APRILIA HABANA 125 - PART1 User manual

2use and maintenance Habana 50/125 - Habana Custom 50/125
© 1999 aprilia s.p.a. - Noale (VE)
First edition: may 1999
Reprint: july 1999, january 2000,
february 2001
Produced and printed by:
editing division
Soave (VERONA) - Italy
Tel. +39 - 045 76 11 911
Fax +39 - 045 76 12 241
E-mail: [e-mail]
www.stp.it
On behalf of:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - Italy
Tel. +39 - 041 58 29 111
Fax +39 - 041 44 10 54
www.aprilia.com
3!&%497!2.).'3
The following precautionary warnings are
used throughout this manual in order to
convey the following messages:
Safety warning. When you find this
symbol on the vehicle or in the
manual, be careful to the potential risk
of personal injury. Non-compliance with
the indications given in the messages
preceded by this symbol may result in
grave risks for your and other people’s
safety and for the vehicle!
aWARNING
Indicates a potential hazard which may
result in serious injury or even death.
aCAUTION
Indicates a potential hazard which may
result in minor personal injury or dam-
age to the vehicle.
NOTE The word “NOTE” in this manual
precedes important information or instruc-
tions.
4%#(.)#!,
The operations preceded by this
symbol must be repeated also on
the opposite side of the vehicle.
If not expressly indicated otherwise, for the
reassembly of the units repeat the disas-
sembly operations in reverse order.
The terms “right” and “left” are referred to
the rider seated on the vehicle in the nor-
mal riding position.
wvAny mention to the use of the
vehicle with passenger is to be intended as
referred only to the countries where this is
allowed.
7!2.).'302%#!54)/.3
'%.%2!,!$6)#%
Before starting the engine, carefully read
this manual and in particular the section
“SAFE DRIVE”.
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 the vehicle, on its efficiency and on
your knowledge of the basic information for
“SAFE DRIVE”. Therefore, get a thorough
knowledge of the vehicle, in such a way as
to be able to drive in the traffic safety.
a
★

3
use and maintenance Habana 50/125 - Habana Custom 50/125
NOTE This manual must be considered
as an integral part of the vehicle and must
always accompany it, even in case of re-
sale.
aprilia has carried out this manual with the
maximum attention, in order to supply the
user with correct and updated information.
However, since aprilia constantly im-
proves the design of its products, there
may be slight discrepancies between the
characteristics of your vehicle and those
described in this manual.
For any clarification concerning the infor-
mation contained in this manual, do not
hesitate to contact your aprilia Official
Dealer.
For control and repair operations not ex-
pressly described in this publication, for the
purchase of aprilia genuine spare parts,
accessories and other products, as well as
for specific advice, contact exclusively
aprilia Official Dealers and Service Cent-
ers, which guarantee prompt and accurate
assistance.
Thank you for choosing aprilia. We wish
you a nice ride.
All rights as to electronic storage, repro-
duction and total or partial adaptation, with
any means, are reserved for all Countries.
NOTE In some countries the antipollu-
tion and noise regulations in force require
periodical inspections.
The user of the vehicle in these countries
must:
–contact an aprilia Official Dealer to have
the non-homologated components re-
placed with others homologated for use
in the country in question;
–carry out the required periodical inspec-
tions.
NOTE Soon after purchasing the vehi-
cle, write down the identification data indi-
cated on the SPARE PARTS IDENTIFICA-
TION LABEL in the table here below. The
label is stuck on the right beam of the
frame; to be able to read it, remove the
right inspection cover, see p. 59 (REMOV-
ING THE RIGHT AND LEFT INSPECTION
COVERS).
These data indicate:
–YEAR = year of manufacture (Y, 1, 2, ...);
–I.M. = modification code (A, B, C, ...);
–COUNTRY CODES = homologation
country (I, UK, A, ...).
and are to be supplied to the aprilia Offi-
cial Dealer as reference data for the pur-
chase of spare parts or specific accesso-
ries of the model you have acquired.
In this manual the various versions are in-
dicated by the following symbols:
@Habana model 50 cm
#
?Habana Custom model 50 cm
#
=
Habana model 125 cm #
>Habana Custom model 125 cm
#
eautomatic light switching version
(Automatic Switch-on Device)
moptional
ocatalytic version
VERSION:
IItaly SSingapore
UUnited Kingdom sSlovenia
aAustria iIsrael
pPortugal ¬South Korea
FFinland MMalaysia
BBelgium cChile
dGermany HCroatia
fFrance AAustralia
ESpain uUnitedStates
of America
GGreece ÄBrazil
OHolland RSouth Africa
YSwitzerland New Zealand
DDenmark CCanada
JJapan

