aprilia instrukcja english - 1998

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ETX 125

use and maintenance

aprilia

part# 8102852



2

use and maintenance ETX 125

© 1998 aprilia s.p.a. - Noale (VE)

This manual is to be considered an integral part of the vehicle,which must be delivered complete with it also in case of resale.

aprilia s.p.a. reserves the right to modify its models at any time,without prejudice to the main characteristics here described.

All rights as to electronic storage, reproduction and total or par-tial adaptation, with any means, are reserved for all Countries.

The mention to products or services supplied by third parties ismade only for information purposes and is not binding in anycase.

aprilia s.p.a takes no responsibility as to the performance or the

use of said products.

First edition: march 1998

Reprint:

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) - Italy

Tel. +39 (0)41 - 58 29 111Fax +39 (0)41 - 44 10 54www.aprilia.com



3use and maintenance ETX 125

FOREWORD

Before starting the engine, carefully read this manual, payingparticular attention to the chapter "RIDING SAFELY".Your and other people’s safety depends not only on your quick-

ness of reflexes and on your agility, but also on what you knowabout the vehicle, on its efficiency and on your knowledge of thebasic information for RIDING SAFELY. Therefore, get a thor-ough knowledge of the vehicle, in such a way as to be able todrive in the traffic safely.For the controls and repairs not expressly described in this man-ual, for the purchase of aprilia

Genuine Spare Parts, accesso-ries and other products, as well as for specific technical advice,

contact only aprilia

Authorized Outlets and Official Dealers, whocan ensure you reliable and prompt servicing.Thank you for choosing aprilia

. We wish you a nice ride.

IMPORTANT:

When asking your Dealer for spare parts, specify the spare partscode indicated on the SPARE PARTS IDENTIFICATION LA-

BEL.Write down the identification code in the space here below, in or-der to remember it also in case of loss or deterioration of the la-bel.The label is positioned under the left side cover, see p. 40 (RE-MOVING THE SIDE COVERS).

Carefully observe the instructions preceded by the followingwarning signs:

Safety norms and regulations to protect the driverand other people from severe injuries or grave risks.

Indications to make the operations easier. Technicalinformation.

The operations preceded by this symbol must be re-peated on the opposite side of the vehicle.

In this manual the various versions are indicated by the followingsymbols:

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

&

optional

2

catalytic version

I Italy version £ Denmark version

UUnited Kingdom version

JJapan 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 Americaversion

O Holland version ^ Australia version

C Switzerland version

ac5



safe drive



6 use and maintenance ETX 125

SAFETY RULES

To drive the vehicle it is necessary to be inpossession of all the requirements pre-

scribed by law (driving licence, minimumage, psychophysical ability, insurance,state taxes, vehicle registration, numberplate, etc.).

Gradually get to know the vehicle by driv-ing it first in areas with low traffic and/or pri-vate areas.

The use of medicins, alcohol and drugs orpsychotropic substances notably increasesthe risk of accidents.Be sure that you are in good psychophysi-

cal conditions and fit for driving and payparticular attention to physical wearinessand drowsiness.

Most road accidents are caused by thedriver’s lack of experience.

NEVER lend the vehicle to beginners and,

in any case, make sure that the driver hasall the requirements for driving.




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 considerationto 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 increaseyour speed.

Always drive with both hands on the han-dlebars and both feet on the footrests (oron the rider’s footboards), in the correctdriving posture.

Avoid standing up or stretching your limbswhile driving.

STOP 150m

STOP

¡150m




The driver should pay attention and avoiddistractions caused by people, things andmovements (never smoke, eat, drink, read,etc.) while driving.

Use only the vehicle’s specific fuels and lu-bricants indicated in the "LUBRICANTCHART"; check the oil, fuel and coolantlevels 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 byan aprilia

Official Dealer, who should care-fully check the frame, handlebars, suspen-sions, safety parts and all the devices thatyou 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 ofdamage it has suffered endangers yoursafety.

COOLER

OIL




Never change the position, inclination orcolour of: number plate, direction indica-tors, lights and horns.

Any modification of the vehicle will result inthe invalidity of the guarantee.

Any modification of the vehicle and/or theremoval of original components can com-promise vehicle performance levels andsafety or even make it illegal.

We recommend respecting all regulationsand national and local provisions regardingthe equipment of the vehicle.

In particular, avoid all modifications that in-

crease the vehicle’s performance levels oralter its original characteristics.

Never race with other vehicles.

CLOTHING

Before starting, always wear a correctlyfastened crash helmet. Make sure that it is

homologated, in good shape, of the rightsize and that the visor is clean.

Wear protective clothing, preferably in lightand/or reflecting colours. In this way youwill make yourself more visible to the otherdrivers, thus notably reducing the risk ofbeing knocked down, and you will be more

protected in case of fall.This clothing should be very tight-fittingand fastened at the wrists and ankles.Strings, belts and ties should not be hang-ing loose; prevent these and other objectsfrom interfering with driving by getting en-tangled with moving parts or driving mech-

anisms.

ONLY ORIGINALS

A 1 2 3 4 5




Do not keep objects that can be dangerousin case of fall, for example pointed objectslike keys, pens, glass vials etc. in yourpockets (the same recommendations also

apply to passengers).

ACCESSORIES

The owner of the vehicle is responsible forthe choice, installation and use of any ac-

cessory.Avoid installing accessories that coverhorns or lights or that could impair theirfunctions, limit the suspension stroke andthe steering angle, hamper the operation ofthe controls and reduce the distance fromthe ground and the angle of inclination inturns.Avoid using accessories that hamper ac-cess to the controls, since this can prolongreaction times during an emergency.Large fairings and windscreens assembledon the vehicle can produce aerodynamicforces capable of compromising the stabili-ty of the vehicle while driving.

Make sure that the equipment is well fas-tened to the vehicle and not dangerousduring 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 orthere could be a dangerous current short-age in the horn and in the lights. aprilia

recommends the use of genuine accesso-ries (

aprilia

genuine accessories).

LOAD

Be careful and moderate when loadingyour luggage. Keep any luggage loaded asclose as possible to the centre of the vehi-cle and distribute the load uniformly onboth sides, in order to reduce imbalance tothe minimum. Furthermore, make sure thatthe load is firmly secured to the vehicle, es-pecially during long trips.




Avoid hanging bulky, heavy and/or danger-ous objects on the handlebars, mudguardsand forks, because the vehicle might re-spond more slowly in turns and its ma-

noeuvrability could be unavoidably im-paired.

Do not place bags that are too bulky on thevehicle sides and do not ride with the crashhelmet hanging from its string, because itcould hit people or obstacles making youlose 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 muchfrom the luggage rack or which cover thelights, horn or indicators.

Do not carry animals or children on theglove compartment or on the luggage rack.

Do not exceed the maximum load allowedfor each side-bag.

When the vehicle is overloaded, its stabilityand its manoeuvrability can be compro-mised.

KG!




