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APRILIA HABANA 125 - PART3 User Manual

APRILIA HABANA 125 - PART3
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51
use and maintenance Habana 50/125 - Habana Custom 50/125
#(%#+).'4(%3(/%7%!2
Carefully read p. 29 (REAR DRUM
BRAKE) and p. 43 (MAINTENANCE).
w v Check the wear of the rear brake
shoes after the first 500 km (312 mi) and
successively every 4000 km (2500 mi).
xu
Have the rear brake shoe wear checked by
an aprilia Official Dealer after the first
1000 km (625 mi) and successively every
6000 km (3750 mi).
In any case:
aWARNING
If the adjuster (1) can be screwed com-
pletely, this means that the shoes are
worn; in this case, contact an
APRILIA
Official Dealer.
wv
To verify the wear of the rear brake shoes,
proceed as follows:
Pull the rear brake lever (2) completely
and keep it pulled.
Check the position of the rear 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 after the
first:
w v 500 km (312 mi) and succes-
sively every 4000 km (2500 mi);
x u 1000 km (625 mi) and succes-
sively every 6000 km (3750 mi).
aCAUTION
If you notice irregularities in the opera-
tion or if the help of a qualified techni-
cian is necessary, contact your
APRILIA
Official Dealer.
Position Wear condition
Indicator between
the two reference
teeth (4) and (5)
.
Rear brake shoes
within the wear limit.
Indicator on or
beyond the lower
reference tooth(5)
.
Rear brake shoes
worn
.
To be replaced.
Ing-02.fm Page 51 Wednesday, December 15, 1999 4:17 PM

Table of Contents

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APRILIA HABANA 125 - PART3 Specifications

General IconGeneral
Fuel SystemCarburetor
Front BrakeDisc
Rear BrakeDrum
EngineSingle cylinder, 4-stroke
CoolingAir
TransmissionAutomatic

Summary

Checking Rear Brake Shoe Wear

H50 HC50 Rear Brake Shoe Check Interval

Check rear brake shoes after first 500 km and every 4000 km.

H125 HC125 Rear Brake Shoe Wear Check by Dealer

Have rear brake shoe wear checked by dealer after 1000 km and every 6000 km.

Rear Brake Shoe Wear Indicator Verification

Verify rear brake shoe wear using the indicator and reference teeth.

WARNING: Worn Brake Shoes Indication

If adjuster is fully screwed, shoes are worn; contact dealer.

Inspecting Front and Rear Suspensions

Suspension Component Tightening and Functionality Check

Check tightening of suspension components and articulation functionality.

Suspension Inspection Intervals

Inspect suspension after first 500/1000 km and every 4000/6000 km.

CAUTION: Addressing Suspension Irregularities

Contact dealer for operational irregularities or if technician help is needed.

Checking Vehicle Steering

Steering Slack Check Procedure

Position vehicle, prepare support, check steering slack by shaking fork.

WARNING: Ensuring Vehicle Stability

Ensure vehicle is stable when checking steering. Do not shake fork excessively.

CAUTION: Correcting Excessive Steering Slack

If considerable slack is found, contact dealer for optimal steering conditions.

Checking Engine Fulcrum Axis

Engine Fulcrum Axis Slack Inspection

Periodically check slack in engine pin bushings by shaking the wheel.

Action for Noticed Engine Axis Slack

If slack is noticed, contact dealer for optimal operating conditions.

Removing the Front Cover

Front Cover Removal Steps

Steps to remove front cover, including screws, couplings, and grille.

CAUTION: Handling Front Cover Components

Handle plastic and painted components with care to avoid damage.

Removing the Lower Handlebar Cover

Lower Handlebar Cover Removal Procedure

Steps to remove lower handlebar cover, including screws.

CAUTION: Handle Handlebar Plastic Parts

Handle plastic and painted components with care to avoid damage.

Removing the Headlight Metal Ring

Headlight Metal Ring Removal Steps

Steps to remove headlight metal ring, including screw.

Partial Removal of Upper Handlebar Cover

Upper Handlebar Cover Removal Steps

Steps for partial removal, including mirrors, rubber ring, and coupling.

CAUTION: Upper Handlebar Cover Handling

Handle carefully, do not force electric wires, proceed with care.