4use and maintenance Habana 50/125 - Habana Custom 50/125
4!",%/&#/.4%.43
SAFE DRIVE ..................................................... 5
BASIC SAFETY RULES.................................. 6
CLOTHING...................................................... 9
ACCESSORIES ............................................ 10
LOAD............................................................. 10
ARRANGEMENT
OF THE MAIN ELEMENTS wv.............. 12
ARRANGEMENT
OF THE MAIN ELEMENTS xu.............. 14
ARRANGEMENT OF THE CONTROLS /
INSTRUMENTS AND INDICATORS............... 16
INSTRUMENT AND INDICATOR TABLE..... 17
MAIN INDEPENDENT
CONTROLS wx...................................... 18
CONTROLS ON THE LEFT SIDE
OF THE HANDLEBAR.................................. 18
CONTROLS ON THE RIGHT SIDE
OF THE HANDLEBAR.................................. 19
MAIN INDEPENDENT
CONTROLS vu...................................... 20
CONTROLS ON THE LEFT SIDE
OF THE HANDLEBAR.................................. 20
CONTROLS ON THE RIGHT SIDE
OF THE HANDLEBAR.................................. 21
IGNITION SWITCH ....................................... 22
STEERING LOCK......................................... 22
AUXILIARY EQUIPMENT ............................... 23
UNLOCKING / LOCKING THE SADDLE ...... 23
CRASH HELMET /
GLOVE COMPARTMENT............................. 23
ANTI-THEFT HOOK...................................... 23
TOOL KIT...................................................... 24
BAG HOOK ................................................... 24
GLOVE COMPARTMENT............................. 24
MAIN COMPONENTS..................................... 25
FUEL ............................................................. 25
LUBRICANTS................................................ 26
BRAKE FLUID - recommendations............... 27
FRONT BRAKE DISC ................................... 28
REAR DRUM BRAKE ................................... 29
TYRES .......................................................... 30
AUTOMATIC
LIGHT SWITCHING VERSION _............... 31
wvCATALYTIC SILENCER 2........... 32
EXHAUST SILENCER .................................. 32
INSTRUCTIONS FOR USE............................. 33
PRELIMINARY
CHECKING OPERATIONS........................... 33
STARTING .................................................... 34
DEPARTURE AND DRIVE............................ 37
RUNNING-IN................................................. 39
STOPPING.................................................... 40
PARKING...................................................... 41
POSITIONING THE VEHICLE
ON THE STAND............................................ 42
SUGGESTIONS TO PREVENT THEFT ....... 42
MAINTENANCE .............................................. 43
REGULAR SERVICE
INTERVALS CHART wv...................... 44
REGULAR SERVICE
INTERVALS CHART xu...................... 46
IDENTIFICATION DATA ............................... 48
CHECKING THE ENGINE OIL LEVEL
AND TOPPING UP xu......................... 49
AIR CLEANER wv................................ 50
AIR CLEANER xu................................ 51
CHECKING THE BRAKE PAD WEAR.......... 52
CHECKING THE SHOE WEAR.................... 53
INSPECTING THE FRONT
AND REAR SUSPENSIONS......................... 53
CHECKING THE STEERING........................ 54
CHECKING
THE ENGINE FULCRUM AXIS..................... 54
REMOVING THE FRONT COVER ............... 55
REMOVING
THE LOWER HANDLEBAR COVER ........... 56
REMOVING
THE HEADLIGHT METAL RING .................. 56
PARTIAL REMOVAL
OF THE UPPER HANDLEBAR COVER ...... 57
REMOVING THE REAR-VIEW MIRRORS ... 58
PARTIAL REMOVAL
OF THE DASHBOARD ................................ 58
REMOVING THE CENTRAL
INSPECTION COVER................................... 59
REMOVING THE RIGHT AND LEFT
INSPECTION COVERS................................ 59
REMOVING
THE BATTERY COVER wv................. 59
CHECHING THE STAND.............................. 60
CHECKING THE SWITCHES....................... 60
IDLING ADJUSTMENT................................. 61
ADJUSTING
THE ACCELERATOR CONTROL................. 62
SPARK PLUG ............................................... 62
BATTERY ..................................................... 64
LONG INACTIVITY OF THE BATTERY ....... 64
CHECKING AND CLEANING
THE TERMINALS ......................................... 65
REMOVING THE BATTERY wv.......... 65
REMOVING THE BATTERY xu.......... 66
CHECKING THE ELECTROLYTE LEVEL.... 66
RECHARGING THE BATTERY .................... 67
INSTALLING THE BATTERY wv......... 67
INSTALLING THE BATTERY xu......... 67
CHANGING THE FUSES.............................. 68
ADJUSTING
THE VERTICAL HEADLIGHT BEAM............ 69
BULBS........................................................... 69
CHANGING
THE HEADLIGHT BULBS w...................... 70
CHANGING
THE HEADLIGHT BULBS x...................... 71
CHANGING
THE HEADLIGHT BULBS v...................... 72
CHANGING
THE HEADLIGHT BULBS u...................... 73
CHANGING THE FRONT AND REAR
DIRECTION INDICATOR BULBS................. 74
CHANGING
THE DASHBOARD BULBS wx............ 75
CHANGING THE DASHBOARD BULBS ..... 76
CHANGING THE REAR LIGHT BULB.......... 77
CHANGING
THE NUMBER PLATE BULB xu......... 78
TRANSPORT................................................... 78
DRAINING THE FUEL TANK........................ 79
CLEANING ...................................................... 80
LONG PERIODS OF INACTIVITY ................ 81
TECHNICAL DATA ......................................... 82
LUBRICANT CHART wv...................... 86
LUBRICANT CHART xu...................... 87
Importers .................................................. 90-91
WIRING DIAGRAM Habana 50..................... 92
WIRING DIAGRAM - Habana 50 J-...... 94
WIRING DIAGRAM Habana Custom 50 ....... 96
WIRING DIAGRAM Habana 125................... 98
WIRING DIAGRAM Habana Custom 125 ... 100

