© 1996 aprilia s.p.a: - Noale (VE) FOREWORD · Your and other people's safety depends not only on your quickness of reflexes and on your agility, but also on what you know about

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© 1996 aprilia s.p.a: - Noale (VE)This manual is to be considered an integral part ofthe vehicle, which must be delivered complete with italso in case of resale.

aprilia s.p.a.

reserves the right to modify its modelsat any time, without prejudice to the main characteris-tics here described.All rights as to electronic storage, reproduction andtotal or partial adaptation, with any means, are re-served for all Countries. The mention to products orservices supplied by third parties is made only for in-formation purposes and it isn't binding in any case.

aprilia s.p.a

takes no responsibility as to the per-formance or the use of said products.

First edition: january 1996

Reprint: september 1996, january 1997, september 1997, march 1998

Produced and printed by:

Studio Tecno Public

Viale del Progresso - 37038 Soave (VR) - ItalyTel. +39 (0)45 -76 11 911Fax +39 (0)45 -76 12 241www.stp.itE-mail: [email protected]

On behalf of:

aprilia s.p.a.

via G. Galilei, 1 - 30033 Noale (VE) - ItalyTel. +39 (0)41 - 58 29 111Fax +39 (0)41 - 44 10 54www.aprilia.com

FOREWORD

Before starting the engine, carefully read this manu-al, paying particular attention to the chapter "SAFEDRIVE".Your and other people's safety depends not only onyour quickness of reflexes and on your agility, butalso on what you know about the vehicle, on its effi-ciency and on your knowledge of the basic informa-tion for SAFE DRIVE.Therefore, get a thorough knowledge of the vehicle,in such a way as to be able to drive in the traffic safe-ly.For the controls and repairs not expressly describedin this manual, for the purchase of

aprilia

GenuineSpare Parts, accessories and other products, as wellas for specific technical advice, contact only

aprilia

Official Outlets and Officials Dealers, who can ensureyou reliable and prompt servicing.Thank you for choosing

aprilia

. We wish you a niceride.

3

Carefully observe the instructions preceded by thefollowing warning signs:

Safety norms and regulations to protectthe driver and other people from severeinjuries or grave risks.

Caution norms and suggestions to avoiddamaging the vehicle and/or hurtingyourself or other people.

Indications to make the operations easier.Technical information.

IMPORTANT:

When asking your Dealer for spare parts, specify thespare parts code indicated on the SPARE PARTSIDENTIFICATION LABEL. Write down the identification code in the space herebelow, in order to remember it also in case of loss ordeterioration of the label. The label is placed under the saddle.

In this manual the various versions are indicated bythe following symbols:

aprilia

CODICE RICAMBI spare parts code number

N˚ I.M. A B C D E

I UK A P SF B D F E

GR NL CH DK J SGP PL IL ROK

MAL RCH BM USA AUS

abc

_

automatic light switching version (Automatic Switch-on Device)

2

catalytic version

I

Italy version

£

Denmark version

U

United Kingdom version

J

Japan version

A

Austria version

S

Singapore version

P

Portugal version

V

Poland version

"

Finland version

%

Israel version

B

Belgium version

K

South Korea version

D

Germany version

M

Malaysia version

F

France version

R

Chile version

E

Spain version

Q

Bermuda version

G

Greece version

-

United States of America version

O

Holland version

^

Australia version

C

Switzerland version

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GENERAL CONTENTS

SAFE DRIVE,

5 - basic safety rules, 6 - clothing, 12 - accessories, 13 - load, 14.ARRANGEMENT OF THE MAIN ELEMENTS, 16ARRANGEMENT OF THE INSTRUMENTS, 17INSTRUMENTS AND INDICATORS, 18 - instrument and indicator table, 19MAIN INDEPENDENT CONTROLS, 20 - controls on the left side of the handlebars, 20 - controls on the right side

of the handlebars, 21 - ignition switch and steering lock, 22AUXILIARY EQUIPMENT, 23 - glove compartment, 23 - tool kit, 23 - crash helmet hook, 24 - raising the fuel tank,

25 - multifunction computer, 26MAIN COMPONENTS, 29 - fuel, 29 - mixer oil tank, 30 - transmission oil, 31 - brake fluid, 31 - front brake, 32 - rear

brake, 34 - adjusting the rear brake, 35 - adjusting the clutch, 36 - coolant, 38 - tyres, 39 - automatic lightswitching version

_

, 40 - catalytic silencer

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, 41INSTRUCTIONS FOR USE, 42 - preliminary checking operations, 43 - starting, 44 - departure and drive, 46 - run-

ning-in, 47 - stopping and parking, 48 - suggestions to prevent theft, 49MAINTENANCE, 50 - regular service intervals chart, 51 - identification data, 52 - checking the transmission oil lev-

el and topping up, 53 - changing the transmission oil, 54 - drive chain, 55 - front wheel, 58 - rear wheel, 60 -removing the fuel tank, 62 - air cleaner, 63 - inspecting the front and rear suspension, 64 - adjusting the rearsuspension, 64 - checking the steering, 65 - adjusting the exhaust port valve "electronic rave", 66 - checkingthe brake pad wear, 67 - bleeding the mixer oil tank, 68 - idling adjustment, 69 - adjusting the accelerator con-trol, 70 - spark plug, 71 - battery, 72 - long inactivity, 73 - changing the fuses, 74 - adjusting the headlightbeam, 75 - bulbs, 76 - changing the headlight bulbs, 76 - changing the dashboard bulbs, 77 - changing therear light bulbs, 77 - changing the direction indicator bulbs, 78 - changing the number plate bulb, 78

TRANSPORT, 79 - draining the fuel tank, 79CLEANING, 79LONG PERIODS OF INACTIVITY, 80 - after a long period of inactivity, 80TECHNICAL DATA, 81 - lubricant table, 84 - importers, 85 - wiring diagram, 86 - wiring diagram key, 87 - wiring

diagram for version 11kW, 88 - wiring diagram key for version 11kW, 89

safe drive

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BASIC SAFETY RULES

To drive the vehicle it is necessary to be in possession of allthe requirements prescribed by law (driving licence, minimumage, psychophysical ability, insurance, state taxes, vehicleregistration, number plate, etc.). Gradually get to know the vehicle by driving it first in areaswith low traffic and/or private areas.

The use of medicins, alcohol and drugs or psychotropic sub-stances notably increases the risk of accidents. Be sure that you are in good psychophysical conditions and fitfor driving and pay particular attention to physical wearinessand drowsiness.

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Most road accidents are caused by the driver's lack of experi-ence.

NEVER lend the vehicle to beginners and, in any case, makesure that the driver has all the requirements for driving.

Rigorously observe all road signs and national and local roadregulations.

Avoid abrupt movements that can be dangerous for yourselfand other people (for example: rearing up on the back wheel,speeding, etc.), and give due consideration to the road sur-face, visibility and other driving conditions.

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Avoid obstacles that could damage the vehicle or make youlose control.

Avoid riding in the slipstream created by preceding vehicles inorder to increase your speed.

Always drive with both hands on the handlebars and both feeton the footrests, in the correct driving posture.

Absolutely avoid standing up or stretching your limbs whiledriving.

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The driver should pay attention and avoid distractions causedby people, things and movements (never smoke, eat, drink,read, etc.) while driving.

Use only the vehicle's specific fuels and lubricants indicated inthe "Lubricant Chart"; check all oil, fuel and coolant levels reg-ularly.

COOLEROIL

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If the vehicle has been involved in an accident, make sure thatno damage has occurred to the control levers, pipes, wires,braking system and vital parts.

If necessary, have the vehicle inspected by an

aprilia

OfficialDealer, who should carefully check the frame, handlebars, sus-pensions, safety parts and all the devices that you cannotcheck by yourself.

Always remember to report any malfunction to the techniciansto help them in their work.

Never use the vehicle when the amount of damage it has suf-fered endangers your safety.

Never change the position, inclination or colour of: numberplate, direction indicators, lights and horns.

Any modification of the vehicle will result in the invalidity of theguarantee.

A12345

11

Any modification of the vehicle and/or the removal of originalcomponents can compromise vehicle performance levels andsafety or even make it illegal.

We recommend respecting all regulations and national and lo-cal provisions regarding the equipment of the vehicle.

In particular, avoid all modifications that increase the vehicle'sperformance levels or in any case alter its original characteris-tics.

Never race with other vehicles.Avoid off-road riding.

ONLY ORIGINALS

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CLOTHING

Before starting, always wear a correctly fastened crash hel-met. Make sure that it is homologated, in good shape, of theright size and that the visor is clean. Wear protective clothing,preferably in light and/or reflecting colours. In this way you willmake yourself more visible to the other drivers, thus notablyreducing the risk of being knocked down, and you will be moreprotected in case of fall. This clothing should be very tight-fit-ting and fastened at the wrists and ankles. Strings, belts andties should not be hanging loose; prevent these and other ob-jects from interfering with driving by getting entangled withmoving parts or driving mechanisms.

Do not keep objects that can be dangerous in case of fall, forexample pointed objects like keys, pens, glass vials etc. inyour pockets (the same recommendations also apply to pas-sengers).

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ACCESSORIES

The owner of the vehicle is responsible for the choice, installa-tion and use of any accessory. Avoid installing accessoriesthat cover horns or lights or that could impair their functions,limit the suspension stroke and the steering angle, hamper theoperation of the controls and reduce the distance from theground and the angle of inclination in turns.

Avoid using accessories that hamper access to the controls,since this can prolong reaction times during an emergency.

Large fairings and windscreens assembled on the vehicle canproduce aerodynamic forces capable of compromising thestability of the vehicle while driving.Make sure that the equipment is well fastened to the vehicleand not dangerous during driving. Do not install electrical devices and do not modify those al-ready existing to avoid electrical overloads, because the vehi-cle could suddenly stop or there could be a dangerous currentshortage in the horn and in the lights.

aprilia recommends the use of genuine accessories (apriliagenuine accessories).

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LOAD

Be careful and moderate when loading your luggage.

Keep any luggage loaded as close as possible to the baryc-enter of the vehicle and distribute the load uniformly on bothsides, in order to reduce imbalance to the minimum.

Furthermore, make sure that the load is firmly secured to thevehicle, especially during long trips.

Absolutely avoid hanging bulky, voluminous, heavy and/ordangerous objects on the handlebars, mudguards and forks,because the vehicle might respond more slowly in turns andits manoeuvrability could be unavoidably impaired.Do not place bags that are too bulky on the vehicle sides anddo not ride with the crash helmet hanging from its string, be-cause it could hit people or obstacles making you lose controlof the vehicle.Do not carry any bag if it is not tightly secured to the vehicle.Do not carry bags which protrude too much from the luggage-rack or which cover the lights, horn or indicators.

