moderately...

Page 74: ... incorrectly 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...

Page 75: ... the stoplight bulb 2 only slightly press the bulb and rotate it anticlock wise Remove the bulb from its seat NOTE Insert the bulb in the socket mak ing the two bulb pins coincide with the rele vant guides on the socket Correctly install a new bulb of the same type aCAUTION Upon reassembly correctly position the protection screen in its seat Tighten the screw 3 carefully without exerting too much ...

Page 76: ...T Position the vehicle on the centre stand Stop the engine and wait until it has cooled down Prepare a container with capacity ex ceeding the fuel quantity present in the 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 positi...

Page 77: ...se 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 washed the vehicle Polish...

Page 78: ...66 REMOV ING THE BATTERY Wash and dry the vehicle see p 77 CLEANING Polish the painted surfaces with wax Inflate the tyres see p 32 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 final pipe of the exh...

Page 79: ...arting 94 kg 112 kg Weight ready for starting 1 99 kg ENGINE Type MINARELLI 2 stroke with controlled ignition Type aprilia Engines S A 2 stroke with controlled ignition Number of cylinders 1 Total displacement 49 26 cm 123 54 cm 149 98 cm Bore stroke 40 mm 39 2 mm 55 mm 52 mm 60 6 mm 52 mm Compression ratio 12 5 0 5 1 10 2 0 5 1 9 19 0 5 1 Starting electric kick starter Engine idle 1800 100 rpm 15...

Page 80: ...cle max load driver luggage 105 kg Vehicle max load driver passenger luggage 180 kg in the countries where this is allowed TRANSMISSION Speed change gear automatic and stepless Primary V belt Ratios minimum for stepless change 2 6 2 39 maximum for stepless change 0 862 0 79 Secondary with gears CARBURETTOR MODEL standard DELL ORTO PHBN 12 MIKUNI VM20 alternative TEI KEY TK 3AA DELL ORTO PHVB 20 5 ...

Page 81: ...petrol according to the DIN 51607 stan dard min O N 95 N O R M and 85 N O M M FRAME Type one beam split in two at the rear SUSPENSIONS Front hydraulically operated telescopic fork Stroke 90 mm Rear hydraulic mono shock absorber Stroke 72 mm BRAKES Front disc brake Ø190 mm with hydraulic transmission Rear 3 drum brake Ø110 mm with mechanic transmis sion Rear disc brake Ø190 mm with hydraulic transm...

Page 82: ...ar Rear 190 kPa 1 9 bar 210 kPa 2 1 bar INFLATION PRESSURE WITH PASSENGER in the countries where this is allowed Front 170 kPa 1 7 bar 210 kPa 2 1 bar Rear 210 kPa 2 1 bar 230 kPa 2 3 bar IGNITION Type C D I Spark advance 14 2 before T D C 19 1 before T D C at 4000 rpm SPARK PLUG Standard NGK BR7 HS NGK BR8 ES alternative BOSCH WR3CC CHAMPION RN2C CHAMPION QN2C 1 Standard NGK BR8 HS Spark plug gap...

Page 83: ... W H1 Front parking light 12 V 5 W Low high beam C K _ 12 V 35 35 W Front parking light C K _ 12 V 3 W Direction indicators 12 V 10 W Rear parking light 12 V 5 W Stoplight 12 V 21 W Number plate 12 V 3 W Number plate A C K _ 12 V 3 W Dashboard lighting 12 V 1 2 W WARNING LIGHTS High beam 12 V 1 2 W High beam C K _ 12 V 1 2 W Direction indicators 12 V 2 W 2 stroke oil reserve 12 V 2 W Low fuel 12 V...

Page 84: ...K 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 use hig...

Page 85: ...comparison with the 0F A 5W and 0F A 20W or FORK 5W 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 GRE...

Page 86: ...86 use and maintenance SR 50 SR 125 SR 150 MPORTERS ...

Page 87: ...87 use and maintenance SR 50 SR 125 SR 150 MPORTERS ...

Page 88: ...88 use and maintenance SR 50 SR 125 SR 150 7 2 2 32 AIR AND LIQUID COOLED VERSION 1 ...

Page 89: ...l diode 21 Coolant thermistor 1 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 Low beam warning light 30 Coolant temperature instrument 1 31 Front right direction indicator 32 Front left direction indicator 33 Front parking light 34 Low beam bulb 35 Horn 36 Pick up 37 Fuse ...

Page 90: ...90 use and maintenance SR 50 SR 125 SR 150 7 2 2 32 C K _ AIR AND LIQUID COOLED VERSION 1 ...

Page 91: ... switch steering lock 20 Control diode 21 Coolant thermistor 1 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 Coolant temperature instrument 1 31 Front right direction indicator 32 Front left direction indicator 33 Front parking light 34 Low high ...

Page 92: ...92 use and maintenance SR 50 SR 125 SR 150 7 2 2 32 AIR AND LIQUID COOLED VERSION 1 ...

Page 93: ...l diode 21 Coolant thermistor 1 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 Coolant temperature instrument 1 31 Front right direction indicator 32 Front left direction indicator 33 Front parking light 34 Low high beam bulb 35 Horn 36 Pick up 37...

Page 94: ...94 use and maintenance SR 50 SR 125 SR 150 7 2 2 32 32 ...

Page 95: ... Dashboard 22 Horn push button 23 Dashboard light 24 Low fuel warning light 25 Direction indicator switch 26 Start push button 27 Control diode 28 High beam warning light 29 Direction indicator warning light 30 Horn 31 Front right direction indicator 32 High beam bulb 33 Front parking light 34 Front left direction indicator 35 2 stroke oil reserve warning light 36 Multiple connectors 37 Spark plug...

Page 96: ...96 use and maintenance SR 50 SR 125 SR 150 7 2 2 32 32 J ...

Page 97: ...board 22 Horn push button 23 Dashboard light 24 Low fuel warning light 25 Direction indicator switch 26 Start push button 27 Control diode 28 High beam warning light 29 Direction indicator warning light 30 Horn 31 Front right direction indicator 32 High beam bulb 33 Front parking light 34 Front left direction indicator 35 2 stroke oil reserve warning light 36 Multiple connectors 37 Spark plug 38 A...

Page 98: ...ilia 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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APRILIA SR 125 - 1999, Manual

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Summary of Contents for SR 125 - 1999

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