ARRANGEMENT OF THE MAIN ELEMENTS

KEY

1) Horn2) Fuel tank plug3) Fuel tank4) Anti-theft hook (for the aprilia

“Body-Guard” armored cable&

)

5) Battery6) Glove/tool kit compartment

7) Fuse carrier8) Rear luggage rack9) Passenger left grab rail

10) Passenger left footrest(snapping, closed/open)

11) Side stand

12) Rider left footrest(with spring, always open)

13) Transmission oil drain plug14) Shifting lever15) Transmission oil filling cap

16) Starting lever




KEY

1) Passenger right grab rail2) 2 stroke oil tank plug3) 2 stroke oil tank4) Air cleaner5) Rear brake fluid tank

6) Fuel cock

7) Brake fluid reservoir (front brake)8) Ignition switch/steering lock9) Coolant radiator cap

10) Coolant radiator11) Rear brake control lever

12) Rider right footrest(with spring, always open)

13) Rear brake pump14) Drive chain15) Passenger right footrest

(snapping, closed/open)16) Crash helmet hook




ARRANGEMENT OF THE INSTRUMENTS

KEY

1) Light switch (

o

-p

- • )2) Direction indicator switch (

c

)3) Horn push button (

f

)4) Dimmer switch (

b

-a

)5) High beam signalling push button (a

)

6) Left rear-view mirror7) Clutch lever8) Cold start lever (

e

)9) Instruments and indicators

10) Ignition switch/steering lock (

n

-m

- s

)11) Front brake lever12) Right rear-view mirror13) Throttle grip

INSTRUMENTS AND INDICATORS

KEY

1) Red 2 stroke oil reserve warning light (

j

)2) Total kilometres odometer3) Speedometer4) Red coolant overheating warning light (

h

)5) Green neutral indicator warning light (

q

)

6) Green direction indicator warning light (

c

)7) Blue high beam warning light (

a

)8) Partial kilometres odometer9) Odometer trip control




INSTRUMENTS AND INDICATORS TABLE

Description Function

2 stroke oil reservewarning light (

j

)

Comes on, for about 0.5 seconds, whenever the ignition switch is brought to position “

n

”,thus testing the correct operation of the bulb.

If the light does not come on in this phase, contact an aprilia

Official Dealer .

If the warning light comes on during the normal operation of the engine, thismeans that the 2 stroke oil reserve is being used; in this case, provide for top-ping up, see p. 21 (2 STROKE OIL TANK).

Total kilometres odometer

It indicates the total number of kilometres covered.

Speedometer

It indicates the driving speed.

Coolant overheating

warning light (

h

)

It comes on when the coolant reaches or exceeds the limit temperature.

In this case, stop the engine and check the coolant level, see p. 28 (COOLANT).

If the maximum allowed temperature is exceeded (the warning light comes on),the engine may be seriously damaged.

Neutral indicator warning light

(

q) It comes on when the gear is in neutral.

Direction indicatorwarning light (c)

Blinks when the direction indicators are on.

High beam warning light (a)Comes on when the headlight is in "high beam" position or when the high beam signalling isoperated.

Partial kilometres odometerIt indicates the partial number of kilometres covered.To set it to zero, use the odometer trip control.

Odometer trip control Rotate it anticlockwise to set the partial kilometres odometer to zero.

a

a




MAIN INDEPENDENT CONTROLS

CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR

The electrical parts work only when the ignitionswitch is in position "

n

".

1) HIGH BEAM SIGNALLING PUSH BUTTON

(a

)It makes it possible to use the high beam for signalling to

forthcoming vehicles while overtaking and in case of periland/or emergency.

2) COLD START LEVER (

e

)

The starter for the cold start of the engine is operated byrotating the lever “

e

” anticlockwise

(Pos. A)

.To disconnect the starter, return the lever “

e

” to its initial

position.

3) HEADLIGHT SWITCH (

o

-p

-

•

)

Before operating the light switch, make sure that

the dimmer switch (

b

-a

) (6) 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 andthe dashboard light are on.

When the switch is in position “

o

”, the parking lights, thedashboard light and the low or high beam are on.By means of the dimmer switch (

b

-a

) (6) it is possible to

operate the low or high beam.

4) DIRECTION INDICATOR SWITCH (

c

)

To indicate the turn to the left, move the switch to the left; toindicate the turn to the right, move the switch to the right.To turn off the direction indicator, press the switch.

5) HORN PUSH BUTTON (

f

)

The horn is activated when the push button is pressed.

6) DIMMER SWITCH (

b

- a

)

When the light switch (

o

-p

- •

) (3) is in position “

o

”, if thedimmer switch is in position “

a

”, the high beam comes on,while if it is in position “

b

”, the low beam comes on.

c

c




IGNITION SWITCH

The ignition switch (1) is positioned on theupper plate of the steering column.

The key operates the ignition

switch/steering lock.Two keys are supplied together with thevehicle (one spare key).

STEERING LOCK

Never turn the key to position"

s

" in running conditions, in or-der to avoid losing control of the

vehicle.

OPERATION

To lock the steering:

x

Turn the handlebar completely leftwards.

x

Turn the key to position “

m

”.

Turn the key and steer the han-

dlebar at the same time.

x

Press and rotate the key anticlockwise(leftwards), steer the handlebar slowlyuntil the key reaches position “

s

”.

x

Extract the key.

ca

c

Position FunctionKey

removal

sSteering

lock

The steer-ing is

locked.It is neitherpossible tostart theengine, norto switch onthe lights.

It is possi-ble to

remove thekey.

mNeither theengine, northe lightscan beswitched on.

It is possi-ble toremove thekey.

nThe engine

and thelights can beswitched on.

It is not pos-

sible toremove thekey.




AUXILIARY EQUIPMENT

GLOVE/TOOL KIT COMPARTMENT

The g love / too l k i t compar tment i spositioned under the left side cover; to

reach it:

x

Remove the left side cover, see p. 40(REMOVING THE SIDE COVERS).

x

Withdraw the compartment cover frombehind (1).

The tool kit (2) includes:

– n˚ 1 tool case – n˚ 1 4 mm bent Allen spanner – n˚ 1 5 mm bent Allen spanner – n˚ 1 6 mm bent Allen spanner – n˚ 1 8 mm bent Allen spanner – n˚ 1 7x8mm double fork spanner – n˚ 1 10x13 mm double fork spanner – n˚ 1 19 mm fork spanner – n˚ 1 21x24 mm double socket spanner – n˚ 1 cross-/cut-headed screwdriver

– n˚ 1 screwdriver handle – n˚ 1 3x70 mm cross-headed screwdriver

Max. allowed weight: 1.5 kg

CRASH HELMET HOOK

Thanks to the crash helmet hook, you nolonger have to carry the crash helmet with

you every time you park the vehicle.

Do not ride with the crash helmethanging from the hook, as thismay seriously compromise your

safety.

To hang the crash helmet, proceed asfollows:

x

Insert the key in the lock (3).

x

Rotate the key clockwise.

x

Pass the crash helmet cable through thehook (4).

x

Rotate the key anticlockwise.

Make sure that you have correctly

closed the hook (4).

a

c




ANTI-THEFT HOOK

The anti-theft hook (1) is positioned on theleft side of the vehicle.

To prevent the vehicle from being stolen, itis advisable to secure it with the aprilia

“Body-Guard” armored cable &

(2),available at any aprilia Official Dealer.

Do not use the hook to lift thevehicle or for any purpose otherthan securing the vehicle once it

has been parked.

SPECIAL TOOLS&

To perform some specific operations, it isadvisable to use the following specialtools (to be requested to an aprilia

OfficialDealer ):

a

Tool Operations Page

Square pinspanner (3)

Rear shockabsorber ringadjustment.