Removing Rear-View Mirrors

Rear-View Mirror Removal Procedure

Steps to remove rear-view mirrors, including nut and washer.

Partial Removal of the Dashboard

Dashboard Partial Removal Steps

Steps to partially remove dashboard, including nuts and screws.

Accessing Dashboard Bulbs

Steps to reach dashboard bulbs by removing covers and elements.

Removing Central Inspection Cover

Central Inspection Cover Removal Steps

Steps to remove central inspection cover, including screw.

CAUTION: Handling Painted Components

Handle painted components with care to avoid scraping or damaging them.

Removing Right and Left Inspection Covers

Right/Left Inspection Cover Removal Steps

Steps to remove right/left inspection covers, including screws and saddle lift.

CAUTION: Handling Plastic Components

Handle plastic and painted components with care to avoid damage.

Removing the Battery Cover

Battery Cover Removal Steps

Steps to remove battery cover, including saddle lift and screw.

Checking the Stand

Stand Rotation and Spring Check

Check stand rotation and spring condition. Grease joint if necessary.

WARNING: Side Stand Safety

Side stand automatically retracts when vehicle is straightened. Beware of falling.

Checking Vehicle Switches

Stoplight Switch Identification

Vehicle has stoplight switches on rear and front brake levers.

Switch Inspection Procedure

Check switches for dirt, ensure pin movement, and cable connections.

Idling Adjustment Procedure

Idling Adjustment Intervals

Adjust idling after first 500/1000 km and whenever irregular.

Idling Adjustment Steps

Warm engine, connect rev counter, adjust idling speed using specified controls.

WARNING: Ventilation During Idling Adjustment

Ensure proper ventilation when engine is running during adjustment.

H50 HC50 Carburetor Idling Adjustment

Act on adjusting screw (1) on the carburetor for H50/HC50.

H125 HC125 Idling Knob Adjustment

Act on adjusting knob (2) for H125/HC125; clockwise increases RPM.

Adjusting Accelerator Control

Accelerator Control Slack Specification

Ideal slack of accelerator control should be about 2-3 mm.

Accelerator Control Adjustment Steps

Adjust slack by loosening nut, acting on adjuster, and tightening nut.

WARNING: Post-Adjustment Throttle Check

Ensure handlebar rotation doesn't affect idling and throttle returns smoothly.

Spark Plug Maintenance

Spark Plug Check and Change Intervals

Check spark plug after first 500/1000 km; change every 4000/6000 km.

Spark Plug Cleaning and Replacement

Periodically clean spark plug, removing carbon deposits; change if necessary.

Accessing the Spark Plug

Steps to access spark plug by removing inspection covers.

Spark Plug Maintenance Details

Spark Plug Removal and Cleaning

Remove cap, clean area, unscrew plug, extract carefully.

Spark Plug Gap Specification

Check spark plug gap (0.6-0.7mm H50/HC50, 0.7-0.8mm H125/HC125). Adjust if needed.

Spark Plug Tightening Torque

Tighten spark plug by hand, then with tool kit. Specific torque values provided.

CAUTION: Proper Spark Plug Tightening

Ensure spark plug is well tightened to prevent engine overheating and damage.

Battery Maintenance

WARNING: Battery Fire Hazard

Keep flammable substances away from electrical components. Risk of fire.

CAUTION: Battery Cable Connection Order

Never invert battery cable connections; connect positive first, then negative.

Electrolyte Level and Terminal Check

Check electrolyte level and terminal tightening after first 500 km and every 4000 km.

WARNING: Electrolyte Hazards and Safety

Electrolyte is toxic and caustic; wear protection. Handle with care.

H125 HC125 Maintenance-Free Battery

H125/HC125 has a maintenance-free battery; only occasional checks/recharge needed.

Long Periods of Battery Inactivity

Recharge battery if unused for >15 days to prevent sulphation. Check charge monthly.

Checking and Cleaning Battery Terminals

Battery Terminal Condition Check

Ensure terminals are in good condition, not corroded, and covered with grease.

Battery Terminal Cleaning and Greasing

Disconnect battery, clean terminals with wire brush, reconnect, and grease.

Removing the Battery

Battery Removal Steps

Remove battery cover, disconnect cables, remove breather pipe, and extract battery.

WARNING: Safe Battery Storage

Store removed battery in a safe place away from children.