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Do not carry animals or children on the glove compartment oron the luggage-rack.

Do not exceed the maximum load allowed for each side-bag.

When the vehicle is overloaded, its stability and its manoeu-vrability can be compromised.

KG!

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ARRANGEMENT OF THE MAIN ELEMENTS

KEY Fig. 1

1) Fuel tank plug2) Saddle lock3) Mixer oil tank plug4) Transmission control lever5) Side stand6) Passenger's handle

KEY Fig. 2

1) Pillion2) Rear brake fluid tank 3) Coolant expansion tank plug4) Front brake fluid tank5) Rear brake control lever6) Fuel cock

Fig. 1

Fig. 2

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ARRANGEMENT OF THE INSTRUMENTS

KEY Fig. 3

1) Left rear-view mirror 2) High beam signaller push button (a) 3) Clutch lever 4) Cold start lever (e) 5) Dimmer switch (a - b) 6) Multifunction computer push button (LAP) 7) Horn push button (f) 8) Direction indicator switch (c) 9) Start push button (r) 10) Headlight switch (o - p - •)

(not provided in the _ version)11) Throttle grip12) Front brake lever13) Engine stop switch (n - m)14) Right rear-view mirror15) Instruments and indicators16) Ignition switch/steering lock (n - m - s)

Fig. 3

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INSTRUMENTS AND INDICATORS

KEY Fig. 4

1) Multifunction computer2) Revolution counter3) Speedometer4) Total kilometres odometer5) Trip odometer6) Trip odometer control knob 7) Low fuel warning light (g)8) High beam warning light (a)9) Neutral indicator warning light (q)

10) Direction indicator warning light (c)11) Mixer oil reserve warning light LED (j)

Remember: 1 mile = 1.6 km1 km = 0.625 miles.

Fig. 4

c

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INSTRUMENTS AND INDICATORS TABLE


Description Function

Multifunction computer It indicates the water temperature, the battery voltage, the hour and minutes and it makes it possible to clock and record the track lap times.

Revolution counter It indicates the number of engine revolutions per minute.

Speedometer It indicates the driving speed.

Total kilometres odometer It indicates the total number of kilometres covered.

Trip odometer It indicates the partial number of kilometres covered.

Trip odometer control knob By rotating it clockwise, it is possible to set the trip odometer to zero.

Low fuel warning light g It comes on when the quantity of fuel left in the tank is about 3 l.

High beam warning light a It comes on when the headlight is on "high beam" position.

Neutral indicator warning light q It comes on when the transmission is in neutral.

Direction indicator warning light c It blinks when the direction indicators are on.

Mixer oil reserve warning light LED j It comes on when the ignition switch is in position "n" and the start push button “r“ is pressed, thus checking the proper functioning of the LED. If the light LED does not come on during the starting, provide for replacing the bulb.

If the warning light LED comes on and does not go outafter the start push button "r" has been released, orif it comes on during normal functioning, this means

that the mixer oil reserve is being used; in this case, top upthe mixer oil tank, (see “MIXER OIL TANK” - page 30).

a

c

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MAIN INDEPENDENT CONTROLS

CONTROLS ON THE LEFT SIDE OF THEHANDLEBAR (Fig. 5)

The electrical parts work only when theignition switch is in position "n".

1) DIMMER SWITCH (a - b)When the light switch (“CONTROLS ON THERIGHT SIDE OF THE HANDLEBAR” - page 21) isin position "o", if the dimmer switch is in position"a" the high beam comes on, while if it is in posi-tion "b" the low beam comes on.

1) DIMMER SWITCH (b - a ) _ When it is in position “b” the parking lights, thedashboard light and the low beam are always on.When it is in position “a”, the high beam comeson.

2) DIRECTION INDICATOR SWITCH (c)To indicate the turn to the left, move the switch tothe left; to indicate the turn to the right, move theswitch to the right.To turn off the direction indicator, press the switchon its centre.

3) HIGH BEAM SIGNALLER PUSH BUTTON (a)This push button makes it possible to use the highbeam signaller, which is useful to send signals tothe forthcoming vehicles when passing and incase of danger or emergency.

4) HORN PUSH BUTTON (f)The horn is activated when the "f" push button ispressed.

5) COLD START LEVER (e)The starter for the cold start of the engine is oper-ated by rotating the cold start lever downwards.To disconnect the starter, rotate the lever com-pletely upwards.

6) MULTIFUNCTION COMPUTER PUSH BUTTON (LAP)

It makes it possible to use the chronometer of themultifunction computer, (see pages 26÷28).Fig. 5

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CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR (Fig. 6)

The electrical parts work only when theignition switch is in position "n".

1) HEADLIGHT SWITCH (oooo - pppp - • ) (not provided in the _ version)When the light switch is in position "•", the lightsare off; when the switch is in position "p", theparking lights and the dashboard light are on;when the switch is in position "o", the parkinglights, the dashboard light and the low beamare on. The high beam can be operated bymeans of the dimmer switch (“CONTROLS ONTHE LEFT SIDE OF THE HANDLEBAR” - pag.20).

2) START PUSH BUTTON (r)When pressed, this push button starts the engine.For the starting, see “STARTING” - page 44.

3) ENGINE STOP SWITCH (n - m)

Do not operate the engine stop switch“n - m” in running conditions.

This is a safety or emergency switch.With the switch in position "n", it is possible tostart the engine; the engine can be stopped bymoving the switch to position "m".

With stopped engine and ignition switchin position "n", the battery may dis-charge. When the vehicle has come to

rest, after stopping the engine, move the ignitionswitch to position "m".

c

a

Fig. 6

a

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IGNITION SWITCH (Fig. 7)

The ignition switch is positioned on the upper plate ofthe steering tube (Fig. 7).

The ignition key (1) operates the ignitionswitch/steering lock and opens the glove

compartment and the fuel tank plug. Two keys are supplied together with the vehicle(one spare key).

STEERING LOCK

Never turn the key to position "s" in run-ning conditions, in order to avoid losingcontrol of the vehicle.

To lock the steering, turn the handlebars completelyleftwards with the key (1) in position "m", press thekey, release it and turn it to position "s".Extract the key.

Fig. 7

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Position Function Key removal

sSteering lock

The steering is loc-ked. It is neither possible to start the engine nor to switch on the lights.

It is possible to remove the key.

mNeither the engine nor the lights can be switched on.

It is possible to remove the key.

nThe engine and the lights can be switched on.

It isn't possible to remove the key.

a

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AUXILIARY EQUIPMENT

GLOVE COMPARTMENT (Fig. 8-9)

The glove compartment is under the saddle.– To unlock the saddle, introduce the ignition key in

the lock (2-Fig. 8) and turn it clockwise, after whichyou can raise the saddle (1-Fig. 8).

To lock the saddle it isn't necessary to use the igni-tion key; it is sufficient to introduce the tangs intotheir seats, lower the saddle and press it until it locks.

Before locking the saddle, make sure thatyou have not left the key inside the com-

partment.

Before leaving, make sure that the saddleis properly locked.

c

a

Fig. 8

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TOOL KIT (Fig. 9)

To reach the tool kit (1), just unlock and raise thesaddle.In the tool kit the following spanners are provided:no. 1 3 mm hexagon spannerno. 1 5 mm hexagon spannerno. 1 6 mm hexagon spannerno. 1 8/10 mm double-ended spannerno. 1 10/13 mm double-ended spannerno. 1 cross-tip/flat-tip screwdriver no. 1 screwdriver handleno. 1 17x21x75 mm spark plug spannerno. 1 socket spanner rodno. 1 pin for 8x180 wheels, bentno. 1 tool case.

CRASH HELMET HOOK (Fig. 10)

Do not drive with your helmet hangingfrom the hook, as this could compromiseyour safety while driving.

Thanks to this hook, you no longer have to carry thecrash helmet with yourself every time you park thevehicle.To hang the crash helmet, raise the saddle (see p.23), take out the looped wire (1) and pass it throughthe visor space or through the fitted slot, then fix theloop to the hook (2).

Fig. 9

Fig. 10

a

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Now lower the saddle and lock it.

To release the crash helmet from the hook, raise thesaddle, release the wire from the hook and lower thesaddle; before leaving, take care that the wiredoesn't get crushed and that the saddle is welllocked.

RAISING THE FUEL TANK (Fig. 11)

To reach the engine from the upper side without re-moving the fuel tank, proceed as follows:– remove the saddle;– unscrew the front fastening screw of the tank;– raise the front part of the tank;– keep the tank raised introducing the stem (2) in the

apposite seat (1). Said stem is placed on the innerleft side of the saddle support.

Fig. 11

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MULTIFUNCTION COMPUTER

KEY Fig. 121) MODE push button2) LOCK push button3) START push button4) LAP push button

(on the left half of the handlebars - pos. 6 - Fig. 5)5) Upper display6) Lower display

If the writing "LLL" is displayed, checkthe sensor and/or the electrical connec-tion circuit (possible failure).

If necessary contact your aprilia Official Dealer.

FUNCTION DESCRIPTIONBy pressing the "M" push button once and more thanonce in succession, the following functions are oper-ated, in their respective order:

TEMP H20 (coolant temperature)

By pressing the "M"function push buttononce, the coolanttemperature in cen-tigrade degrees (°C)is indicated on theupper part of thedisplay, while thecurrent time is dis-

played on its lower part. If the temperature exceeds 100°C, the upper part ofthe display blinks, even if the set function is differentfrom "TEMP H2O".If the temperature is lower than 30°C, the writing"COLD" appears on the display.Reading range: 0 ÷ 130°C.

Fig. 12

M

S

L

VBATTEXTTH2OTIME

LAPTIME

b

BATTERY

VBATTEXTTH2OTH2OTIME

LAPTIME

M

S

L

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V BATT (Battery voltage)By pressing the "M"push button for thesecond t ime, thebattery voltage, ex-pressed in volt, isindicated on the dis-play. The rechargesystem funct ionsproperly if at 4000

rpm the battery voltage, with low beam on, is includ-ed between 13 and 15 V. The current time appears inthe lower part of the display.

TIME (Setting the hour/minutes)By pressing the "M"push button for thethird time, the hourand minutes are dis-played.

To change the time data, proceedas follows:Press the "L" push button and thenumber indicating the hours willstart blinking.

To increase the value, press the"S" push button.

To set the minutes, press the "M"push button.

To increase the value, press the"S" push button.

Now, to store the setting of the hourand minutes, press the central "L"push button.

LAP (Stop-watch)By pressing the "M"push button for thefourth time, the LAPfunction is displayed,which makes it pos-sible to time each lapwith the vehicle onthe track and to storethe data in order to

be able to consult them successively.