51

Specialsocket

spanner (4)

Clutch clearanceadjustment. 26




MAIN COMPONENTS

FUEL

The fuel used for internal com-

bustion engines is extremely in-flammable and in particular con-ditions it can become explosive. It isimportant to carry out the refuelling andthe maintenance operations in a well-ventilated area, with the engine off. Donot smoke while refuelling or near fuelvapours, in any case avoid any contact

with naked flames, sparks and any oth-er heat source to prevent the fuel fromcatching fire or from exploding. Further,prevent fuel from flowing out of the fuelfiller, as it could catch fire when gettingin contact with the red-hot surfaces ofthe engine.

In case some fuel has accidentally beenspilt, make sure that the area has com-pletely dried before starting the vehicle.Since petrol expands under the heat ofthe sun and due to the effects of sun ra-diation, never fill the tank to the brim.Screw the plug up carefully after refuel-ling. Avoid any contact of the fuel withthe skin and the inhalation of vapours;do not swallow fuel or pour it from a re-ceptacle into another by means of atube.

DO NOT DISPOSE OF FUELIN THE ENVIRONMENT

KEEP AWAY FROM CHILDREN

Use only premium grade petrol (4 Stars

U

), in conformity 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 conformitywith the DIN 51607 standard, min. O.N. 95(N.O.R.M.) and 85 (N.O.M.M.).

FUEL TANK CAPACITY(reserve included): 11 l

TANK RESERVE: 4 l (mechanical re-serve)

To refuel, proceed as follows:

x

Unscrew and remove the fuel tank plug(1).

x

Refuel.

TRANSMISSION OIL

Remember: 1 mile = 1.6 km1 km = 0.625 miles

Check the transmission oil level every

4000 km, see p. 42 (CHECKING THETRANSMISSION OIL LEVEL AND TOP-PING UP).Change the transmission oil after the first1000 km and successively every 12000km, see p. 43 (CHANGING THE TRANS-MISSION OIL).

Use high-quality 75W-90 oil, seep. 72 (LUBRICANT CHART).

Engine oil can cause seriousdamage to the skin if handledevery day and for long periods.

Wash your hands carefully after using

the oil.

Do not dispose of the oil in the environ-ment.Put it in a sealed container and take it tothe filling station where you usually buyit or to an oil salvage center.

In case any maintenance operation hasto be carried out, it is advisable to uselatex gloves.

a

c

c

a




2 STROKE OIL TANK


Top up the 2 stroke oil tank every 500 km.

The vehicle is provided with a separate

mixer that ensures the mixing of petroland oil for the engine lubrication, see p. 72(LUBRICANT CHART).

The 2 stroke oil reserve is indicated by thecoming on of the 2 stroke oil reserve warn-ing light “

j

” positioned on the dashboard,see p. 15 (INSTRUMENTS AND INDICA-

TORS TABLE).

The use of the vehicle without 2stroke oil seriously damages theengine.

If you run out of oil in the 2 stroke oiltank or if the 2 stroke oil pipe has been

removed, contact an aprilia

OfficialDealer , who will provide for bleedingthe system.

This operation is indispensable, sincethe running of the engine with air in the2 stroke oil system may result in seri-

ous damage to the engine.

To introduce the 2 stroke oil in the tank,proceed as follows:

x

Remove the right side cover, see p. 40(REMOVING THE SIDE COVERS).

x

Remove the plug (1).

TANK CAPACITY: 1.4

l

TANK RESERVE: 0.5

l

Carefully wash your hands afterhandling the oil.Do not dispose of the 2 stroke oil

in the environment.


c a

a

M k h h b k di DISC BRAKES




BRAKE FLUID - recommendations

This vehicle is provided withfront and rear disc brakes, with

separate hydraulic circuits.The following information refers to a

single braking system, but is valid forboth.

Sudden resistance or clearanceproblems on the brake lever maybe due to troubles in the hydrau-

lic system.

For any doubt regarding the perfectfunctioning of the braking system andin case you are not able to carry out theusual checking operations, contactyour aprilia

Official Dealer .

Make sure that the brake discsare neither oily nor greasy, espe-cial ly after maintenance or

checking operations.Check that the brake cables are neither

twisted nor worn out.Prevent water or dust from accidentallygetting into the circuit.

In case maintenance operations are tobe performed on the hydraulic circuit, itis advisable to use latex gloves.

If the brake fluid gets in contact with theskin or the eyes, it can cause serious ir-ritations.Carefully wash the parts of your bodythat get in contact with the liquid.Consult a doctor or an oculist if the liq-uid gets in contact with your eyes.

Do not dispose of the brake fluid in theenvironment.


When using the brake fluid, take

care not to spill it on the plasticor pa inted par ts , s ince i tdamages them irreparably.

DISC BRAKES

The brakes are the parts thatmost ensure your safety and forthis reason they must always be

perfectly working; check them beforeevery trip.

The brake fluid must be changed once ayear by an aprilia

Official Dealer .

Use brake fluid of the type specified inthe lubricant chart, see p. 72 (LUBRI-CANT CHART).

When the disc pads wear out, the level ofthe fluid inside the reservoir decreases toautomatically compensate for their wear.

The front brake reservoir is positioned

near the front brake lever coupling.

The rear brake reservoir is positioned onthe right side of the vehicle, before the airfilter casing.

Periodically check the brake fluid level in

the tanks, see p. 23 (FRONT BRAKE),p. 24 (REAR BRAKE) and the wear of thepads, see p. 52 (CHECKING THE BRAKEPAD WEAR).

c

a

a

a

a




FRONT BRAKE

Carefully read p. 22 (BRAKE FLUID - rec-ommendations) and (DISC BRAKES).

CHECKING

Position the vehicle on firm andflat ground.

To check the brake fluid level, proceed asfollows:

x

Position the vehicle on the stand.

x

Rotate the handlebar leftwards, so thatthe fluid contained in the reservoir (1) isparallel to the “

MIN

” mark stamped onthe glass (2).

x

Make sure that the level of the brake fluidcontained in the tank exceeds the “

MIN

”mark stamped on the glass (2).

x

If not, provide for topping up.

TOPPING UP

The brake fluid may flow out ofthe reservoir. Do not operate thebrake lever if the screws (3) are

loose or, most important, if the brake

fluid tank cover has been removed.

x

Unscrew the two screws (3).

x

Remove the cover (4).

In order not to spill the brake fluidwhile topping up, keep the fluid inthe reservoir parallel to the reser-

voir rim.

x

Remove the gasket (5).

x

Fill the tank with brake fluid, see p. 72(LUBRICANT CHART), until it covers theglass completely.

x

Put back the gasket (5) in its seat cor-

rectly.

x Put back the cover (4).x Screw and tighten the two screws (3).

Check the braking efficiency. Ifnecessary, contact your apriliaOfficial Dealer.

In case of excessive movement of thebrake lever, of excessive elasticity or incase there is air in the circuit, contactyour aprilia Official Dealer, since itmay be necessary to bleed the system.

c

a

a

a




REAR BRAKE

Carefully read p. 22 (BRAKE FLUID - rec-ommendations) and (DISC BRAKES).

CHECKING


x

Keep the vehicle in vertical position, sothat the fluid contained in the tank (1) isparallel to the plug (2).

x

Make sure that the fluid level exceedsthe "

MIN

" mark.

x

If the fluid does not reach the "

MIN

"mark, provide for topping up.