safe drive

6use and maintenance Habana 50/125 - Habana Custom 50/125
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To drive the vehicle it is necessary to be in
possession of all the requirements pre-
scribed by law (driving licence, minimum
age, psychophysical ability, insurance,
state taxes, vehicle registration, number
plate, etc.).
Gradually get to know the vehicle by driv-
ing it first in areas with low trafficand/or pri-
vate areas.
The use of medicins, alcohol and drugs or
psychotropic substances notably increases
the risk of accidents.
Be sure that you are in good psychophysi-
cal conditions and fit for driving and pay
particular attention to physical weariness
and drowsiness.
Most road accidents are caused by the
driver’s lack of experience.
NEVER lend the vehicle to beginners and,
in any case, make sure that the driver has
all the requirements for driving.

7
use and maintenance Habana 50/125 - Habana Custom 50/125
Rigorously observe all road signs and na-
tional and local road regulations.
Avoid abrupt movements that can be dan-
gerous for yourself and other people (for
example: rearing up on the back wheel,
speeding, etc.), and give due consideration
to the road surface, visibility and other driv-
ing conditions.
Avoid obstacles that could damage the ve-
hicle or make you lose control.
Avoid riding in the slipstream created by
preceding vehicles in order to increase
your speed.
Always keepboth hands on the handlebars
and both feet on the footboard (or on the
footrests), in the correct driving posture.
Avoid standing up or stretching your limbs
while driving.