VBATTEXTTH2OTIME

LAPTIME

M

S

L

VBATTEXTTH2OTIME

LAPTIME

M

S

L

VBATTEXTTH2OTH2OTIME

LAPTIME

M

S

L

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How to use the LAP function.(Only for races in places that are closed to traf-fic).

To initialize the computer for thetiming function, press the "S" pushbutton. The letter "L" (Lap) will blinkon the display.

To start the stop-watch, press the"LAP" push button, positioned onthe left half of the handlebars.

To display the time taken for onelap, press the "LAP" push buttonagain. After pressing the "LAP"push button, the time obtained inthe previous lap is displayed for

about 15 seconds, after which the current time is dis-played again.

To end the timing, press the "S"push button.

It is possible to carry out up to 10 timings.At the last timing, the writing "L10" will

appear on the display.

How to recall the time per lap (LAP MEMORY)

To recall the time per lap, press the"L" push button.The writing "Ld" will appear on thedisplay.

To run through the stored times perlap, press the "LAP" push button.The writing "Ld 01" corresponds tolap no. 1, "Ld 02" corresponds tolap no. 2 and so on.

How to delete the stored data

To delete the stored data, pressthe "L" push button.The writing "L10", "L9" or "L8", etc.will appear on the display.

Now, press the "S" push buttonand, keeping it pressed, press alsothe "LAP" push button on the lefthalf of the handlebars.In this way the stored data will be

definitively deleted.

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MAIN COMPONENTS

FUEL

The fuel used for internal combustion en-gines is extremely inflammable and inparticular conditions it can become ex-

plosive.It is important to carry out the refuelling and themaintenance operations in a well-ventilated area,with the engine off. Do not smoke while refuelling or near fuel va-pours, in any case avoid any contact with freeflames, sparks and any other heat source to pre-vent the fuel from catching fire or from explod-ing.Further, prevent fuel from flowing out of the fuelfiller, as it could catch fire when getting in con-tact with the red-hot surfaces of the engine. Incase some fuel has accidentally been spilt, makesure that the area has completely dried beforestarting the vehicle. Since petrol expands underthe heat of the sun and due to the effects of sunradiation, never fill the tank to the brim. Screwthe plug up carefully (Fig. 13) after refuelling. Avoid any contact of the fuel with the skin andthe inhalation of vapours; do not swallow fuel orpour it from a receptacle into another by meansof a tube.

KEEP AWAY FROM CHILDREN

Use only premium grade petrol (4 Stars U), in con-formity with the DIN 51600 standard, min. O.N. 98(N.O.R.M.) and 88 (N.O.M.M.).

2 Use only unleaded petrol, in conformity with theDIN 51607 standard, min. O.N. 95 (N.O.R.M.) and 85(N.O.M.M.).

The fuel tank capacity is approximately 13 l, about 3 lof which make up the reserve.

To unlock the fuel tank plug, insert the key in the lockand turn it anticlockwise (Fig. 13).

a

Fig. 13

30

MIXER OIL TANK (Fig. 14)

Top up the mixer oil tank every 500 km.

The vehicle is provided with a separate mixer toblend the petrol with oil for the lubrication of the en-gine (see “LUBRICANT CHART “ - page 84).

The mixer oil reserve is indicated by the coming on ofthe mixer oil reserve warning light LED “j” posi-tioned on the dashboard, see p. 18 (INSTRUMENTSAND INDICATORS TABLE).

The use of the vehicle without mixer oilseriously damages the engine.

In case you run out of oil in the mixer oil tank orin case the mixer oil pipe is removed, it is neces-sary to bleed the mixer oil tank (see "BLEEDINGTHE MIXER OIL TANK" - page 68).This operation is indispensable, since the run-ning of the engine with air in the mixer oil systemcould cause serious damages to the engine it-self.

To pour oil into the tank, remove the saddle (see"GLOVE COMPARTMENT" - page 23) and then takeoff the pressure plug (1).

OIL TANK CAPACITY: 1.4 l

TANK RESERVE: 0.35 l

Wash your hands carefully after using theoil.

Do not dispose of oil in the environment.

KEEP AWAY FROM CHILDREN.

b Fig. 14

a

31

TRANSMISSION OIL


It is necessary to change the transmission oil afterthe first 1000 km and successively every 12000 km(see "CHECKING THE TRANSMISSION OIL LEVELAND TOPPING UP" - page 53, "CHANGING THETRANSMISSION OIL" - page 54 and "LUBRICANTCHART" - page 84).

Used transmission oil can cause severedamages to the skin if handled every dayand for long.

Wash your hands carefully after using it.

If the vehicle is used in very dusty areas,the transmission oil should be changedmore frequently.

Do not dispose of oil in the environment.Put it in a sealed container and take it to the fill-ing station where you usually buy it.

BRAKE FLUID (recommendations)

Sudden clearance variations or elastic re-sistance on the brake lever are due totroubles in the hydraulic system.

For any doubt regarding the perfect functioningof the braking system and in case you are notable to carry out the usual checking operations,contact your aprilia Official Dealer. Make sure that the brake disc and the friction sur-faces are neither oily nor greasy, especially aftermaintenance or checking operations.Check that the brake cable is neither twisted norworn out. Prevent water or dust from accidentally gettinginto the circuit.If the brake fluid gets in contact with the skin orthe eyes, it can cause serious irritations. Carefully wash the parts of your body that get incontact with the liquid. Consult a doctor or an oc-ulist if the liquid gets in contact with your eyes. Do not dispose of fluid in the environment.


When using the brake fluid, take care notto spill it on the plastic or painted parts,since it can damage them.

c

a

b

a

b

32

FRONT BRAKE (Fig. 15)

The brakes are the parts that most ensureyour safety and for this reason they mustalways be perfectly working. The brake

fluid must be changed once a year by an apriliaOfficial Dealer.

This vehicle is provided with front hydraulic discbrake. When the disc pads wear out, the level of thefluid decreases to automatically compensate for theirwear. Periodically check the brake fluid level in thetank (1) and the wear of the pads (see "CHECKINGTHE BRAKE PAD WEAR" - page 67).

To check the fluid level, keep the vehicle in verticalposition and incline the tank (1), so that the fluid itcontains is parallel to the ground. Make sure that thefluid level is included between the "MIN" and "MAX"marks. If the fluid level does not reach the "MIN" mark, pro-vide for topping up.

Proceed as follows:– unscrew and remove the plug (2);

Fig. 15

a

33

In order not to spill the brake fluid whiletopping up, keep the fluid in the tank par-allel to the ground.

– remove the gasket;– fill the tank until the fluid reaches the "MAX" mark;– put the gasket back;– put the plug back (2).

Check the braking efficiency.If necessary, contact your aprilia OfficialDealer.

In case of excessive stroke of the brake lever, of ex-cessive elasticity or in case there is air in the circuit,contact your aprilia Official Dealer, since it may benecessary to bleed the system.In any case, the bleeding must be carried out afterthe first 1000 km.


b

a

c

34

REAR BRAKE (Fig. 16)

The brakes are the parts that most ensureyour safety and for this reason they mustalways be perfectly working. The brake

fluid must be changed once a year by an apriliaOfficial Dealer.

This vehicle is provided with rear hydraulic discbrake. When the disc pads wear out, the level of thefluid decreases to automatically compensate for theirwear.Periodically check the brake fluid level in the tank (1)and the wear of the pads (see "CHECKING THEBRAKE PAD WEAR" - page 67).

To check the fluid level, keep the vehicle in verticalposition and incline the tank, so that the fluid it con-tains is parallel to the ground. Make sure that the fluid level is included between the"MIN" and "MAX" marks. If the fluid level does notreach the "MIN" mark, provide for topping up. Proceed as follows:– remove the screw (2);– remove the tank (1);– unscrew the plug (3);

In order not to spill the brake fluid whentopping up, keep the fluid in the tank par-allel to the ground.

– remove the gasket;– fill the tank until the fluid reaches the "MAX" mark;– put the gasket back;– screw and tighten the plug (3) and reassemble the

tank (1).

Check the braking efficiency.If necessary, do not hesitate to contactyour aprilia Official Dealer.

In case of excessive stroke of the brake lever, of ex-cessive elasticity or in case there is air in the circuit,contact your aprilia Official Dealer, since it may benecessary to bleed the system. In any case, thebleeding must be carried out after the first 1000 km.

Remember: 1 mile = 1.6 km1 km = 0.625 miles.Fig. 16

a

b

a

c

35

ADJUSTING THE REAR BRAKE (Fig. 17)

It is possible to position the brake lever at the wantedheight by means of the adjusting screw: – loosen the lock nut (1);– tighten the screw thoroughly (2);– loosen the pump adjuster lock nut (3);– screw or unscrew the lever adjustment rod (4), un-

til reaching the wanted height of the brake lever;– tighten the pump adjuster lock nut (3);– put the adjusting screw back (2);

minimum lever clearance: 3 - 4 mm– tighten the lock nut (1).

After the adjustment, make sure thatwhen the brake is released the wheelturns freely.

Minimum lever clearance: 3 - 4 mm.

Check the braking efficiency. If necessary, do not hesitate to contactyour aprilia Official Dealer.

b

a

Fig. 17

36

ADJUSTING THE CLUTCH

If the engine stops or tends to advance when thegears are engaged, or if the clutch slips causing adelay in the acceleration in comparison with the en-gine speed, adjust the clutch.Minor adjustments can be carried out by means ofthe adjuster (1-Fig. 18):– loosen the lock nut (2-Fig. 18);– turn the adjuster (1-Fig. 18) until the idle stroke at

the clutch lever end is about 10÷15 mm (see Fig.18). Tighten the lock nut (2-Fig. 18) and check theadjustment.

Fig. 18

37

If the adjuster is completely screwed or completelyunscrewed or if it is not possible to obtain a correctidle stroke:– unscrew the clutch inspection cover by means of a

screwdriver or a coin (Fig. 19);– loosen the inside nut with the special spanner you

will find in the tool kit (2-Fig. 20);– turn the adjusting screw with a screwdriver (3-Fig.

20) until you take up the slack completely;– unscrew the above mentioned screw by giving it

half a turn, which corresponds to 3-4 mm of cablestroke (1-Fig. 20);

– keeping the adjusting screw fast by means of thescrewdriver, tighten the nut with the special span-ner;

– reassemble the clutch inspection cover.

If it is not possible to obtain a correct ad-justment or if the clutch does not functionproperly, contact your aprilia Official

Dealer.