TOPPING UP

The brake fluid may flow out ofthe tank. Do not operate the rearbrake lever if the brake fluid tank

plug is loose or has been removed.

x

Unscrew and remove the plug (2).

In order not to spill the brake flu-id while topping up, keep the flu-

id in the tank parallel to the tank rim (inhorizontal position).

x

Remove the gasket (3).

x

By means of a syringe, top up the brakefluid reservoir (1), see p. 72 (LUBRI-CANT CHART) until reaching the “

MAX

”mark.

x

To reassemble the components, follow

the reverse order.

Check the braking efficiency. Ifnecessary, contact your aprilia

Official Dealer .

In case of excessive stroke of the brake

lever, of excessive elasticity or in casethere is air in the circuit, contact your

aprilia

Official Dealer , since it may benecessary to bleed the system.

c

a

c a




ADJUSTINGTHE REAR BRAKE LEVER HEIGHT

The brake lever is installed in ergonomicposition on assembly of the vehicle.If necessary, it is possible to adjust thebrake lever height, by proceeding asfollows:

x

Loosen the lock nut (1).

x

Unscrew the brake adjuster (2) completely.

x

Screw the lock nut (3) completely on thepump control rod (4).

x

Screw the pump control rod (4) com-pletely, then unscrew it by giving 3-4turns.

x

Unscrew the brake adjuster (2) andmove the brake lever (5) to the desiredheight.

x

Lock the brake adjuster (2) by means ofthe lock nut (1).

x

Unscrew the pump control rod (4) andbring it in contact with the pump piston.

x

Screw the rod in order to ensure a mini-mum clearance of 0.5

÷

1 mm betweenthe pump control rod (4) and the pumppiston.

Make sure that there is a certainclearance between the brake ad-juster and the point of contact,

to prevent the brake from remaining op-erated and the consequent untimelywear of the braking elements.

Clearance between brake adjuster andpoint of contact: 0,5 ÷ 1 mm.

x

Lock the pump control rod by means ofthe lock nut (3).

Check the braking efficiency.If necessary, contact an aprilia

Official Dealer .

After the adjustment, make sure that thewheel rotates freely with releasedbrake.a

a




ADJUSTING THE CLUTCH

Adjust the clutch and if the engine stops ortends to advance when the clutch lever ispulled and the gears are engaged, or if theclutch slips causing a delay in the acceler-ation in comparison with the engine speed.

Minor adjustments can be carried out bymeans of the adjuster (1):

x

Withdraw the protection element (2).

x

Loosen the nut (3) (by screwing it).

x

Rotate the adjuster (1), until the idlestroke at the end of the clutch lever is

about 10 mm (see figure).x

Tighten the nut (3) (by unscrewing it) andlock the adjuster (1).

x

Check the idle stroke at the end of theclutch lever.

x

Put back the protection element (2).

If the adjuster (1) is completely screwed or

unscrewed, or if it is not possible to obtainthe correct idle stroke:

x


x

Tighten the nut (3) completely on the adjuster (1).

x

Tighten the adjuster (1) completely.

x

Unscrew and remove the plug (4) bymeans of a cut-headed screwdriver (or a

coin).

The spec ia l spanner (5 ) isavailable at any aprilia

OfficialDealer .

x

Insert the special spanner (5) and loosenthe inner nut (6).

x

Insert a cut-headed screwdriver (7) in

the special spanner (5) and tighten theadjusting screw (8) completely.

x

Loosen the adjusting screw (8) by givingit half a turn, which corresponds to 3÷4mm of the lever (9) stroke.

x

Keep the adjusting screw (8) locked bymeans of the screwdriver (7), act on thespecial spanner (5) and tighten the inner

nut (6).

x

Tighten the plug (4) again.

x

Check the idle stroke at the end of theclutch lever (10 mm).

x

Start the engine.

x

Operate the clutch completely and andengage the 1st gear. Make sure that theengine does not stop, that the vehicle

does not tend to advance or that theclutch does not slip during the accelera-tion phase or while the vehicle is running.

If it is not possible to obtain acorrect adjustment or if theclutch does not function proper-

ly, contact your aprilia

Official Dealer .

Make sure that the clutch cableis intact: it must not present flat-

tened parts and the sheath must not beworn out in any point.

x

Periodically lubricate the clutch cablewith a suitable lubricant, see p. 72 (LU-BRICANT CHART), in order to avoid its

untimely wear and corrosion.

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TYRES Check the surface and the wear of the If the tyres are old, even if not complete-




TYRES

This vehicle is provided with tyres with in-ner tube.

Periodically check the tyre infla-

tion pressure at room tempera-ture, see p. 68 (TECHNICAL DA-

TA).

If the tyres are hot, the measurement isnot correct.Carry out the measurement especially

before and after long rides.

If the inflation pressure is too high, theground unevenness cannot be damp-ened and is therefore transmitted to thehandlebar, thus compromising the driv-ing comfort and reducing the road hold-ing during turns.

If, on the contrary, the inflation pres-sure is too low, the tyre sides are undergreater stress and the tyre itself mayslip on the rim or it may become loose,with consequent loss of control of thevehicle.

In case of sudden braking the tyrescould even get out of the rims.Further, the vehicle could skid whileturning.

Check the surface and the wear of thetyres, since tyres in bad conditions canimpair both the grip and the controlla-bility of the vehicle.

Change the tyre when it is worn out orin case of puncture on the tread side, ifthe puncture is larger than 5 mm.After repairing a tyre, have the wheelsbalanced. Use only tyres in the sizesuggested by aprilia, see p. 68 (TECH-NICAL DATA).

Make sure that the tyres always havetheir valve sealing caps on, to preventthem from suddenly going flat.

Change, repair, maintenance and bal-ancing operations are very importantand should be carried out by qualified

technicians with appropriate tools.

For this reason, it is advisable to havethe above mentioned operations carriedout by an aprilia

Official Dealer or by aqualified tyre repairer.

If the tyres are new, they may still becovered with a slippery film: drive care-fully for the first miles.Do not oil the tyres with unsuitable flu-ids.

If the tyres are old, even if not completely worn out, they may become hard andmay not ensure good road holding.In this case, replace them.

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The coolant is noxious: do not The coolant is made up of 50% water and

a




COOLANT

Do not use the vehicle if thecoolant is below the minimumprescribed level.


Check the coolant level every 2000 km andafter long rides; change it every 24months.

e coo a t s o ous do otswallow it; if the coolant gets incontact with the skin or the eyes,

it can cause serious irritations.

If the coolant gets in contact with yourskin or eyes, rinse with plenty of waterand consult a doctor. If it is swallowed,induce vomit, rinse mouth and throatwith plenty of water and consult a doc-tor without delay.

KEEP AWAY FROM CHILDREN.

Be careful not to spill the coolant on thered-hot parts of the engine: it may catchfire and send out invisible flames.

In case maintenance operations are tobe performed, it is advisable to use la-

tex gloves.

Have the coolant changed by an

aprilia

Official Dealer .

e coo a t s ade up o 50% ate a d50% antifreeze.

This mixture is ideal for most running tem-peratures and ensures good protectionagainst corrosion.

