© 1999 aprilia s.p.a. - Noale (VE) 3!&%49 7!2.).'3 The following precautionary warnings are used throughout this manual in order to convey the following messages: find aSafety warning. When youor in this symbol on the vehicle the 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 disassembly operations in reverse order. The terms "right" and "left" are referred to the rider seated on the vehicle in the normal riding position. Any mention to the use of the vehicle with passenger is to be intended as referred only to the countries where this is allowed. # 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! First edition: may 1999 Reprint: july 1999, january 2000, february 2001 wv aWARNING Indicates a potential hazard which may result in serious injury or even death. 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. aCAUTION Indicates a potential hazard which may result in minor personal injury or damage to the vehicle. Produced and printed by: editing division Soave (VERONA) - Italy Tel. +39 - 045 76 11 911 Fax +39 - 045 76 12 241 E-mail: customer@stp.it 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 NOTE The word "NOTE" in this manual precedes important information or instructions. 2 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 resale. 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 improves 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 information contained in this manual, do not hesitate to contact your aprilia Official Dealer. For control and repair operations not expressly 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 Centers, which guarantee prompt and accurate assistance. Thank you for choosing aprilia. We wish you a nice ride. All rights as to electronic storage, reproduction and total or partial adaptation, with any means, are reserved for all Countries. The user of the vehicle in these countries must: ­ contact an aprilia Official Dealer to have the non-homologated components replaced with others homologated for use in the country in question; ­ carry out the required periodical inspections. Soon after purchasing the vehicle, write down the identification data indicated on the SPARE PARTS IDENTIFICATION 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 (REMOVING THE RIGHT AND LEFT INSPECTION COVERS). chase of spare parts or specific accessories of the model you have acquired. In this manual the various versions are indicated by the following symbols: @ Habana model 50 cm# ? Habana Custom model 50 cm# = Habana model 125 cm# > Habana Custom model 125 cm# e automatic light switching version (Automatic Switch-on Device) NOTE m optional o catalytic version VERSION: I Italy U p B f United Kingdom S Singapore s Slovenia i Israel ¬ South Korea M Malaysia c Chile H Croatia A Australia u United States of America a Austria Portugal F Finland Belgium d Germany France E Spain 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 Official Dealer as reference data for the purG Greece O Holland Y Switzerland D Denmark J Japan Ä Brazil R South Africa n New Zealand C Canada NOTE In some countries the antipollution and noise regulations in force require periodical inspections. use and maintenance Habana 50/125 - Habana Custom 50/125 3 4!",% /& #/.4%.43 SAFE DRIVE ..................................................... 5 BASIC SAFETY RULES.................................. 6 CLOTHING...................................................... 9 ACCESSORIES ............................................ 10 LOAD............................................................. 10 ARRANGEMENT OF THE MAIN ELEMENTS w v .............. 12 ARRANGEMENT OF THE MAIN ELEMENTS x u .............. 14 ARRANGEMENT OF THE CONTROLS / INSTRUMENTS AND INDICATORS ............... 16 INSTRUMENT AND INDICATOR TABLE ..... 17 MAIN INDEPENDENT CONTROLS w x ...................................... 18 CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR .................................. 18 CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR .................................. 19 MAIN INDEPENDENT CONTROLS v u ...................................... 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 w v CATALYTIC 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 w v ...................... 44 REGULAR SERVICE INTERVALS CHART x u ...................... 46 IDENTIFICATION DATA ............................... 48 CHECKING THE ENGINE OIL LEVEL AND TOPPING UP x u......................... 49 AIR CLEANER w v................................ 50 AIR CLEANER x u................................ 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 w v ................. 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 w v .......... 65 REMOVING THE BATTERY x u .......... 66 CHECKING THE ELECTROLYTE LEVEL .... 66 RECHARGING THE BATTERY .................... 67 INSTALLING THE BATTERY w v ......... 67 INSTALLING THE BATTERY x u ......... 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 w x ............ 75 CHANGING THE DASHBOARD BULBS ..... 76 CHANGING THE REAR LIGHT BULB .......... 77 CHANGING THE NUMBER PLATE BULB x u ......... 78 TRANSPORT................................................... 78 DRAINING THE FUEL TANK ........................ 79 CLEANING ...................................................... 80 LONG PERIODS OF INACTIVITY ................ 81 TECHNICAL DATA ......................................... 82 LUBRICANT CHART w v...................... 86 LUBRICANT CHART x u...................... 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 4 use and maintenance Habana 50/125 - Habana Custom 50/125 safe drive "!3)# 3!&%49 25,%3 To drive the vehicle it is necessary to be in possession of all the requirements prescribed by law (driving licence, minimum age, psychophysical ability, insurance, state taxes, vehicle registration, number plate, etc.). Gradually get to know the vehicle by driving it first in areas with low traffic and/or private areas. The use of medicins, alcohol and drugs or psychotropic substances notably increases the risk of accidents. Be sure that you are in good psychophysical 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. 6 use and maintenance Habana 50/125 - Habana Custom 50/125 Rigorously observe all road signs and national and local road regulations. Avoid abrupt movements that can be dangerous 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 driving conditions. Avoid obstacles that could damage the vehicle or make you lose control. Avoid riding in the slipstream created by preceding vehicles in order to increase your speed. Always keep both hands on the handlebars and both feet on the footboard (or on the footrests), in the correct driving posture. Avoid standing up or stretching your limbs while driving. use and maintenance Habana 50/125 - Habana Custom 50/125 7 OIL COOLER 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 lubricants indicated in the "LUBRICANT CHART"; check all oil, fuel and coolant levels regularly. If the vehicle has been involved in an accident, make sure that no damage has occurred to the control levers, pipes, wires, braking system and vital parts. If necessary, have the vehicle inspected by an aprilia Official Dealer, who should carefully check the frame, handlebars, suspensions, safety parts and all the devices that you canno ...