Periodically lubricate the clutch cable with a suitablelubricant, in order to avoid premature wear and corro-sion.Check the integrity of the cable: it must not presentflattened parts and the sheath must not be worn outin any point.

a

Fig. 19

Fig. 20

38

COOLANT (Fig. 21)


Check the coolant level every 1500 km and after longrides; change it every 2 years.The vehicle is sold with a mixture made up of 70%water and 30% antifreeze.To use the vehicle when the temperature is below ze-ro, check the coolant level more frequently and, if thetemperature is lower than -31°C, add antifreeze untilreaching the maximum recommended percentage,that is, 60%, with water in the corresponding percent-age of 40%.

For the cooling solution, use drinkable water with fewminerals or distilled water, in order not to damage thealuminium engine.

Do not remove the radiator plug when theengine is hot, since the coolant is underpressure and its temperature is high. If it

gets in contact with the skin or with clothes it cancause severe burns and/or damages.

The coolant is noxious:DO NOT SWALLOW IT


Fig. 21

c

a

39

CheckingProceed as follows:– position the vehicle on the side stand;– raise the fuel tank (see "RAISING THE FUEL

TANK" - page 25);– visually check the coolant level in the tank (the

right level should be included between the "MIN"and "MAX" marks);

– if necessary, top up.

Topping upProceed as follows:– position the vehicle on the side stand;– remove the filling plug (1);– top up until the level of the fluid contained in the

expansion tank reaches the "MAX" mark.

Do not exceed such level, otherwise thefluid will flow out when the engine is run-ning.

– Screw and tighten the filling plug (1);– lower the fuel tank and put it in its initial position.

To change the fluid, or in case of leaks inthe circuit, contact your aprilia OfficialDealer.

TYRES

This vehicle is provided with tubeless tyres.

Check the tyre inflation pressure at roomtemperature every month. If the tyres arehot, the measurement is not correct.

Carry out the measurement especially after longrides.If the inflation pressure is too high, the groundunevenness cannot be dampened and is there-fore transmitted to the handlebars, thus compro-mising the driving comfort and reducing the roadholding during turns.If, on the contrary, the inflation pressure is toolow, the tyre sides are under greater stress andthe tyre itself may slip on the rim or it may be-come loose, with consequent loss of control ofthe vehicle.In case of sudden braking the tyres could evenget out of the rims. Further, the vehicle couldskid while turning.Check the surface and the wear of the tyres,since tyres in bad conditions can impair boththeir grip and the controllability of the vehicle.Change the tyre when it is worn out or in case ofpuncture on the tread side, if the puncture is larg-er than 5 mm.

b

a

a

40

After repairing a tyre, have the wheels balanced.Use only tyres in the size suggested by aprilia(see "TECHNICAL DATA" - page 82).Do not install tyres with air tube on rims for tube-less tyres and vice versa.Make sure that the tyres always have their valvesealing caps, to prevent them from suddenly go-ing flat.Change, reparation, maintenance and balancingoperations are very important and should be car-ried out by qualified technicians with appropriatetools.For this reason, it is advisable to have the abovementioned operations carried out by an apriliaOfficial Dealer or by a qualified tyre repairer.If the tyres are new, they may still be coveredwith a slippery film: drive carefully for the first kil-ometres. Do not oil the tyres with unsuitable fluids.

INFLATION PRESSUREFRONT ......................................... 180 kPa (1,8 bar)REAR ............................................. 200 kPa (2 bar)

FOR DRIVE WITH PASSENGERFRONT ......................................... 180 kPa (1,8 bar)REAR .......................................... 230 kPa (2,3 bar)

MINIMUM TREAD DEPTH LIMITFRONT ............................................................2 mmREAR .............................................................2 mm

AUTOMATIC LIGHT SWITCHING VERSION _The vehicles provided with the Automatic Switch-onDevice can be immediately recognized, since thelights come automatically on as soon as the engine isstarted.For this reason the light switch is replaced by a dim-mer switch.The lights can be switched off only by stopping theengine.◆ Before starting the vehicle, make sure that the

dimmer switch is in position “b” (front low beam).

41

CATALYTIC SILENCER 2Avoid parking the vehicle catalytic ver-sion near dry brush wood or in placeseasily accessible to children, as the cata-

lytic silencer becomes extremely hot during use;be very careful and avoid any kind of contact be-fore it has completely cooled down.

The catalytic vehicle is fitted with a silencer with met-al catalytic converter of the "platinum-rhodium biva-lent" type.This device provides for the oxidation of the CO (car-bonic oxide) and of the HC (unburned hydrocarbons)contained in the exhaust gases, changing them intocarbon dioxide and steam, respectively.Due to the catalytic reaction, the high temperaturereached by the exhaust gases allows the burning ofthe oil particles, thus keeping the silencer clean andeliminating the exhaust fumes.

To have the catalytic converter function correctly andfor long and to reduce possible problems regardingthe soiling of the thermal unit and of the exhaust, it isnecessary to avoid covering long distances with theengine running at constantly low rpm.It is sufficient to alternate these periods with periodsin which the engine runs at relatively high rpm, evenif only for a few seconds, but rather frequently. What has been stated above assumes particular im-portance for the cold starting of the engine: in thiscase, in order to reach a rpm regime sufficient to en-able the "priming" of the catalytic reaction, just makesure that the temperature of the thermal unit hasreached at least 50°C, which generally occurs a fewseconds after starting the engine.

Do not use leaded petrol, since it causesthe destruction of the catalytic converter.

a

b

42

INSTRUCTIONS FOR USE

Before departure, always carry out a pre-liminary checking of the vehicle to makesure that it functions correctly and safely

(see the "PRELIMINARY CHECKING OPERA-TIONS" table - page 43).The non-performance of these checking opera-tions can cause severe personal injuries or dam-ages to the vehicle.

Do not hesitate to consult your apriliaOfficial Dealer in case there is somethingyou do not understand about the func-

tioning of some controls or in case you suspector discover some irregularities.It does not take long to carry out a check-up andthis operation ensures you much more safety.

aa

43

PRELIMINARY CHECKING OPERATIONS

Component Check Page

Front and rear disc brake Check the functioning, the idle stroke of the control lever, the brake fluid oil level and make sure there are no leaks. Check the wear of the pads.If necessary, top up the fluid tank.

32 ÷ 37

Accelerator 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. 70

Mixer oil / transmission oil Check and/or top up if necessary 30 - 3153 - 54

Wheels / tyres Check the tyre surface, the inflation pressure, wear and tear and any damage. 39 - 40

Brake levers Make sure that they work smoothly. If necessary, lubricate the articulations and adjust the stroke. 35

Steering Make sure that the steering rotates smoothly, without any clearance or slacke-ning. 65

Clutch The idle stroke at the end of the clutch lever must be 10 ÷ 15 mm; the clutch must function without jerks. 36 - 37

Side stand Make sure that it works smoothly and that the spring tension brings it back to its normal position. If necessary, lubricate joints and hinges. –

Fastening elements If necessary, tighten all the fastening elements. –

Gearing chain Check the slack. 55 ÷ 57

Fuel tank Check the fuel level and top up, if necessary. Make sure there are no leaks or occlusions in the circuit. 29

Coolant The coolant level in the expansion tank must be included between the "MIN" and "MAX" marks. 38 - 39

Lights, warning lights, horn and electric devices

Check the proper functioning of acoustic and visual devices.Change the bulbs or intervene in case of failure. 72 ÷ 78

44

STARTING

Exhaust gases contain carbon monoxide,which is extremely noxious if inhaled.Avoid starting the vehicle in closed or

badly-ventilated rooms.The non-observance of these warnings couldcause loss of consciousness or even lead todeath by asphyxia.

The stand is provided with an automaticrecovery device.

– Before starting the engine, let the side stand upand block at least one wheel, in order to avoid los-ing control of the vehicle.If this operation is carried out on uphill or downhillroads, be particularly careful;

– turn the fuel cock to position "ON" (Fig. 22);– turn the ignition switch to position "n";– put the gears in neutral (green warning light

"q" on);– move the engine stop switch (1-Fig. 23) to position

"n";– press the start push button "r" (2-Fig. 23) with re-

leased throttle grip.If the engine is cold, rotate the lever "e" down-wards (1-Fig. 24).

Fig. 22

Fig. 23

a

c

45

When the start push button "r" ispressed, the mixer oil reserve warning lightLED "j" comes on.

With the engine in running condition, when thestart push button "r" is released, the mixer oilreserve warning light LED "j" must go out; ifthis does not occur, top up the mixer oil tank,(see “MIXER OIL TANK” - page 30).

– Warm the engine up until it runs normally, with thecold start lever "e" (1-Fig.-Fig. 24) completely ro-tated upwards.

Never leave with cold engine.Do not use the cold start lever "e" (1-Fig.24) when starting with hot engine.

Starting with flooded engineIf the starting is not carried out properly or if there istoo much fuel in the intake ducts and in the carburet-tor, the engine may get flooded.

To clean a flooded engine:– carry out the first six operations described for the

starting (page 44);– rotate the cold start lever "e" (1-Fig. 24) complete-

ly upwards;– let the engine run idly for a few seconds with com-

pletely open throttle.At this point, if the engine starts, bring the throttleto the minimum rpm position and, if the minimumspeed is not constant, keep the engine idling withslight movements of the throttle grip.If the engine does not start, wait 10 seconds andcarry out the starting (pages 44 - 45).

b

b Fig. 24

46

DEPARTURE AND DRIVE

Before leaving, carefully read the "SAFEDRIVE" chapter page 5 ÷ 15.Adjust the inclination of the rear-view

mirrors properly.If there is no other passenger with you, makesure that the rear footrests are closed.If there is a passenger with you, instruct him/herso that he/she doesn't create problems duringthe manoeuvres.

For the departure, proceed as follows:– make sure that the engine is warm;– with released throttle grip and idling engine, pull

the clutch lever and engage the first gear by press-ing the gearshift foot lever downwards (Fig. 25);

– release the clutch lever gently and at the sametime gradually increase the engine speed by rotat-ing the throttle grip;

– when the vehicle reaches a certain speed, releasethe throttle grip, pull the clutch lever and engagethe second gear by lifting the gearshift foot lever.To shift up, repeat this operation.

Avoid opening and closing the throttlegrip repeatedly and continuously, so thatyou do not accidentally lose control of

the vehicle.If you have to brake, close the throttle and put onboth brakes in order to obtain uniform decelera-tion, properly exerting pressure on the brakingparts.By putting on the front brake only or the rearbrake only, you reduce the braking force consid-erably, thus running the risk of locking one wheeland consequently losing grip.Before beginning to turn, slow down or brakedriving at moderate and constant speed.

Fig. 25

a

a

47

If the brakes only are continuously oper-ated on downhill stretches, the frictionsurfaces can become overheated, thusreducing the braking efficiency.

Exploit the engine compression and shift downusing both brakes intermittently.Do not drive with the engine off!In case of wet ground or scarce wheel grip (snow,ice, mud, etc.), drive slowly, avoiding suddenbrakings or manoeuvres that could make youlose grip and fall down.