Ii is advisable to keep the same mixturealso in the hot season, since in this waylosses due to evaporation are reduced andit is not necessary to top up very frequent-ly.

The mineral salt deposits left in the radiator

by evaporated water are thus reduced andthe efficiency of the cooling system re-mains unchanged.

If the outdoor temperature is below 0˚,check the cooling circuit frequently and ifnecessary increase the antifreeze concen-tration (up to maximum 60%).

For the cooling solution use distilled water,in order not to damage the engine.

Do not remove the radiator capwhen the engine is hot, since thecoolant is under pressure and its

temperature is high.

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CHECKING AND TOPPING UP

Check the coolant level and topup the expansion tank with coldengine.

x

Stop the engine and wait until it hascooled down.


x

Keep the vehicle in vertical position, withthe two wheels resting on the ground.

x

Rotate the radiator cap (1) anticlockwise,giving it one click.

x

Wait for a few seconds, in order to permitthe bleeding of any pressure present in

the system.

x

Rotate the radiator cap (1) anticlockwiseagain and remove it.

x

Check if the coolant covers the radiatorplates completely.

x

If necessary, top up with coolant, seep. 72 (LUBRICANT CHART), until cover-ing the radiator plates completely.

Do not exceed th is leve l ,otherwise the fluid will flow outof the tank when the engine is

running.

x

Put back the radiator cap (1).

In case of excessive consump-tion of coolant and in case thetank remains empty, make sure

that there are no leaks in the circuit.Have it repaired by an aprilia

OfficialDealer .

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CATALYTIC SILENCER2

Avoid parking the vehicle cata-lytic version near dry brushwood or in places easily accessi-

ble to children, as the catalytic silencerbecomes extremely hot during use; be

very careful and avoid any kind of con-tact before it has completely cooleddown.

The catalytic vehicle is fitted with a silencerwith metal catalytic converter of the “plati-num-rhodium bivalent” type.

This device provides for the oxidation ofthe CO (carbon monoxide) and of the HC(unburned hydrocarbons) contained in the

exhaust gases, changing them into carbondioxide and steam, respectively.

Due to the catalytic reaction, the high tem-perature reached by the exhaust gasesmakes for the burning of the oil particles,thus keeping the silencer clean and elimi-nating the exhaust fumes.

To have the catalytic converter functioncorrectly and for long and to reduce possi-ble problems regarding the soiling of thethermal unit and of the exhaust, it is neces-sary to avoid covering long distances withthe engine running at constantly low rpm.

It is sufficient to alternate these periodswith periods in which the engine runs at rel-atively high rpm, even if only for a few sec-onds, but rather frequently.

What has been stated above assumes par-ticular importance for the cold starting of

the engine: in this case, in order to reach arpm regime sufficient to enable the “prim-ing” of the catalytic reaction, just makesure that the temperature of the thermalunit has reached at least 50˚C, which gen-erally occurs a few seconds after startingthe engine.

Do not use leaded petrol, since itcauses the destruction of thecatalytic converter.

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INSTRUCTIONS FOR USE PRELIMINARY CHECKING OPERATIONS




Before departure, always carryout a preliminary checking of thevehicle to make sure that it func-

tions correctly and safely, see the fol-lowing table (PRELIMINARY CHECKINGOPERATIONS). The non-performance ofthese checking operations can causesevere personal injuries or damages tothe vehicle.

Do not hesitate to consult your aprilia

Official Dealer in case there is some-thing you do not understand about thefunctioning of some controls or in caseyou suspect or discover some irregular-ities.It does not take long to carry out acheck-up and this operation ensures

you much more safety.

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Component Check Pagina

Front and rear discbrakes

Check the functioning, the idle stroke of the control levers,the fluid level and make sure there are no leaks. Checkthe wear of the pads. If necessary, top up the fluid tank.

22-23-24-52

Accelerator Make sure that it works smoothly and that it is possible toopen and close it completely, in all steering positions.If necessary, adjust and/or lubricate it.

53

2 stroke oil/ transmission oil

Check and/or top up if necessary. 20/21-42-43

Wheel/tyres Check the tyre surface, the inflation pressure, wear and

tear and any damage.

27

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

23-24

Clutch The idle stroke at the end of the clutch lever must beabout 10 mm; the clutch must operate without jerkingand/or slipping.

26

Steering Make sure that the steering rotates smoothly, without any

clearance or slackening. —

Side stand and centerstand

Make sure that it works smoothly and that the spring ten-sion brings it back to its normal position. If necessary,lubricate joints and hinges. Make sure that the safetyswitch on the side stand operates correctly.

59-60

Fastening elements Make sure that the fastening elements are not loose.If necessary, adjust or tighten them.

—

Drive chain Check the slack. 48-49

Fuel tank Check the fuel level and top up, if necessary. Make surethere are no leaks or air bubbles in the circuit.

20-65

Coolant The coolant level in the expansion tank must be includedbetween the "

MIN

" and "

MAX

" marks.28-29

Lights, warning lights,horn and electricdevices

Check the proper functioning of the acoustic and visualdevices. Change the bulbs or intervene in case of failure. 54÷64




STARTING

Exhaust gases contain carbonmonoxide, which is extremelynoxious if inhaled.

Avoid starting the engine in closed or

badly-ventilated rooms.The non-observance of this warningmay cause loss of consciousness oreven lead to death by asphyxia.

With the side stand down, theengine can be started only if the

gears are in neutral; in this case, if youtry to engage the gears, the enginestops.With the side stand up, it is possible tostart the engine either in neutral gear orwith engaged gears and pulled in clutchlever.

x


x

Move to the left side of the vehicle.

Or:

x

Let the stand up.

x

Get on the vehicle.

Then:

x

Rotate the fuel tap lever (1) to position“

ON

”.

x

Make sure that the light switch (2) is inposition “

•

”.

x

Make sure that the dimmer switch (3) isin position “

b

”.

x

Rotate the key (4) and move the ignitionswitch to position “

n

”.At this point: – the red 2 stroke oil reserve warning

light “

j

” comes on on the dashboard,see p. 14 and 15 (INSTRUMENTSAND INDICATORS).

x

Lock the front wheel, by pulling the frontbrake lever (5).

x

Position the shifting lever (6) in neutral(green warning light “

q

” on).

x

If the vehicle is started with cold engine,rotate the cold start lever “

e

” (7) anti-clockwise (

Pos. A

).

x

Rotate the start pedal (8) outwards.

Do not press the start pedalwhen the engine is running.

x

Press the start pedal (8) with energy andrelease it immediately. If necessary,repeat this operation until the enginestarts.

x

Keep the front brake lever (5) pulled anddo not accelerate until you start.

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x Slightly rotate the throttle grip (9) and atthe same time press the start pedal (8)




Never leave abruptly with coldengine.To reduce the emission of pollut-

ing substances and the consumption offuel, warm the engine up by proceedingat low speed for the first miles.

x

After warming up the engine, rotate thecold start lever “

e

” (7) clockwise (

Pos.B

).

Starting with flooded engine

If the starting is not carried out properly, orif there is too much fuel in the intakeducts, the engine may get flooded.

To clean a flooded engine:

x

Carry out the first twelve operationsdescribed for the starting procedure.

x

Rotate the throttle grip (9) completely(

Pos. C

).


x

Press the start pedal (8) with energy afew times and release it immediately.