8use and maintenance Habana 50/125 - Habana Custom 50/125
The driver should pay attention and avoid
distractions caused by people, things and
movements (never smoke, eat, drink, read,
etc.) while driving.
Use only the vehicle’s specific fuels and lu-
bricants indicated in the “LUBRICANT
CHART”; check all oil, fuel and coolant lev-
els regularly.
If the vehicle has been involved in an acci-
dent, make sure that no damage has oc-
curred to the control levers, pipes, wires,
braking system and vital parts.
If necessary, have the vehicle inspected by
an aprilia Official Dealer, who should care-
fully check the frame, handlebars, suspen-
sions, safety parts and all the devices that
you cannot check by yourself.
Always remember to report any malfunc-
tion to the technicians to help them in their
work.
Never use the vehicle when the amount of
damage it has suffered endangers your
safety.
Never change the position, inclination or
colour of: number plate, direction indica-
tors, lights and horns.
Any modification of the vehicle will result in
the invalidity of the guarantee.
For only vehicles up to 50 cm3
Any modification of the engine or of other
members which is aimed at increasing the
speed or the power of the vehicle is prohib-
ited by the law; in fact, any modification re-
sulting in an increase of the maximum
speed or of the engine displacement would
change the scooter into a motorcycle,
COOLER
OIL

9
use and maintenance Habana 50/125 - Habana Custom 50/125
which implies the following obligations for
the owner:
–new homologation;
–new registration;
–appropriate driving license.
Further, said modifications cause the loss
of the insurance cover, since insurance
policies expressly prohibit to make techni-
cal changes aimed at increasing the vehi-
cle performance levels.
For the reasons stated above, the failure to
comply with the tampering prohibition is
punished by law with appropriate sanctions
(including the confiscation of the vehicle),
which, according to the case, can be com-
bined with the sanctions provided for not
using the crash helmet and/or the number
plate, for the violation of fiscal obligations
(ownership tax) and with penal sanctions
provided for using the vehicle without driv-
ing license.
For only vehicles over 50 cm3
Any modification of the vehicle and/or the
removal of original components can com-
promise vehicle performance levels and
safety or even make it illegal.
We recommend respecting all regulations
and national and local provisions regarding
the equipment of the vehicle.
In particular, avoid all modifications that in-
crease the vehicle’s performance levels or
alter its original characteristics.
Never race with other vehicles.
Avoid off-road driving.
#,/4().'
Before starting, always wear a correctly
fastened crash helmet. Make sure that it is
homologated, in good shape, of the right
size and that the visor is clean.
Wear protective clothing, preferably in light
and/or reflecting colours.
In this way you will make yourself more vis-
ible to the other drivers, thus notably re-
ducing the risk of being knocked down, and
you will be more protected in case of fall.
This clothing should be very tight-fitting
and fastened at the wrists and ankles.
Strings, belts and ties should not be hang-
ing loose; prevent these and other objects
from interfering with driving by getting en-
tangled with moving parts or driving mech-
anisms.
A12
345
ONLY ORIGINALS

10 use and maintenance Habana 50/125 - Habana Custom 50/125
Do not keep objects that can be dangerous
in case of fall, for example pointed objects
like keys, pens, glass vials etc. in your
pockets (the same recommendations also
apply to passengers).
!##%33/2)%3
The owner of the vehicle is responsible for
the choice, installation and use of any ac-
cessory.
Avoid installing accessories that cover
horns or lights or that could impair their
functions, limit the suspension stroke and
the steering angle, hamper the operation of
the controls and reduce the distance from
the ground and the angle of inclination in
turns.
Avoid using accessories that hamper ac-
cess to the controls, since this can prolong
reaction times during an emergency.
Big fairings and windshields installed on
the vehicle may produce aerodynamic forc-
es that affect the stability of the vehicle, es-
pecially when riding at high speed.
Make sure that the equipment is well fas-
tened to the vehicle and not dangerous
during driving. Do not install electrical de-
vices and do not modify those already ex-
isting to avoid electrical overloads, be-
cause the vehicle could suddenly stop or
there could be a dangerous current short-
age in the horn and in the lights.
aprilia recommends the use of aprilia
genuine accessories.
,/!$
Be careful and moderate when loading
your luggage. Keep any luggage loaded as
close as possible to the center of gravity of
the vehicle and distribute the load uniform-
ly on both sides, in order to reduce umbal-
ance to the minimum. Furthermore, make
sure that the load is firmly secured to the
vehicle, especially during long trips.