Pay the utmost attention to any obstacle or varia-tion of the ground. Uneven roads, rails, manholecovers, indications painted on the road surface,building site metal plates become rather slipperyby rain. For this reason all these obstacles haveto be carefully avoided, driving smoothly andbending the vehicle as little as possible.Always use the direction indicators timely whenyou intend to change lane or direction, avoidingsharp and dangerous movements.

If the mixer oil reserve warning light LED"j" comes on during the normal func-tioning of the engine, this means that the

mixer oil reserve is being used; in this case, topup the mixer oil tank, (see “MIXER OIL TANK” -page 30).

RUNNING-IN


After the first 1000 km, carry out thechecking operations indicated in the Reg-ular Service Intervals Chart (see "REGU-

LAR SERVICE INTERVALS CHART" - page 51), inorder to avoid hurting yourself or other peopleand/or damaging the vehicle.

The running-in of the engine is primary to ensure itsworking life and its correct functioning.If possible, drive on hill roads and/or roads with manybends, so that the engine, the suspensions and thebrakes undergo a more effective running-in.Keep to the following indications:– Do not open the throttle completely if the speed is

low, both during and after the running-in.– During the first 100 km put on the brakes with cau-

tion, avoiding sharp and prolonged brakings.– This ensures a correct settlement of the friction

material on the brake disc pads.– During the first 800 km, the engine speed should

not exceed 6000 rpm.– Between the first 800 and 1600 km drive more

briskly, change speed and use the maximum ac-celeration only for a few seconds, in order to en-sure better coupling of the components subject towear; never exceed 9000 rpm.

– After the first 1600 km you can expect better perform-ance from the engine, in any case without exceeding11000 rpm (red sector of the revolution counter).

a

b

ca

48

STOPPING AND PARKING

To stop the vehicle:– release the throttle grip, stop the vehicle by putting

on both brakes and shifting down according to thespeed of the vehicle;

– disengage the clutch before the vehicle has com-pletely stopped, in order to prevent the engine fromstalling.

To park:– shift the gears to the neutral;– turn the ignition switch to position "m" (Fig. 26);– turn the fuel cock to position "OFF";– turn the handlebars completely leftwards;– lock the steering (see "STEERING LOCK" - page

22) and extract the key;– use the apposite side stand for parking.

Park the vehicle on firm and flat ground,to prevent it from falling down.Neither lean the vehicle against walls, nor

lay it on the ground.Make sure that the vehicle and especially its red-hot parts do not represent a danger for personsand children.

Do not leave the vehicle unattended when the en-gine is on or the key is inserted into the ignitionblock.

Do not seat on the vehicle when the stand isdown.

Fig. 26

a

49

SUGGESTIONS TO PREVENT THEFT

NEVER leave the ignition key inserted and alwaysuse the steering lock.

Park the vehicle in a safe place, possibly in a garageor a protected place.

When possible, use an additional anti-theft device.

Make sure that all documents are in order and theroad tax has been paid.

Write down your personal data and telephonenumber in the space provided in this manual, to facil-itate the identification of the owner in case of findingafter theft.

SURNAME: ................................................................

NAME: .......................................................................

ADDRESS: ................................................................

...................................................................................

TELEPHONE NO.: ....................................................

Very often stolen vehicles are identifiedthanks to the data written on the use/

maintenance manual.c

50

MAINTENANCE

Before beginning any maintenance oper-ation or any inspection of the vehicle,stop the engine, extract the key from the

ignition block, if possible lift the vehicle bymeans of the proper equipment, on firm and flatground.Keep away from the red-hot parts of the engineand of the exhaust system, in order to avoidburns.

The vehicle is made up of not edibleparts. Never bite, suck, chew or swallowany part of the vehicle for any reason.

To carry out maintenance operations a basic knowl-edge of mechanics and sometimes specific tools andtechnical training are required.

If you need assistance or technical advice consult,when possible, your aprilia Official Dealer, who canensure you quick and careful servicing.

After any maintenance operation, carry out the pre-liminary checking operations (see the "PRELIMI-NARY CHECKING OPERATIONS" table - page 43).

a

a

51

REGULAR SERVICE INTERVALS CHART

Checking operations After running-in (1000 km or 4 months)

Every 4000 kmor 8 months

Every 8000 kmor 16 months

C =

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Battery - fluid level C CSpark plug P P SCarburettor C PWheel centering CSteering bearings and steering C CWheel bearings CAir cleaner PClutch clearance R RBraking systems C CCooling system C CLight system C CCoolant every 1,500 km: C/ every 2 years: SBrake fluid every year: S/every 4000 km: CMixer oil level every 500 km: CFork oil every 12000 km: STransmission oil S C every 12000 km: SMixer pump and bleeding R RTyre inflation pressure every month: RMinimum rpm R RFuel cock C CNut, bolt, screw tightening C CSuspensions and attitutude C CMixer oil reserve warning light LED C CBrake fluid bleeding after running-in: CChain tension and lubrication every 500 km: CFuel pipes C every 4 years: SPiston and small parts every 8000 km:C/ every 16000 km: S

Remember: 1 mile = 1.6 km 1 km = 0.625 miles.c

52

IDENTIFICATION DATA

It is a good idea to write down the frame and enginenumbers in the space provided in this manual.

The frame number can be used for the purchase ofspare parts.

Do not alter the identification numbersif you do not want to incur severe penal

and administrative sanctions. In particular, thealteration of the frame number results in theimmediate invalidity of the guarantee.

ENGINE NUMBERThe engine number is stamped on the upper part ofthe crankcase, on the left (Fig. 27).

Engine no.

FRAME NUMBERThe frame number is stamped on the right side of thesteering tube (Fig. 28).

Frame no.

Fig. 27

Fig. 28

c

53

CHECKING THE TRANSMISSION OILLEVEL AND TOPPING UP (Fig. 29)


Read pages 31 and 50 carefully.

Check the transmission oil level every 4000 km, ex-cepted the cases in which the oil change is recom-mended (see "CHANGING THE TRANSMISSIONOIL" - page 54).To carry out the checking:– stop the engine and let it cool down for at least 10

minutes, in order to allow the oil to flow back to theoil pan;

– keep the vehicle in vertical position, with the twowheels resting on the ground;

– make sure that the oil level reaches or exceeds themiddle of the peephole (1);

– if this doesn't occur, it means that the oil quantity isinsufficient. In this case, remove the plug (2) andpour small quantities of oil through the filling hole.Wait about 2 minutes, in order to allow the oil todistribute uniformly inside the oil pan, then repeatthe operation until the oil level reaches the middleof the peephole (1);

– retighten the filling plug (2).

c

Fig. 29

54

CHANGING THE TRANSMISSION OIL(Fig. 30)

When warmed up, the engine containshot oil; therefore, in order to avoid burns,be careful while performing the opera-

tions described here below.


Read page 50 carefully.Change the transmission oil after the first 1000 kmand successively every 12000 km (see the "REGU-LAR SERVICE INTERVALS CHART" - page 51).

To carry out the changing:– warm up the engine for a few minutes, to facilitate

the oil outflow during the following draining phase;– keep the vehicle in vertical position, with the two

wheels resting on the ground;– remove the fairing of the left side;– unscrew and remove the oil filling plug (1);– unscrew and remove the oil drain plug (2), posi-

tioned on the bottom of the base;– drain the oil and let it drip into a container for a few

minutes;– remove the metal residues from the drain plug

magnet (2);– retighten the drain plug (2);– pour about 1000 cmC (for version 11 kW, 600 cmC)

of engine oil inside the filling opening (see the “LU-BRICANT CHART” - page 84);

– tighten the oil filling plug (1);– put the fairing back to its position;– check the oil level (see "CHECKING THE TRANS-

MISSION OIL LEVEL AND TOPPING UP” -page 53).

Fig. 30

ac

55

DRIVE CHAIN

An excessive slackening of the chain canmake it come out of the pinion, which of-ten results in accidents or serious dam-

ages to the vehicle. Periodically check the slackand if necessary adjust it (page 56).To change the chain, contact your aprilia Offi-cial Dealer, who will ensure you careful andprompt servicing.

Read page 50 carefully.The RS 125 is provided with a chain in which a ringlink joint is used. If maintenance operations are not performed proper-ly, the chain may wear untimely or the pinions maybe damaged.Provide for maintenance more frequently if you usethe vehicle in difficult conditions or on dusty and/ormuddy roads.

Checking the slackTo check the slack, proceed as follows:– stop the engine, position the vehicle on the side

stand and put the gears into neutral;– make sure that the vertical oscillation, in an inter-

mediate point between pinion and crown in thelower part of the chain, is about 25 mm (Fig. 31);

– move the vehicle forward, in such a way as to beable to check the vertical oscillation of the chainalso when the wheel turns; the slack must be con-stant in all the wheel rotation phases.

If in some sections the slack is greater than in others,this means that there are crushed or seized links. Toeliminate the risk of seizures, lubricate the chain fre-quently (see page 57).If the slack is uniform and greater than prescribed,carry out the adjustment (see page 56).If the chain is disassembled and then reassembled,make sure that the clip of the connection link ismounted with its open part opposite to the directionof advancement (Fig. 31).

a

Fig. 31

56

AdjustmentIf after the checking it is necessary to adjust thechain tension, proceed as follows:– loosen the fastening nut of the rear wheel pin (1-

Fig. 32);– loosen the two lock nuts of the right (2-Fig. 32) and

left (1-Fig. 33) adjusters, positioned near the rearwheel pin;

– act on the right (3-Fig. 32) and left (2-Fig. 33) ad-justers, making sure that the fixed references onthe rear fork coincide on both sides with the markstamped on the mobile plates (4-Fig. 32, 3-Fig. 33);

– once the operation has been completed, tightenthe fastening nut of the rear wheel pin.Driving torque: 100 Nm (10 kgm);

– tighten the lock nuts of the two adjusters;– tighten the right and left screws;– check the slack again (page 55).

Fig. 32

Fig. 33

57

Checking the wear and tear of chain and pinionsFurthermore, make sure that chain and pinions donot present:damaged rollers; loosened pins; dry, rusty, crushedor seized links; incorrect adjustment; excessivewear; excessively worn or damaged pinion teeth.If the chain rollers are damaged, the pins are loos-ened and/or the O rings are either damaged or lack-ing, it is necessary to change the chain.

Lubricate the chain frequently, especiallyif there are dry or rusty parts. Crushed orseized links must be lubricated and re-

paired. If this is not possible, consult youraprilia Official Dealer, who will provide forchanging the chain.