Starting with cold engine

When the room temperature is low (nearor below 0˚C), it may be difficult to startthe engine at the first attempt.

In this case:x

Rotate the cold start lever “

e ” (7) anti-

clockwise (Pos. A).


the same time press the start pedal (8)with energy a few times, releasing it im-mediately afterwards.

If the engine starts

x Release the throttle grip (9).x Rotate the cold start lever “e ” (7) clock-

wise (Pos. B).

If the idling is unstable, twist the throttlegrip (9) slightly and frequently.

If the engine does not startWait for a few seconds and then repeat thestarting procedure.

STARTING AFTER A LONG PERIODOF INACTIVITY

After a long period of inactivity, push thestart pedal (8) with energy for a few timeswithout accelerating, in order to ensurethe filling of the fuel circuit.

To start the engine, slightly open the throt-tle and carry out the starting procedure.

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x Ride at reduced speed for the first miles,in order to warm the engine up




DEPARTURE AND DRIVE

Before departure, carefully readthe "SAFE DRIVE" chapter, see

p. 5 (SAFE DRIVE).

If you run out of the "standard" fuel quantitywhile riding, move the fuel tap lever (1) toposition "

RES

", in order to use the fuel re-serve.

Fuel reserve: 4 l

(mechanical reserve).

Refuel as soon as possible, see

p. 20 (FUEL).

If you drive without passenger,make sure that the passengerfootrests are folded.

While riding, keep your hands on thegrips and your feet on the footrests.

NEVER RIDE IN ANY POSITION OTHERTHAN THOSE INDICATED.

If you drive with a passenger, instructhim/her so that he/she does not createproblems during manouvres.

To leave:

x

Adjust the inclination of the rear-viewmirrors correctly.

With the vehicle at rest, try to getacquainted with the use of therear-view mirrors.

in order to warm the engine up.

x

With released throttle grip (2) (

Pos. A

)and engine idling, pull the clutch lever (3)completely.

x

Engage the first gear, by pressing theshifting lever (4) downwards.

x

Release the brake lever (pulled on thestarting).

On departure, the abrupt releaseof the clutch lever may cause theengine to stall or the vehicle to

jerk forwards.Never accelerate abruptly or excessive-ly when releasing the clutch lever, in or-der to prevent the clutch from "slip-ping" (slow release) or the front wheelfrom raising “rearing up” (quick re-lease).

x

Slowly release the clutch lever (3) and atthe same time accelerate by rotating thethrottle grip moderately (2) (

Pos. B

).The vehicle will start moving.

Do not exceed the recommendedrpm and speeds, see p. 37 (RUN-

NING-IN).

x

Increase the speed by gradually rotatingthe throttle grip (2) (

Pos. B

), withoutexceeding the max. speed (and therecommended rpm) in each gear, seep. 37 (RUNNING-IN).

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To shift down, proceed as follows:

x R l th th ttl i (2) (P A)




To engage the second gear:

Proceed quickly.Never ride the vehicle at too lowrpm.

x

Release the throttle grip (2) (

Pos. A

),pull the clutch lever (3) and lift the shift-ing lever (4). Release the clutch lever (3)and accelerate.

x

Repeat the last two operations and shiftup.

The downshifting should be carried out inthe following situations:

x

When riding downhill or when braking, inorder to increase the braking action byusing the compression of the engine.

x

When riding uphill, if the gear engaged is

not suitable to the speed (high gear,moderate speed) and the engine rpm de-creases.

Shift the gears one by one; thesimultaneous downshifting ofmore than one gear may make

you exceed the maximum rpm (red line).Before and during the downshifting, re-lease the throttle grip and decelerate, inorder to avoid the "red line".

x


Pos. A

).

x

If necessary, pull the brake levers mod-erately and decrease the speed of thevehicle.

x

Pull the clutch lever (3) and lower theshifting lever (4) to shift down.

x

If the brake levers are pulled, releasethem.

x

Release the clutch lever and acceleratemoderately.

If the 2 stroke oil reserve warn-ing light "j" comes on whilethe engine is running, this

means that the 2 stroke oil reserve isbeing used; in this case, top up the 2stroke oil tank, see p. 21 (2 STROKE OILTANK).

I f the coolant overheat ingwarning light “h” comes on,stop the engine and check the

coolant level, see p. 28 (COOLANT).

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Before beginning to turn, slowdown or brake driving at moder-

Pay the utmost attention to anyobstacle or variation of thea a




Avoid opening and closing thethrottle grip repeatedly and con-tinuously, so that you do not ac-

cidentally lose control of the vehicle.If you have to brake, close the throttleand put on both brakes in order to ob-tain uniform deceleration, properly ex-

erting pressure on the braking parts.By putting on the front brake only or therear brake only, you reduce the brakingforce considerably, thus running therisk of locking one wheel and conse-quently losing grip.

If you stop uphill, decelerate completely

and use the brakes only to keep the ve-hicle steady.The use of the engine to keep the vehi-cle steady may cause the overheatingof the clutch.

down or brake driving at moderate and constant speed or accel-

erating slightly; avoid braking at thelast moment: it would be very easy toskid.

If the brakes are operated continuouslyon downhill stretches, the friction sur-faces may overheat, thus reducing thebraking efficiency.Exploit the engine compression andshift down by putting on both brakes in-

termittently.Never drive downhill with the engineoff!

When visibility is insufficient, switch onthe low beam even during the day, in or-der to make your vehicle more visible.

In case of wet ground or scarce wheelgrip (snow, ice, mud, etc.), drive slowly,avoiding sudden brakings or manoeu-vres that could make you lose grip andfall down.

obstacle or variation of theground. Uneven roads, rails,

manhole covers, indications painted onthe road surface, building site metalplates become rather slippery by rain.For this reason all these obstacles haveto be carefully avoided, driving smooth-ly and bending the vehicle as little aspossible.

Always use the turn indicators in timewhen you intend to change lane or di-

rection, avoiding sharp and dangerousmovements.Switch off the direction indicators assoon as you have changed direction.

Be extremely careful when you overtakeother vehicles or are overtaken.

In case of rain, the water cloud createdby big vehicles reduces visibility; theair shift may make you lose control ofthe vehicle.

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RUNNING-IN

The running in of the engine is important to

After the first 1000 km, carry outthe checking operations indicat-a




The running-in of the engine is important toensure its correct functioning.If possible, drive on hilly roads and/orroads with many bends, so that the engine,

the suspensions and the brakes undergo amore effective running-in.During running-in, change speed. In thisway the components are first “loaded” andthen “relieved” and the engine parts canthus cool down.Even if it is important to stress the enginecomponents during running-in, take care

not to exceed.


Only after the first 2000 km ofrunning-in you can expect the

best performance levels from the vehi-cle.

Keep to the following indications:

x

Do not open the throttle completely if thespeed is low, both during and after therunning-in.

x

During the first 100 km put on the brakeswith caution, avoiding sharp and pro-longed brakings.This ensures a correct bedding-in of thepads on the brake disc.

x

During the first 800 km, never exceedthe max. speeds (and the engine rpm)indicated in the table for each gear.

the checking operations indicated in the column "After running-

in" of the REGULAR SERVICE INTER-VALS CHART, see p. 39 (REGULARSERVICE INTERVALS CHART), in orderto avoid hurting yourself or other peo-ple and/or damaging the vehicle.

x

Between the first 800 and 1600 km drivemore briskly, change speed and use themaximum acceleration only for a fewseconds, in order to ensure better cou-

pling of the components; never exceedthe max. speeds (and the engine rpm)indicated in the table for each gear.

x

After the first 1600 km you can expectbetter performance from the engine.However, do not exceed the max.speeds indicated in the table and the

engine max. rpm (6750 rpm).