Battery Removal and Electrolyte Level Check

Partial Battery Removal Procedure

Position vehicle, wait for cooling, ensure ignition off, release belt, move battery.

CAUTION: Handling Battery Cables

Do not force cables while removing battery.

Complete Battery Removal Steps

Disconnect negative then positive cables, position battery safely.

Checking Battery Electrolyte Level

Check fluid level between MIN and MAX marks. Top up with distilled water if needed.

Recharging and Installing the Battery

Battery Recharging Procedure

Remove battery, check electrolyte, connect charger, recharge at 1/10th capacity.

CAUTION: Reassembly After Recharging

Wait 5-10 minutes after disconnecting charger before reassembly.

Battery Installation Steps

Install battery, connect breather pipe, connect cables (positive then negative), cover terminals.

CAUTION: Battery Cable Routing

Guide electric cables correctly during reassembly to avoid crushing.

Changing Vehicle Fuses

CAUTION: Correct Fuse Usage

Use only recommended fuses. Unsuitable fuses can cause damage or fire.

Fuse Checking and Replacement Procedure

Turn ignition off, remove covers, extract fuses, check filament, replace if blown.

Troubleshooting Frequently Blown Fuses

Frequent blown fuses indicate short circuit or overload; consult dealer.

Fuse Arrangement and Functions

Details fuse functions and ratings for H50/HC50 and H125/HC125 models.

Adjusting Vertical Headlight Beam

Headlight Beam Alignment Check

Check beam direction by placing vehicle 10m from a wall, verify height.

H50 HC50 Headlight Beam Adjustment

Adjust beam upwards/downwards using screw (1) with a screwdriver.

H125 HC125 Headlight Beam Adjustment

Adjust inclination by loosening nut (2), adjusting headlight (3), and tightening nut.

Bulb Replacement Precautions

WARNING: Bulb Fire Hazard

Keep flammable substances away from electrical components. Risk of fire.

CAUTION: Bulb Handling and Replacement

Ensure bulb cools, use gloves, avoid fingerprints, do not force wires.

Changing Headlight Bulbs (H50)

Headlight Bulb Components (H50)

Headlight contains parking light bulb (1) and low/high beam bulb (2).

Accessing Headlight Bulbs (H50)

Remove lower handlebar cover and protection element (3) to access bulbs.

Changing Parking Light Bulb (H50)

Grasp socket (4), pull, remove bulb (1), replace with new one.

Changing Low/High Beam Bulb (H50)

Rotate bulb socket (5) anticlockwise, press bulb (2), rotate anticlockwise, extract.

Changing Headlight Bulbs (H125)

Headlight Bulb Components (H125)

Headlight contains parking light bulb (1) and low/high beam bulb (2) (halogen).

Accessing Headlight Bulbs (H125)

Remove headlight metal ring and protection element (3) to access bulbs.

Changing Parking Light Bulb (H125)

Grasp socket (4), pull, remove bulb (1), replace with new one.

Changing Low/High Beam Bulb (H125)

Disconnect connector (5), release clip (7), extract bulb (6).

Changing Headlight Bulbs (HC50)

Headlight Bulb Components (HC50)

Headlight contains parking light bulb (1) and low/high beam bulb (2).

Accessing Headlight Bulbs (HC50)

Remove headlight metal ring and partially remove reflector (3) to access bulbs.

Changing Parking Light Bulb (HC50)

Grasp socket (4), pull, remove bulb (1), replace with new one.

Changing Low/High Beam Bulb (HC50)

Rotate bulb socket (5) anticlockwise, press bulb (2), rotate anticlockwise, extract.

Changing Headlight Bulbs (HC125)

Headlight Bulb Components (HC125)

Headlight contains parking light bulb (1) and low/high beam bulb (2) (halogen).

Accessing Headlight Bulbs (HC125)

Remove headlight metal ring and partially remove reflector (3) to access bulbs.

Changing Parking Light Bulb (HC125)

Grasp socket (4), pull, remove bulb (1), replace with new one.

Changing Low/High Beam Bulb (HC125)

Disconnect connector (5), release clip (7), extract bulb (6).

Changing Front and Rear Direction Indicator Bulbs

CAUTION: Fuse Check Before Bulb Replacement

Check fuses before changing bulbs.