Lubrication and cleaning


Lubricate the chain every 1000 km and whenever it isnecessary.Lubricate the chain with thick oil (SAE 80W - 90) orchain grease available on the market.Never wash the chain with hot water jets, steam jets,high-pressure water jets and highly inflammable sol-vents.a

c

58

FRONT WHEEL

DISASSEMBLY

Never press the front brake lever after re-moving the brake callipers, otherwise thecalliper pistons may go out of their seat,

thus causing the outflow of the brake fluid. In thiscase consult your aprilia Official Dealer, who willcarry out the proper maintenance operation.

Read page 50 carefully.

To remove the front wheel, proceed as follows:– place the vehicle on the side stand;– remove the two fastening screws of the brake calli-

per (1-Fig. 34);– disconnect the odometer cable (1-Fig. 35);– loosen the wheel pin screw (2-Fig. 34);– loosen the four screws of the fork clamps (3-Fig.

34, 2-Fig. 35);– raise the front part of the vehicle and place a sup-

port under the engine, to prevent the vehicle fromfalling down after the wheel has been removed;

– remove the pin screw (2-Fig. 34);– unscrew and extract the pin (3-Fig. 35);– remove the wheel.

Fig. 34

Fig. 35

a

59

REASSEMBLY


To reassemble the wheel:– position the wheel between the fork rods;– insert the pin (3-Fig. 35);– insert and turn the screw (2-Fig. 34) until the pin

sets in the seat;– position the odometer cable correctly (1-Fig. 35);– tighten the four screws of the fork clamps (2-Fig.

34) (3-Fig. 35);– tighten the screw (2-Fig. 34).

Driving torque: 80 Nm (8 kgm);– mount the brake calliper, tightening the screws (1-

Fig. 34).

After the reassembly, pull the brake leverrepeatedly and check the correct func-tioning of the braking system.

Check the wheel centering.Have the driving torque, centering and balancingof the wheel checked by your aprilia OfficialDealer, in order to avoid accidents that may beharmful for you and other people.

a

60

REAR WHEEL

DISASSEMBLY

Never press the rear brake lever after re-moving the wheel, since otherwise thecalliper piston may go out of its seat, thus

causing the outflow of the brake fluid. In thiscase consult your aprilia Official Dealer, whowill carry out the proper maintenance operation.


To remove the wheel, proceed as follows:– raise the rear part of the vehicle and place a sup-

port under the engine, to prevent the vehicle fromfalling down after the wheel has been removed;

– remove the nut (1-Fig. 36);– extract the pin (1-Fig. 37);– remove the transmission chain from the crown, by

pushing the rear wheel forward;– remove the wheel from the rear fork.

Fig. 36

Fig. 37

a

61

REASSEMBLY


To reassemble the wheel, carry out the following op-erations:– position the wheel between the rear fork arms;– push the wheel forward and position the chain in

its seat;– position the antirotation pin correctly in the brake

plate seat;– insert the pin (1-Fig. 37);– insert and screw the nut (1-Fig. 36) until the pin

sets in the seat;– check the chain tension (page 55);– tighten the nut (1-Fig. 36).Driving torque: 100 Nm (10 kgm).

After the reassembly, pull the brake leverrepeatedly and check the correct func-tioning of the braking system.

Check the wheel centering.Have the driving torque, centering and balancingof the wheel checked by your aprilia OfficialDealer, in order to avoid accidents that may beharmful for you and other people.

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62

REMOVING THE FUEL TANK

When you perform the following opera-tions, be extremely careful: the petrolmay flow out of the tank and catch fire if it

gets in contact with the red-hot surfaces of theengine!

Read pages 29 and 50 carefully.

To remove the fuel tank, proceed as follows:– move the fuel cock to position "OFF" (Fig. 38);– raise the tank (see "RAISING THE FUEL TANK" -

page 25);– disconnect the fuel pipe (2-Fig. 39) and the electric

cable (3-Fig. 39);– unscrew and remove the nut and the fastening

screw of the tank (1-Fig. 39);– remove the fuel tank (4-Fig. 39).

For the reassembly, carry out the same operationsreversing the order.

Fig. 38

Fig. 39

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63

AIR CLEANER

Do not use petrol or inflammable solventsto wash the air cleaner, in order to avoidfires or explosions.


Read pages 29 and 50 carefully.Periodically check the conditions of the air cleanerand clean it every 4000 km.If the vehicle is used on dusty or wet roads, thecleaning operations should be carried out more fre-quently.

For the cleaning, proceed as follows:– raise the fuel tank (see "RAISING THE FUEL

TANK" - page 25);– remove the filter case cover (1-Fig. 40), by loosen-

ing the two screws (2-Fig. 40) (other two screwsare positioned on the front part);

– remove the filtering element (3-Fig. 40) and thegrid (4-Fig. 40);

– wash the filtering element with clean, non-inflam-mable solvents or solvents with high volatility point,then let it dry thoroughly;

– apply a filter oil or a thick oil (SAE 80W-90) on thewhole surface, then squeeze it to eliminate the oilin excess. It must be well impregnated, though notdripping.

For the reassembly, repeat the same operations re-versing the order.

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Fig. 40

64

INSPECTING THE FRONT AND REARSUSPENSION


Read page 50 carefully.Change the front suspension oil every 12000 km.Furthermore, carry out the following checking opera-tions:– Push the fork repeatedly downwards, locking the

front brake. The stroke must be gentle and theremust be no trace of oil on the rods.

– Lift the rear wheel from the ground by using theproper stand and check the rear fork bearings.

– Check the fastening of all the components and thefunctionality of the front and rear suspension joints.

If you notice irregularities in the operationor if the help of a qualified technician isnecessary, contact your aprilia Official

Dealer.

To change the fork oil, contact youraprilia Official Dealer, who will ensureyou prompt and accurate servicing.

ADJUSTING THE REAR SUSPENSION

Fig. 41

c

Adjusting ring (1-Fig. 41) By screwing it By unscrewing it

Function Spring preload increase

Spring preload decrease

Attitude The vehicle is more rigid

The vehicle is less rigid

Recommen-ded kind of

road

Smooth or normal roads

Roads with uneven surface

Notes Drive with passen-ger

Drive without pas-senger

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CHECKING THE STEERING

Read page 50 carefully.To check the steering it is necessary to:– raise the front wheel, by means of a support or a

special stand;– shake the fork in the driving direction (Fig. 42);– if the slack must be adjusted, loosen the lock nut

(1 - Fig. 43) and act with the apposite key on theadjusting nut (2-Fig. 43), in order to take up theslack;

– repeat the check until the problem is over;– tighten the lock nut firmly (1-Fig. 43).

Once this operation has been carried out,make sure that the handlebars turnsmoothly, to avoid damaging the balls

and losing control of the vehicle.a

Fig. 42

Fig. 43

66

ADJUSTING THE EXHAUST PORT VALVE"ELECTRONIC RAVE" (Fig. 44) (only forthe standard version)

Read page 50 carefully.The opening and closing of the exhaust port valve"RAVE" are controlled by a solenoid which, when ex-cited, attracts a magnetic core connected with a ca-ble that acts on the valve.In order to ensure the proper functioning of the sys-tem, it is necessary to adjust the cable stroke careful-ly, proceeding as follows:– Loosen the adjuster nut (1).– Unscrew the adjuster completely (2).– Pull the cable (5), pushing the core (3) inside the

solenoid (4). The core (3) will not enter completely.In this way the cable (5) is under traction and theRAVE valve is completely open.

– Keeping the same traction on the core (3), screwthe solenoid adjuster (4) almost completely (leaveabout 0,5 mm before the end of stroke).

– Tighten the nut of the adjuster (1).– To verify if the operation has been correctly per-

formed, make the core (3) go back inside the sole-noid (4), then let it go out slowly, accompanying itwith the hand to its rest position.

– In this condition the distance must be included be-tween 7,5 and 8,5 mm.

Fig. 44

67

CHECKING THE PAD WEAR (Fig. 45)


Read pages 31, 32, 33, 34, 35 and 50 carefully.Check the brake pad wear after the first 1000 km,then every 4000 km.

The wear of the disc brake pads depends on the use,on the kind of drive and on the road.The wear will be greater when the vehicle is drivenon dirty or wet roads.

To carry out a rapid checking of the wear of the frontpads, proceed as follows:– remove the protection cover (1);– look through the opening of the brake calliper;– if the thickness (even of one pad only) is reduced

to about 1 mm, replace both pads.

To carry out a rapid checking of the wear of the rearpads, proceed as follows:– open the cover;– if the thickness (even of one pad only) has reduced

to about 1 mm, replace both pads.

Have the pads changed by your apriliaOfficial Dealer.

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Fig. 45

68

BLEEDING THE MIXER OIL TANK(Fig. 46-47)


If you run out of oil in the mixer tank, or ifthe mixer oil pipe is removed, it is neces-sary to bleed the system. This operation

is indispensable, since the running of the enginewith air in the mixer oil system may cause seri-ous damages to the engine itself.

Proceed as follows:– remove the saddle (see "GLOVE COMPART-

MENT"- page 23);– remove the plug (1-Fig. 46);– top up the mixer oil tank (see "MIXER OIL TANK" -

page 30);– remove the left fairing;– remove the mixer oil pump cover ;– remove the cross-slotted screw (1-Fig. 47) posi-

tioned on the oil mixer pump and wait until the oilhas flowed out of the hole;

– when the outflowing oil doesn't present air bubblesany more, put the screw back and tighten it (1-Fig. 47).

It is important to wait until the air hascompletely gone out, since the enginecan be seriously damaged if it runs with

air in the mixer oil system.

Fig. 46

Fig. 47

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69

– For the reassembly, carry out the same operationsreversing the order.

IDLING ADJUSTMENT (Fig. 48)

Read page 50 carefully.Adjust the idling every time it is irregular.

To carry out this operation:– Warm the engine up until it reaches the normal

running temperature.– Position the vehicle on the stand, keeping the en-

gine on.– Act on the adjusting screw (1) with a screwdriver,

in such a way as to obtain constant rpm of the en-gine; by rotating it clockwise, you increase the en-gine rpm, by rotating it anticlockwise, you de-crease the engine rpm.

– Screw or unscrew the air screw (2), until you ob-tain the maximum engine revolutions per minute.

– If necessary, further adjust the idling screw.– The minimum speed of the engine (idling) must be

about 1300±150 rpm.– By acting on the throttle grip, accelerate and decel-

erate a few times to verify the correct functioningand to check if the idling speed is constant.

If necessary, contact your aprilia OfficialDealera

Fig. 48

70

ADJUSTING THE ACCELERATOR CONTROL (Fig. 49)

The accelerator control must have a slack such as toallow the closing of the carburettor valve and of thelubrication pump.In order to obtain this, act on the special adjuster (1)positioned at the beginning of the accelerator controlcable, after removing the protection element (2).