STOPPING

I f possible, avoid stoppingabruptly, slowing down suddenlyand braking at the last moment.

x


Pos. A

),gradually put on the brakes and at thesame time shift down in order to de-crease the speed, see p. 34 (DEPAR-TURE AND DRIVE).

Once the speed has decreased, beforestopping the vehicle:

x

Pull the clutch lever (2) in order to pre-vent the stopping of the engine.

When the vehicle has come to rest:

x

Position the shifting lever in neutral(green warning light "

q" on).x Release the clutch lever (2).x In case of a brief stop, keep at least one

brake on.

cc

Max. speeds for the running-inkm/h

Mileagekm

0÷800 800÷1600over1600

Gear

1st 22 27 30

2nd

32 39 443rd 42 51 57

4th 51 61 69

5th 61 73 82

6th 70 84 95

rpm 5000 6000 6750

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SUGGESTIONSTO PREVENT THEFT




PARKING

Park the vehicle on firm and flatground, to prevent it from fallingdown.

Neither lean the vehicle against walls,

nor lay it on the ground.Make sure that the vehicle and especial-ly its red-hot parts do not represent adanger for persons and children.

Do not leave the vehicle unattendedwhen the engine is on or the key is in-serted into the ignition switch.

Do not sit on the vehicle when the standis down.

x

Stop the vehicle, see p. 37 (STOPPING).

x

Rotate the key (1) and move the ignitionswitch (2) to position "

m

".

x

Move the fuel tap lever (3) to position

"

OFF

".

x

Position the vehicle on the stand, seep. 38 (POSITIONING THE VEHICLE ONTHE STAND).

Never leave the key in the igni-tion switch.

x

Lock the steering, see p. 17 (STEERINGLOCK) and extract the key.

POSITIONING THE VEHICLEON THE STAND

Carefully read beside (PARKING).

x

Grasp the left grip (4) and the passengergrab rail (5).

x

Press the side stand with your right footand extend it completely (6).

x

Incline the vehicle until the stand restson the ground.

Make sure that the vehicle is sta-ble.

NEVER leave the ignition key inserted andalways use the steering lock.

Park the vehicle in a safe place, possibly in

a garage or a protected place.

If possible, use the appropriate aprilia

“Body-Guard” armored cable&

, or an ad-ditional anti-theft device.

Make sure that all documents are in orderand the road tax has been paid.

Write down your personal data and tele-phone number in this page, to facilitate theidentification of the owner in case of findingafter theft.

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

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

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

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

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

Very often stolen vehicles areidentified thanks to the data writ-

ten in the use/maintenance manual.

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MAINTENANCE REGULAR SERVICE INTERVALS CHART

After running-in Every 4000 km Every 8000 km




Before beginning any mainte-nance operation or any inspec-tion of the vehicle, stop the en-

gine, extract the key from the ignitionblock, wait until the engine and the ex-haust system have cooled down and ifpossible lift the vehicle by means of theproper equipment, on firm and flatground.Keep away from the red-hot parts of theengine and of the exhaust system, in or-der to avoid burns.The vehicle is made up of not edibleparts. Never bite, suck, chew or swallowany part of the vehicle for any reason.

If not expressly indicated other-wise, for the reassembly of the

units repeat the disassembly op-erations in reverse order.

Ordinary maintenance operations can usu-ally be carried out by the user, but some-times a basic knowledge of mechanics andspecific tools are required. If you need as-

sistance or technical advice, consult your

aprilia

Official Dealer, who can ensure youprompt and accurate servicing.After any maintenance operation, carry outthe "Preliminary checking operations", seep. 31 (PRELIMINARY CHECKING OPER-ATIONS).

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ComponentAfter running-in

(1000 km) or 4 monthsEvery 4000 km

or 8 monthsEvery 8000 kmor 16 months

Battery - electrolyte level C C

Spark plug P P S

Carburettor C PDrive chain every 500 km: C

Wheel balancing C

Steering bearings and steering C C

Wheel bearings C

Air cleaner P C

Clutch clearance R R

Braking systems C C

Cooling system C CLight system C C

Brake fluid C every year: S

2 stroke oil level every 500 km: C

Coolant every 2000 km: C / every 2 years: S

Fork oil every 16000 km: S / every 8000 km: C

Transmission oil S C every 12000 km: S

Start lever pin every 8000 km: C (lubricate with water-repellent grease) (*)

Piston and linings every 8000 km: C / every 16000 km: S

2 stroke oil pump and air bleeding C R

Tyre pressure R every month: C

Engine idling rpm R C

Fuel cock C C

Nut, bolt, screw tightening C C

Suspensions C

2 stroke oil reserve warning light C CDrive chain tension and lubrication every 500 km: C

Wheel spoke tension C C

Fuel pipes C C every 4 years: S

Exhaust silencer(catalytic version excluded)

C C

C = check, clean, adjust, lubricate or change, if necessary. P = clean; S = change; R = adjust.Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas or

on uneven ground. Have maintenance operations on the components indicated by carried out byaprilia Official Dealers ONLY.(*) Use MOLYCOTE 6 Rapidplus grease.




IDENTIFICATION DATA

It is a good rule to write down the frameand engine numbers in the space providedin this manual.

The frame number can be used for thepurchase of spare parts.

Do not alter the identificationnumbers if you do not want to in-

cur severe penal and administrativesanctions. In particular, the alteration ofthe frame number results in the immedi-ate invalidity of the guarantee.

ENGINE NUMBER

The engine number (1) is stamped on theright side of the engine casing base.

Engine no.

FRAME NUMBER

The frame number is stamped on the rightside of the steering column.

Frame no.

REMOVING THE SIDE COVERS

Carefully read p. 39 (MAINTENANCE).

x


The description of the following

operations refers to one sidecover, but it is valid for both.

x

Rotate the quick fastening screw (3) anti-clockwise by giving it 1/4 turn.

Proceed with care.Do not damage the tangs and/or

their seats.Handle the plastic components withcare and avoid scraping or damagingthem.

x

Withdraw and remove the side cover (4).

c

a

x Clean the filtering element (3) with clean,non-inflammable solvents or solvents

i h hi h l ili i h l i d




AIR CLEANER

Do not use petrol or inflammablesolvents to wash the air cleaner,in order to avoid fires or explo-sions.

Carefully read p. 39 (MAINTENANCE).Remember: 1 mile = 1.6 km1 km = 0.625 miles

Check the conditions of the air cleaner andclean it monthly or every 4000 km, depend-ing on the conditions in which the vehicle isused. If the vehicle is used on dusty or wet

roads, the cleaning operations and any re-placement should be carried out more fre-quently. Before the cleaning operation, it isnecessary to remove the air cleaner fromthe vehicle.

REMOVAL

x

Remove the right side cover, see p. 40(REMOVING THE SIDE COVERS).

x

Unscrew and remove the three screws(1) and take the relevant washers.

x

Remove the filter casing cover (2).