Front/Rear Indicator Bulb Replacement Steps

Remove screws, screen, ring, colored screen, and press bulb to extract.

Changing Dashboard Bulbs (H50 H125)

CAUTION: Fuse Check Before Dashboard Bulb Change

Check fuses before changing dashboard bulbs.

Dashboard Bulb Types (H50 H125)

Lists warning light bulbs and lighting bulbs by position and color.

Warning Light Bulb Extraction (H50 H125)

Partially remove upper handlebar cover, extract bulb sockets carefully.

Dashboard Lighting Bulb Extraction (H50 H125)

Remove lower handlebar cover, extract dashboard bulb sockets carefully.

Changing Dashboard Bulbs (HC50 HC125)

CAUTION: Fuse Check Before Dashboard Bulb Change

Check fuses before changing dashboard bulbs.

Dashboard Bulb Types (HC50 HC125)

Lists warning light bulbs and lighting bulbs by position and color.

Warning Light Bulb Extraction (HC50 HC125)

Partially remove dashboard, extract bulb sockets carefully.

Dashboard Lighting Bulb Extraction (HC50 HC125)

Extract dashboard bulb sockets carefully for light decrease.

Changing the Rear Light Bulb

CAUTION: Fuse and Switch Checks Before Rear Light Bulb Change

Check fuse and stoplight switches before changing rear light bulb.

Rear Light Bulb Replacement Procedure

Remove screws, screen, press bulb, rotate anticlockwise, and extract.

Changing the Number Plate Bulb

Number Plate Bulb Replacement Steps

Remove screw, light unit, grasp bulb socket, pull, and remove bulb.

CAUTION: Bulb Socket Handling

Do not pull electric wires to extract the bulb socket.

Vehicle Transport

WARNING: Vehicle Preparation for Transport

Empty fuel tank and carburetor. Keep vehicle vertical and anchored.

Safe Vehicle Transport Guidelines

Ensure vehicle is vertical and anchored to prevent leaks. Do not tow if failed.

Draining the Fuel Tank

WARNING: Fuel Handling and Fire Safety

Risk of fire. Fuel vapours are noxious. Do not smoke or use flames.

Fuel Tank Draining Procedure

Position vehicle, stop engine, prepare container, remove fillercap, empty tank.

Draining the Carburettor

Carburettor Draining Procedure

Remove inspection cover, insert pipe into receptacle, loosen drain screw, drain fuel.

WARNING: Carburettor Drain Screw Tightening

Tighten drain screw carefully to avoid fuel leakages during refuelling.

Vehicle Cleaning

WARNING: Post-Wash Braking Performance

Braking may be impaired after washing. Brake repeatedly to restore.

Recommended Cleaning Areas and Conditions

Clean frequently in polluted areas, high salinity/humidity, or after winter chemical use.

Cleaning Painted Surfaces

Use low-pressure water jet, soft sponge with shampoo, rinse, and dry with chamois.

CAUTION: General Cleaning Precautions

Avoid high pressure jets on specific parts. Use water/mild soap for rubber/plastic.

Long Periods of Inactivity Precautions

Vehicle Inactivity Preparation Steps

Empty fuel/carburettor, extract spark plug, add oil, remove battery, wash, polish, inflate.

Recommended Storage Environment

Store in unheated, not-humid room, away from sunlight, with minimal temperature variations.

Post-Inactivity Vehicle Checks

Uncover, clean, check battery, refuel, perform preliminary checks.

WARNING: Post-Inactivity Test Ride

Have a test ride at moderate speed in a low-traffic area after inactivity.

Technical Data Overview

Vehicle Dimensions Specifications

Provides vehicle dimensions like length, width, height, and seat height.

Engine Specifications

Details engine type, displacement, bore/stroke, compression, starting, clutch, etc.

Transmission, Capacity, and Load Data

Transmission Details

Information on speed change gear, primary and secondary transmission.

Capacity, Fuel, and Load Limits

Details fuel, oil capacities, seats, and maximum load limits.

Frame, Suspension, Brakes, Wheels, Tyres, Ignition Data

Frame and Suspension Specifications

Details frame type, front/rear suspension stroke.

Brakes, Wheels, Tyres, and Ignition Specifications

Specifications for brakes, wheels, tire inflation, and ignition type.