11
use and maintenance Habana 50/125 - Habana Custom 50/125
Avoid hanging bulky, heavy and/or danger-
ous objects on the handlebars, mudguards
and forks: the vehicle might respond more
slowly in turns and its manoeuvrability
could be unavoidably impaired.
Do not place bags that are too bulky on the
vehicle sides, because they could hit peo-
ple or obstacles, making you lose control of
the vehicle.
Do not carry any bag if it is not tightly se-
cured to the vehicle.
Do not carry bags which protrude too much
from the luggage-rack or which cover the
lights, horn or indicators.
Do not carry animals or children on the
glove compartment or on the luggage-
rack.
Do not exceed the maximum load allowed
for each side-bag.
When the vehicle is overloaded, its stability
and its manoeuvrability can be compro-
mised.
KG!

12 use and maintenance Habana 50/125 - Habana Custom 50/125
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+%9
1) Left rear-view mirror
( wnot provided in the Uversion)
2) Left inspection cover
3) Central inspection cover
4) Glove compartment
5) Battery
6) Fuse carrier
7) Passenger grab rail
8) Saddle lock
9) Air cleaner
10) Kick starter
11) Centre stand
12) Side stand &
13) Spark plug

13
use and maintenance Habana 50/125 - Habana Custom 50/125
+%9
1) Crash helmet / glove compartment
2) 2 stroke oil tank plug
3) Fuel tank plug
4) Ignition switch / steering lock
5) Bag hook
6) Right inspection cover
7) Right rear-view mirror
( win the countries where required)
8) Brake fluid reservoir (front brake)
9) Horn
10) Fuel tank
11) Anti-theft hook (for the aprilia “Body-
Guard”armored cable &).
12) 2 stroke oil tank

14 use and maintenance Habana 50/125 - Habana Custom 50/125
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+%9
1) Left rear-view mirror
2) Glove compartment
3) Left inspection cover
4) Central inspection cover
5) Passenger left footrest
6) Air cleaner
7) Passenger grab rail
8) Saddle lock
9) Kick starter
10) Centre stand
11) Engine oil filler cap
12) Engine oil level sight glass
13) Side stand &

15
use and maintenance Habana 50/125 - Habana Custom 50/125
+%9
1) Crash helmet / glove compartment
2) Right inspection cover
3) Fuel tank plug
4) Ignition switch / steering lock
5) Bag hook
6) Fuse carrier
7) Right rear-view mirror
8) Brake fluid reservoir (front brake)
9) Horn
10) Fuel tank
11) Anti-theft hook (for the aprilia “Body-
Guard”armored cable &).
12) Spark plug
13) Passenger right footrest
14) Battery

16 use and maintenance Habana 50/125 - Habana Custom 50/125
!22!.'%-%.4/&4(%#/.42/,3  ).3425-%.43 !.$ ).$)#!4/23
+%9
1) Electrical controls on the left side of the handlebar
2) Rear brake lever
3) Instruments and indicators
4) Throttle grip
5) Front brake lever
6) Electrical controls on the right side of the handlebar
7) Ignition switch/steering lock (n- m- s)
8) Speedometer
8) Speedometer –km/h scale only ^
9) Total kilometres odometer
10) Green low beam and parking light warning light (p)
11) Blue high beam warning light (a)
12) Fuel level indicator (g)
13) Green direction indicator warning light (c
14) Amber low fuel warning light (g)
15) wvRed 2 stroke oil reserve warning light (j)
15) xuRed engine oil pressure warning light (j)

17
use and maintenance Habana 50/125 - Habana Custom 50/125
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Description Function
Direction indicator warning light cIt blinks when the direction indicators are on.
wv2 stroke oil reserve warning light 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 bulb.
If the light does not come on during the starting, provide for replacing the bulb.
If the warning light comes on and does not go out
after the start push button “r”has been released,
or if it comes on during normal functioning, this means that the 2 stroke
oil reserve is being used; in this case, top up the 2 stroke oil tank, see p.
26 (wv2 STROKE OIL).
xuEngine oil pressure warning light j
It comes on every time the ignition switch is brought to position “n”and the
engine is not running, thus testing the correct operation of the bulb.
If during this phase the lamp does not turn on, it must be replaced.
The warning light must go off when the engine is running.
If the warning light comes on during the normal
running of the engine, this means that the oil pres-
sure in the circuit is insufficient. In this case, immediately stop the engine
and contact your APRILIA Official Dealer.
Total kilometres odometer It indicates the total number of kilometres covered.
Speedometer It indicates the driving speed.
Parking light and low beam warning light pComes on when the lights are on.
High beam warning light aIt comes on when the headlight in high beam position.
Low fuel warning light gIt comes on when the quantity of fuel left in the tank is about 2 L.
Fuel level indicator gIt indicates the approximate fuel level in the tank.
aCAUTION
aCAUTIONaCAUTION