Perform this operation only after makingsure that the cables of the carburettorand of the lubrication pump are properlyadjusted.

SPARK PLUG (Fig. 50)


Read page 50 carefully.Change the spark plug every 6000 km.Remove the spark plug and clean it carefully, remov-ing carbon deposits; change it if necessary.To remove and clean the spark plug:– remove the saddle (see "GLOVE COMPART-

MENT" - page 23);– raise the fuel tank (see "RAISING THE FUEL

TANK" - page 25);– take off the spark plug cap;– remove all the dirt from the base of the spark plug,

then unscrew it with the spanner you will find in thetool kit and extract it from its seat, taking care thatneither dust nor other substances enter into thecylinder.

If the spark plug is wet or very dark, replace it with anew one having lower heat rating; on the contrary, ifthe spark plug is too light, do just the opposite: a sparkplug that functions correctly should be light brown.– Make sure that on the electrode and on the central

porcelain part there are neither carbon deposits,nor corrosion marks; if necessary, clean them withthe special cleaners for spark plugs, with an ironwire and/or a metal brush.

– Energetically blow some air, in order to prevent theremoved residues from getting into the engine.

Fig. 49

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71

If the spark plug has crackings on the insulating ma-terial, corroded electrodes or excessive deposits, itmust be changed.– Check the spark plug gap (Fig. 50) with a thickness

gauge. The gap must be about 0,5 mm; if neces-sary 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 handin order not to damage the thread.

– Tighten the spark plug by means of the spanner,giving it half a turn to compress the washer.

– Put back the spark plug cap.

The spark plug must be well tightened,otherwise the engine may overheat andbe seriously damaged. Use the suggested

type of spark plug only (see "TECHNICAL DATA"- page 83), in order not to compromise the lifeand performance of the engine.

bFig. 50

72

BATTERY (Fig. 51)


Read page 50 carefully.Check the electrolyte level and the tightening of the ter-minals after the first 1000 km and then every 4000 km.

The electrolyte in the battery is toxic andcaustic and if it gets in contact with theskin it can cause burns, since it containssulphuric acid. Wear protection clothes, a

face mask and/or goggles during maintenanceoperations. In case of contact with the skin, rinsewith plenty of water. In case of contact with theeyes, rinse with plenty of water for 15 minutes,then consult an oculist without delay.

If the electrolyte is accidentally swallowed, drinka lot of water or milk, then continue with milk ofmagnesia or vegetable oil and consult a doctorwithout delay. The battery gives off explosive gases; keep itaway from flames, sparks, cigarettes and anyother source of heat.During the recharging or the use, make sure thatthe room is properly ventilated and avoid inhal-ing the gases released during the recharging.Never invert the connection of the battery cables. Do not incline the vehicle too much, in order toavoid dangerous leakages of battery fluid.


To check the electrolyte level, proceed as follows:– raise the fuel tank (see "RAISING THE FUEL

TANK" - page 25);– extract the battery (1-Fig. 51);– make sure that the fluid covers the elements com-

pletely (the right level must be included betweenthe two "MIN" and "MAX" marks that are stampedon the battery side).

If necessary, top up by adding distilled water.

Fig. 51

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73

To recharge, disconnect the cables, extract the bat-tery from the container and remove the elementplugs.Use an amperage equal to 1/10th of the battery ca-pacity.After the recharging operation, check the electrolytelevel again and if necessary top up with distilled wa-ter.Tighten the plugs.

Always connect the battery breather pipe,to prevent the sulphuric acid vapoursfrom corroding the electric system, paint-

ed parts, rubber elements or gaskets when theyexit the breather pipe.

LONG PERIOD OF INACTIVITY

If the vehicle remains unused for a long period, re-move the battery and recharge it completely, by us-ing a trickle charge.Place the battery in a cool and dry room. If the battery remains on the vehicle, disconnect thecables from the terminals.It is important to check the charge periodically (aboutonce a month), during the winter or when the vehicleremains unused, in order to prevent the deteriorationof the battery.

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CHANGING THE FUSES (Fig. 52)

Never use fuses different from the recom-mended ones. The use of unsuitable fus-es may cause damages to the electric

system or, in case of short circuit, even a fire.

If the fuse blows frequently, there proba-bly is a short circuit or an overload in the

electric system. In this case it is advisable to con-sult an aprilia Official Dealer.


If an electric component doesn't work or works irreg-ularly, or if the vehicle fails to start, it is necessary tocheck the fuses:– turn the ignition switch to position "m", to avoid

any accidental short circuit;– raise the fuel tank (see "RAISING THE FUEL

TANK" - page 25);– extract the fuses one by one (1-Fig. 52) and check

if the filament is broken;– before replacing the fuse, try to find out what

caused the trouble, if possible;– then replace the fuse with a new one having the

same amperage;– put back the saddle.

ARRANGEMENT OF THE FUSES

20A fuse - From the battery to:key switch, regulator, digital clock.

15A fuse - From the key switch to:all functions.

7,5A fuse - From the key switch to:ignition.

Fig. 52

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ADJUSTING THE HEADLIGHT BEAM(Fig. 53-54)

The headlight beam can be adjusted by turning theproper screw with a screwdriver (1-Fig. 53).By turning it clockwise the headlight beam sets up-wards, while by turning it anticlockwise the beamsets downwards.

To rapidly check the correct direction of the beam,place the vehicle on flat ground, 10 m away from awall.

Turn on the low beam, sit on the vehicle and makesure that the beam projected on the wall is slightlyunder the horizontal line of the headlight (about 9/10th of the total height - see Fig. 54).

Fig. 53

Fig. 54

10 m10 m

9/10

H9/

10H

HH

76

BULBS

Before changing a bulb, turn the ignitionswitch to position "m".Change the bulb wearing clean gloves.

Do not leave fingerprints on the bulb,since these may cause its overheatingand consequent breakage.

If you touch the bulb with bare hands, removeany fingerprint with alcohol, in order to prevent itfrom blowing frequently.


CHANGING THE HEADLIGHT BULBS(Fig. 55-56)

To change the low and high beam bulbs, proceedas follows:– take off the rubber cup (1-Fig. 55);– take off the connector;– act on the "V"-spring and extract the socket with

the bulb;– replace the damaged bulb;– to reassembly, carry out the same operations re-

versing the order. To change the parking light bulb, proceed as fol-lows:– remove the rubber socket (1-Fig. 56) and extract

the bulb;– if it is damaged, replace the bulb.

Fig. 55

Fig. 56

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77

The right bulb corresponds to the highbeam, the left bulb to the low beam and

the central bulb to the parking light.

CHANGING THE DASHBOARD BULBS(Fig. 57)

Read pages 76 and 50 carefully.Proceed as follows:– take off the ten screws that fasten the front plastic

protection;– remove the rubber sockets and replace the dam-

aged bulbs.

CHANGING THE REAR LIGHT BULBS(Fig. 58)

Read pages 76 and 50 carefully.Proceed as follows:– remove the two screws (1);– remove the glass (2);– press the bulb slightly and rotate it anticlockwise;– remove the bulb from its seat.

The introduction of a new bulb can becarried out in one sense only, since the

two guide pins are misaligned.

– Install a new bulb correctly, then repeat the aboveoperations in the reverse order for the reassembly.

c

c

Fig. 57

Fig. 58

78

CHANGING THE DIRECTION INDICATORBULBS (Fig. 59)

Read pages 76 and 50 carefully.Proceed as follows:– extract the screw (1);– remove the protection glass (2);– press the bulb slightly and rotate it anticlockwise;– remove the bulb from its seat;– correctly install a new bulb.

Repeat the above operations in the reverse order forthe reassembly.

Tighten the screw (1) with slight pressure,otherwise the protection glass may break.

CHANGING THE NUMBER PLATE BULB(Fig. 60)

Read pages 76 and 50 carefully.Proceed as follows:– remove the 3 screws that fasten the plate frame;– remove the socket (2) by unscrewing the two fas-

tening screws (1);– extract the bayonet joint bulb and install a new

bulb.

For the reassembly, carry out the operations de-scribed above in the reverse order.

Fig. 59

Fig. 60

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79

TRANSPORT

Before transporting the vehicle, it is nec-essary to empty the fuel tank and the car-

burettor completely, making sure that both arecompletely dry.During transport the vehicle must be held up-right, in its normal use position, to avoid any oiland battery fluid leakage.

DRAINING THE FUEL TANK

– Read page 29, "FUEL", carefully .– Stop the engine.– Empty the fuel tank by means of a manual pump or

a similar system.– Put the free end of the fuel draining pipe into a re-

ceptacle.– Open the carburettor breather acting on the drain

screw.

When all the fuel has flowed out, turn the drain screwuntil the breather shuts.

CLEANING

After the vehicle has been washed, itsbraking functions could be temporarilyimpaired because of the presence of wa-

ter on the grip surfaces. Calculate long braking distances to avoid acci-dents. Brake repeatedly to restore normal condi-tions.

To remove dirt and mud from the painted surfacesuse a low- pressure water jet; carefully wet the dirtyparts, remove mud and filth with a soft car spongeimpregnated with a lot of water and shampoo (2 ÷ 4%parts of shampoo in water).

Then rinse with plenty of water and dry with chamoisleather.

To clean the front plastic protection use neutral soaponly.

To clean the outer parts of the engine use a degreas-er, brushes and wipers.

Polish with silicone wax only after having carefullywashed the vehicle.

c a

80

Do not wash the vehicle under the sun,especially during the summer, when thebody is still warm, since if the shampoo

dries before being rinsed away, it can damagethe paint. Use neither high-pressure water/air jets, nor va-pour jets on the following parts: wheel hubs, con-trols on the right and on the left side of the han-dlebars, carburettor, brake pump, instrumentsand indicators, silencer exhaust, tool case, glovecompartment, ignition switch-steering lock.Do not use alcohol or solvents to clean the rub-ber and plastic parts and the saddle: use waterand mild soap.Do not apply protection waxes onto the saddle, inorder not to make it too slippery.

LONG PERIODS OF INACTIVITY

After a long period of inactivity of the vehicle someprecautions are necessary to avoid any problem. Furthermore, it is important to carry out the neces-sary repairs and a general check up BEFORE the pe-riod of inactivity, since you could forget to carry themout later. Proceed as follows:– Empty the fuel tank and the carburettor (see

"DRAINING THE FUEL TANK - page 79). Removethe tank plug.

– Extract the spark plug and pour a teaspoon (5-10 cmC) of two-stroke engine oil into the cylinder. Press the start push button “r” for a few seconds,to distribute the oil evenly on the cylinder surfaces.

– Remove the battery (see "BATTERY" - page 72)and charge it.