Spark Plug, Electric System, Bulbs, and Lights Data

Spark Plug and Electric System Specifications

Details spark plug type, gap, idle rpm, battery, fuses, and generator specs.

Bulbs and Warning Lights Information

Lists bulb wattages and warning light indicators for various functions.

Lubricant Chart (H50 HC50)

Transmission and 2-Stroke Oil Recommendations

Recommended transmission oil (F.C., SAE 75W-90) and 2-stroke oil (GREEN HIT 2).

Fork Oil and Lubrication Points Recommendations

Recommended fork oil (F.A. 5W/20W) and grease for bearings (AUTOGREASE MP).

Battery Pole Protection and Chain Spray

Neutral grease or vaseline for battery poles; CHAIN SPRAY for chains.

Brake Fluid Recommendation

Recommended brake fluid is F.F., DOT 5 (DOT 4 compatible). Use new fluid only.

Lubricant Chart (H125 HC125)

Engine Oil and Transmission Oil Recommendations

Recommended engine oil (EXTRA RAID 4 SAE 15W/50) and transmission oil (F.C., SAE 75W-90).

Fork Oil and Lubrication Points Recommendations

Recommended fork oil (F.A. 5W/20W) and grease for bearings (AUTOGREASE MP).

Battery Pole Protection and Chain Spray

Neutral grease or vaseline for battery poles; CHAIN SPRAY for chains.

Brake Fluid Recommendation

Recommended brake fluid is F.F., DOT 5 (DOT 4 compatible). Use new fluid only.

Important Notes and Genuine Parts

Ask for Genuine Spare Parts Only

Always ask for genuine spare parts from Aprilia.

Important Notes and Genuine Parts

Ask for Genuine Spare Parts Only

Always ask for genuine spare parts from Aprilia.

Aprilia Importers - Europe

Aprilia S.p.A. Italy Headquarters

Italian headquarters contact information for Aprilia s.p.a.

European Aprilia Importer Contacts

Contact details for Aprilia importers in various European countries.

Aprilia Importers - International

International Aprilia Importer Contacts

Contact details for Aprilia importers in countries outside Europe.

Wiring Diagram - Habana 50

Habana 50 Electrical Wiring Diagram

Electrical wiring diagram for the Habana 50 model.

Wiring Diagram Key - Habana 50

Habana 50 Wiring Diagram Component Key

Key for identifying components in the Habana 50 wiring diagram.

Habana 50 Cable Colour Codes

List of cable colours and their corresponding meanings for Habana 50.

Wiring Diagram - Habana 50 USA

Habana 50 USA Electrical Wiring Diagram

Electrical wiring diagram for the Habana 50 USA model.

Wiring Diagram Key - Habana 50 USA

Habana 50 USA Wiring Diagram Component Key

Key for identifying components in the Habana 50 USA wiring diagram.

Habana 50 USA Cable Colour Codes

List of cable colours and their corresponding meanings for Habana 50 USA.

Wiring Diagram - Habana Custom 50

Habana Custom 50 Electrical Wiring Diagram

Electrical wiring diagram for the Habana Custom 50 model.

Wiring Diagram Key - Habana Custom 50

Habana Custom 50 Wiring Diagram Component Key

Key for identifying components in the Habana Custom 50 wiring diagram.

Habana Custom 50 Cable Colour Codes

List of cable colours and their corresponding meanings for Habana Custom 50.

Wiring Diagram - Habana 125

Habana 125 Electrical Wiring Diagram

Electrical wiring diagram for the Habana 125 model.

Wiring Diagram Key - Habana 125

Habana 125 Wiring Diagram Component Key

Key for identifying components in the Habana 125 wiring diagram.

Habana 125 Cable Colour Codes

List of cable colours and their corresponding meanings for Habana 125.

Wiring Diagram - Habana Custom 125

Habana Custom 125 Electrical Wiring Diagram

Electrical wiring diagram for the Habana Custom 125 model.

Wiring Diagram Key - Habana Custom 125

Habana Custom 125 Wiring Diagram Component Key

Key for identifying components in the Habana Custom 125 wiring diagram.

Habana Custom 125 Cable Colour Codes

List of cable colours and their corresponding meanings for Habana Custom 125.

General Notes and Responsibilities

Customer Thanks and Environmental Responsibility

Thanks customers, advises on environmental responsibility, noise, and nature respect.

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