18 use and maintenance Habana 50/125 - Habana Custom 50/125
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NOTE The electrical parts work only when the ignition switch
is in position “n”.
NOTE The lighting system works only when the engine is run-
ning.
1) HORN PUSH BUTTON (f)
The horn is activated when the push button is pressed.
2) DIMMER SWITCH ( a- b)
When the light switch is in position “o”: if the dimmer switch
is in position “a”, the high beam comes on, while if it is in po-
sition “b”, the low beam comes on.
2) DIMMER SWITCH ( a- b)_
When it is in position “b”the parking lights, the dashboard
light and the low beam are always on.
When it is in position “a”, the high beam comes on.
NOTE The lights can be switched off only by stopping the
engine.
3) DIRECTION INDICATOR SWITCH (c)
To indicate the turn to the left, move the switch to the left; to
indicate the turn to the right, move the switch to the right.
To turn off the direction indicator, press the switch.

19
use and maintenance Habana 50/125 - Habana Custom 50/125
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/&4(%(!.$,%"!2
NOTE The electrical parts work only when the ignition switch
is in position “n”.
NOTE The lighting system works only when the engine is run-
ning.
1) LIGHT SWITCH (o- p- •) ( _not provided )
NOTE Before operating the light switch, make sure that the
dimmer switch ( a- b) is in position “b”.
When the light switch is in position “•”, the lights are off; when
the switch is in position “p”, the parking lights and the dash-
board light are on; when the switch is in position “o”, the
parking lights, the dashboard light and the low beam are on.
The high beam can be operated by means of the dimmer
switch ( a- b).
1a) ENGINE STOP SWITCH (n- m)
(in the countries where required)
aCAUTION
Do not operate the engine stop switch “n- m”in running
conditions.
This is a safety or emergency switch. With the switch in po-
sition “n”, it is possible to start the engine; the engine can
be stopped by moving the switch to position “m”.
aCAUTION
With stopped engine and ignition switch in position “n”,
the battery may run down.
When the vehicle has come to a halt, stop the engine, and
move the ignition switch to position “m”.
2) START PUSH BUTTON (r)
When the start push button is pressed and one of the brake
levers (front or rear) is activated at the same time, the starter
makes the engine run.
For the starting procedure, see p. 34 (STARTING)

20 use and maintenance Habana 50/125 - Habana Custom 50/125
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#/.42/,3/.4(%,%&43)$%/&4(%(!.$,%"!2
NOTE The electrical parts work only when the ignition switch
is in position “n”.
NOTE The lighting system works only when the engine is run-
ning.
1) HORN PUSH BUTTON (f)
The horn is activated when the push button is pressed.
2) DIMMER SWITCH ( a- b- a)
When the light switch is in position “o”: if the dimmer switch
is in position “a”, the high beam comes on, while if it is in po-
sition “b”, the low beam comes on.
The high beam signaller is operated by pressing the dimmer
switch (a- b- a) to position (A) (a), independently of
the position of the light switch (o- p- •).
NOTE When the dimmer switch is released, the high beam
signaller is disconnected.
2) DIMMER SWITCH ( a- b- a)_J
When it is in position “b”the parking lights, the dashboard
light and the low beam are always on.
When it is in position “a”, the high beam comes on.
The high beam signaller is operated by pressing the dimmer
switch ( a- b- a) to position (A) ( a).
NOTE When the dimmer switch is released, the high beam
signaller is disconnected.
NOTE The lights can be switched off only by stopping the
engine.
3) DIRECTION INDICATOR SWITCH (c)
To indicate the turn to the left, move the switch to the left; to
indicate the turn to the right, move the switch to the right.
To turn off the direction indicator, press the switch.