– Wash and dry the vehicle (see "CLEANING -page 79). Polish the painted surfaces with wax.

– Inflate the tyres (see "TYRES" - page 39).– By means of a suitable support, position the vehi-

cle so that both tyres are raised from the ground.– Place the vehicle in an unheated, not-humid room,

away from sunlight, with minimum temperaturevariations.

– Cover the vehicle avoiding the use of plastic or wa-terproof materials.

AFTER A PERIOD OF INACTIVITY

– Uncover and clean the vehicle.– Check the electrolyte level in the battery and install

it (see "BATTERY" - page 72).– Refill the fuel tank (see "FUEL" - page 29).– Carry out the preliminary checking operations (see

"PRELIMINARY CHECKING OPERATIONS" -page 43).

Have a low-speed test ride in a low-trafficarea.

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TECHNICAL DATADIMENSIONS Max. length.............................................................. 1960 mm

Max. width............................................................... 780 mmMax. height incl. front plastic protection ................. 1090 mmSeat height .............................................................. 810 mmWheelbase............................................................... 1345 mmMin. ground clearance............................................. 135 mmSteering diameter .................................................... 4090 mmWeight without fuel and oil ...................................... 115 kg

ENGINE Type......................................................................... One-cylinder, 2-stroke, with lamellar inlet and exhaust port valve.Separate lubrication with variable strength automatic mixer (0.9-2%).

Number of cylinders ................................................ 1Total displacement................................................... 124.82 cm3

Bore and stroke ....................................................... 54 x 54.5 mmCompression ratio ................................................... 12.5 ± 0.5 : 1Starting.................................................................... electricClutch ...................................................................... oil-immersed multiple discs with hand control on the left side of

the handlebars.Cooling .................................................................... liquid-cooled

CAPACITY Fuel, reserve included.............................................. 13 lFuel reserve ............................................................. 3 lFork oil .................................................................... 430 cmC per rodTransmission oil ...................................................... 1000 cmC

Transmission oil for version 11 kW ......................... 600 cmC

Mixer oil (reserve included)..................................... 1.4 lMixer oil reserve...................................................... 0.35 lCoolant .................................................................... 0.8 l (mixture: 30% antifreeze and 70% water)Seats ....................................................................... n° 2Vehicle max. load (driver+passenger+luggage) ....... 160 kg

82

GEARS Type......................................................................... no. 6 gears with foot control on the leftRatios: 1st ............................................................... Z=10/30=1:3.002nd .......................................................................... Z=14/29=1:2.0713rd........................................................................... Z=17/27=1:1.5884th ........................................................................... Z=19/25=1:1.3165th ........................................................................... Z=21/24=1:1.1436th ........................................................................... Z=22/23=1:1.045

TRANSMISSION Primary.................................................................... Z = 19/63 = 1:3.316Secondary (chain type)............................................ Z = 17/40 = 1:2.352Secondary (chain type) (for version 11 kW)............ Z = 17/39 = 1:2.294Secondary (chain type) (for derated version for D) Z = 17/39 = 1:2.786

CARBURETTOR Model ...................................................................... Dell’Orto PHBH 28 BDModel M and sport production............................. Dell’Orto VHSB 34 LD Model (for version 11 kW)....................................... Dell’Orto PHBH 28 BD Model C ............................................................... Dell’Orto PHBH 28 Model (for derated version for D) ........................ Dell’Orto PHBL 24

FEED Fuel .......................................................................... premium grade petrol (4 Stars U) according to the DIN 51600 std,min. O.N. 98 (N.O.R.M.) and 88 (NO.M.M.)

Fuel 2 ................................................................... unleaded petrol according to the DIN 51607 std, min. O.N. 95 (N.O.R.M.)and 85 (NO.M.M.)

FRAME Type......................................................................... two-beam with cast elementsSteering inclination angle ........................................ 25° 30’Forestroke ............................................................... 102 mm

SUSPENSIONS Front........................................................................ telehydraulic fork with helical spring reversed rods adjustableStroke...................................................................... 120 mmRear......................................................................... adjustable oscillating rear fork with hydraulic mono-shock

absorber with spring preload adjustmentStroke (wheel) ......................................................... 120 mm

BRAKES Front........................................................................ disc brake, Ø 320 mm with hydraulic transmissionRear......................................................................... disc brake, Ø 220 mm with hydraulic transmission

83

WHEELS RIMS ....................................................................... made of light alloyFront........................................................................ 17"Rear......................................................................... 17"

TYRES Front........................................................................ 110 / 70 ZR 17"Inflation pressure .................................................... 180 kPa (1.8 bar)Rear......................................................................... 150 / 60 ZR 17"Inflation pressure .................................................... 200 kPa (2 bar)Inflation pressure (with passenger)......................... 230 kPa (2.3 bar)

IGNITION Type......................................................................... CDISpark advance ......................................................... 12° before T.D.C. at 1300 rpmSpark plug ............................................................... NGK BR10 EGSpark plug gap ........................................................ 0.5 mmEngine idle rpm ....................................................... 1300 ± 150 rpm

ELECTRICSYSTEM

Battery..................................................................... 12 V - 9 AhFuses....................................................................... 20 / 15 / 7.5 AAlternator ................................................................ 12 V - 180 WLow beam lamp....................................................... 12 V - 55 W H1High beam lamp ...................................................... 12 V - 55 W H3Parking light lamp ................................................... 12 V - 5 WDirection indicator lamp .......................................... 12 V - 10 WRevolution counter lamp ......................................... 12 V - 2 WSpeedometer lamp .................................................. 12 V - 2 WTail lamp.................................................................. 12 V - 5+21 WNumber plate lamp .................................................. 12 V - 5 WMultifunction display lamp ...................................... 12 V - 2 WLow fuel warning light ............................................. 12 V - 2 WIdle indicator warning light...................................... 12 V - 1.2 WHigh beam warning light ......................................... 12 V - 1.2 WDirection indicator warning light ............................. 12 V - 1.2 WMixer oil reserve warning light ................................ LED

84

LUBRICANT TABLETransmission oil (recommended): 0 F.C., SAE 75W-90.As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliancewith or superior to the A.P.I. GL-4 specifications.

Mixer oil (recommended): 0 MAX 2T COMPETITIONAs an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliancewith or superior to the ISO-L-ETC++, A.P.I. TC++ specifications.

Fork oil (recommended): 0 F.A. 5W or 0 F.A. 20 W fork oil.If you need an oil with intermediate characteristics in comparison with the two recommended products, these canbe mixed as indicated below:– SAE 10W 0 F.A. 5W 67% of the volume, + 0 F.A. 20W 33% of the volume.– SAE 15W 0 F.A. 5W 33% of the volume, + 0 F.A. 20W 67% of the volume.

Bearings and other lubrication points (recommended): 0 AUTOGREASE MP.As an alternative to the recommended product, use high-quality grease for rolling bearings, working temperaturerange - 30°C...+ 140°C, dripping point 150°C... 230°C, high protection against corrosion, good resistance to waterand oxidation.

Protection of the battery poles: neutral grease or Vaseline.

Spray grease for chains (recommended): 0 CHAIN SPRAY.

Brake fluid (recommended): 0 F.F., DOT 5 (compatible with DOT 4).

Use new brake fluid only.

Engine coolant (recommended): 0 ECOBLU -40°C.

Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35°C at least.

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85

APRILIA MOTO U.K. LTDDUNRAGITSTRANRAERWIGTOWNSHIRE DG9 8PNSCOTLAND (UK)TEL. (01581) 400660FAX 400661

IDEAL MOTOR SPORT PTE LTD18, HOWARD ROAD1336 SINGAPORE (SGP)TEL. 2820082FAX 2821012

AVIRAM & GOLDMAN IMPORT &MARKETING CO. LTD21, TUSHIA STREET61572 TEL-AVIVP.O. BOX 57266ISRAEL (IL)TEL. (3) 5623951FAX 5623950

Importers

ASK FOR GENUINE SPARE PARTS ONLY

86

WIRING DIAGRAM - RS 125

87

WIRING DIAGRAM KEY - RS 125

1) Generator2) Ignition coil3) Starter4) Voltage regulator 5) Fuses6) Battery7) Start relay8) Front stoplight switch9) Rear stoplight switch

10) Coolant temperature thermistor11) Mixer oil reserve sensor12) Neutral indicator13) Reserve fuel sensor14) Rear left direction indicator15) Rear light16) Rear right direction indicator17) Blinking18) Ignition switch19) Right dimmer switch (not provided in the _ version)20) Left dimmer switch21) Complete dashboard22) Multifunction display23) Dashboard lamps24) Reserve fuel warning light25) Solenoid26) Neutral warning light27) Mixer oil reserve warning light LED28) High beam warning light29) Direction indicator warning light30) Horn

31) Front right direction indicator32) Low beam bulb33) Front parking light34) Front left direction indicator35) Electronic RAVE unit36) Multiple connectors37) Spark plug38) High beam bulb39) Headlight40) Revolution counter41) LAP push button42) CDI 43) Number plate light44) Pick up45) Left dimmer switch _

CABLE COLOURS

Ar OrangeAz Light blueB BlueBi WhiteG YellowGr GrayM Brown N BlackR RedV GreenVi Violet

88

WIRING DIAGRAM - RS 125 11 kW version

89

WIRING DIAGRAM KEY - RS125 11 kW version

1) Generator2) Ignition coil3) Starter4) Voltage regulator 5) Fuses6) Battery7) Start relay8) Front stoplight switch9) Rear stoplight switch

10) Coolant temperature thermistor11) Mixer oil reserve sensor12) Neutral indicator13) Reserve fuel sensor14) Rear left direction indicator15) Rear light16) Rear right direction indicator17) Blinking18) Ignition switch19) Right dimmer switch (not provided in the _ version)20) Left dimmer switch21) Complete dashboard22) Multifunction display23) Dashboard lamps24) Reserve fuel warning light26) Neutral warning light27) Mixer oil reserve warning light LED28) High beam warning light29) Direction indicator warning light30) Horn

31) Front right direction indicator32) Low beam bulb33) Front parking light34) Front left direction indicator36) Multiple connectors37) Spark plug38) High beam bulb39) Headlight40) Revolution counter41) LAP push button42) CDI 43) Number plate light44) Pick up45) Left dimmer switch _

CABLE COLOURS

Ar OrangeAz Light blueB BlueBi WhiteG YellowGr GrayM Brown N BlackR RedV GreenVi Violet

90

NOTES

91

NOTES

92

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 environment.

– Do not keep the engine running if it isn't necessary.

– Avoid disturbing noises.

– Respect nature.

Documents

© 1996 aprilia s.p.a: - Noale (VE) FOREWORD · Your and other people's safety depends not only on your quickness of reflexes and on your agility, but also on what you know about