Clean the inside of the filtercasing before withdrawing the

filtering element, in order to prevent

dust and foreign matters from enteringthe suction manifold.

x

Clean the inside of the filter casing andof the filter casing cover (2) with a cloth.

x

Withdraw the filtering element (3)complete with the grids (4) and (5).

CLEANING

In order not to deform the grids,DO NOT force their sides.

x

Grasp the central part of both grids (4)and (5), pull and separate them.

x

Release the filtering element (3) from the

grid (4).

with high volatility point, then let it drythoroughly.

x

Apply a filter oil or a thick oil (SAE 80W-90) on the whole surface of the filteringelement, then squeeze it to eliminate theoil in excess.

The filtering element (3) must bewell impregnated, though not

dripping.

CHANGE

x

Replace the filtering element (3) with anew one of the same type.

x Check the condition of the gasket (8); if itis damaged, change it.

Upon reassembly:

Be careful to the shape of thefiltering element and the grids:

they must coincide.

x Correctly introduce the filtering element(3) in the two pins (6).

x Position the grid (5).

x Push both grids in correspondence withthe pins (6).

The two protruding elements (7)avoid the incorrect insertion of

the filtering element in the filter casing.

x Introduce the filtering element, complete

with grids, in the filter casing guides.

a

c

c

a

c

c

c

TOPPING UP

If it were necessary to top up, proceed as




CHECKING THE TRANSMISSIONOIL LEVEL AND TOPPING UP

Carefully read p. 20 (TRANSMISSIONOIL) and p. 39 (MAINTENANCE).

Remember: 1 mile = 1.6 km

1 km = 0.625 miles

Check the transmission oil level every4000 km, change it after the first 1000 kmand successively every 12000 km, seep. 43 (CHANGING THE TRANSMISSIONOIL).

CHECKING


x

Stop the engine and let it cool down forat least ten minutes, in order to allow theoil to flow back to the oil pan and to cool

down.

x


The non-performance of the op-erations described above may

result in a wrong measurement of the

level.

x

Make sure that the oil level is includedbetween one fourth (

MIN)

and a half(

MAX

) of the height of the glass (1).

The oil level must neither exceeda half of the height of the glass,

nor fall below one fourth. In the firstcase the excess oil would flow out ofthe oil pan; in the second case theengine may get seriously damaged.

follows:

x

Unscrew and remove the filling cap (2).

x

Pour a small quantity of oil and wait

about one minute, to allow the oil to flowuniformly inside the pan.

x

Make sure that the oil level is includedbetween one fourth (

MIN

) and a half(

MAX

) of the height of the glass (1).

x

If this is not the case, top up again withsmall quantities of oil and repeat the

check through the glass (1), unt i lreaching the prescribed level (

MAX

).

x

At the end of the operation, screw andtighten the filling cap (2).

T i g h t e n t h e fi l l i n g c a pthoroughly and make sure that

there are no oil leaks.

Periodically check that there are noleaks in correspondence with the oilpan cover seal.

Do not use the vehicle with insufficient

lubrication or with contaminated or un-suitable lubricants, since this would ac-celerate the wear of the moving partsand may also cause irreparable failures.

c

c

c

c

a

Change the sealing washer of the drainplug (2) every 12000 km (or every sec-ond engine oil change)




CHANGINGTHE TRANSMISSION OIL

Carefully read p. 20 (TRANSMISSIONOIL) and p. 39 (MAINTENANCE).

Remember: 1 mile = 1.6 km

1 km = 0.625 miles

Check the transmission oil level every4000 km, change it after the first 1000 kmand successively every 12000 km.

To change the oil, proceed as follows:

x

Drive for a few miles, until the enginereaches the normal running temperature.


x

Stop the engine and let it cool down forat least ten minutes, in order to allow theoil to flow back to the oil pan and to cool

down.

When warmed up, the enginecontains hot oil; therefore, whilecarrying out the operations de-

scribed here below be particularly care-ful, in order to avoid burns.

x


x

Put a container (1) with at least 600 cm

C

ca-pacity in correspondence with the drain plug(2).

x

Unscrew and remove the drain plug (2).

x

Unscrew and remove the filling plug (3).

x

Drain the oil and let it drip into the container(1) for a few minutes.

x

Remove the metal residues from the drainplug (2) magnet.

x

Check and if necessary replace the seal-ing washer of the drain plug (2).

ond engine oil change).

x Screw and tighten the drain plug (2).

Drain plug (2) driving torque:27 Nm (2,7 kgm).

x Pour about 550 cmC of transmission oilthrough the filling opening (3), see p. 72(LUBRICANT CHART).

x Tighten the filling plug (3).x Start the engine, see p. 32 (STARTING)

and let it idle for about one minute, in or-der to ensure the filling up of the trans-mission oil circuit.

Check the oil level and top up if necessary,see p. 42 (CHECKING THE TRANSMIS-SION OIL LEVEL AND TOPPING UP).

T i g h t e n t h e fi l l i n g c a pthoroughly and make sure thatthere are no oil leaks.

Periodically check that there are noleaks in correspondence with the oilpan cover seal.

Do not use the vehicle with insufficientlubrication or with contaminated or un-suitable lubricants, since this would ac-celerate the wear of the moving partsand may also cause irreparable failures.

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a

a




FRONT WHEEL

The disassembly and reassem-bly of the front wheel may be dif-ficult for unskilled operators. If

necessary, contact an aprilia

Official

Dealer.If you want to perform these operationspersonally, keep to the following in-structions.


While disassembling and reassembling

the wheel, be careful not to damage thebrake pipe, the disc and the pads.Before performing the operations de-scribed here below, let the engine andthe silencer cool down until they reachroom temperature, in order to avoidburns.

DISASSEMBLY

x


Due to the weight and dimen-sions of the vehicle, the follow-ing operation cannot be per-

formed by one person only.Proceed with care and make sure thatyou can support the weight of the vehi-cle.

Weight of the vehicle (ready forstarting): 129 kg.

x

Raise the front part of the vehicle and have

a suitable support (1) (the weight of whichshould be about 400 mm) placed under theengine, so that the front wheel can rotatefreely and the vehicle cannot fall down.

The vehicle may fall down.Provide for balancing the vehi-cle, in order to prevent it from

falling down.

x

Position and fix a load weighing about 40kg on the rear luggage rack, in order tosupport the front part of the vehicle.

Make sure that the vehicle is sta-

ble.

x

Put a support (2) under the tyre, in sucha way as to keep the wheel in its positionafter loosening it.

x

Have the handlebar held still in drivingposition, so that the steering is locked.

x

Loosen the two screws (3) of the wheel

pin clamp.

x

Unscrew the wheel pin (4) completely.

To facilitate the extraction of thewheel pin, slightly lift the wheel.

x

Support the front wheel and manuallywithdraw the wheel pin (4).

a a

c

a

a

c




REAR WHEEL

The disassembly and reassem-bly of the rear wheel may be dif-ficult for unskilled operators. If

necessary, contact an Official Dealer

aprilia

.

If you want to perform these operationspersonally, keep to the following in-structions.


Before carrying out the following opera-

tions, let the engine and the silencercool down until they reach room tem-perature, in order to avoid burns.

While disassembling and reassemblingthe wheel, be careful not to damage thebrake pipe, the disc and the pads.

For the disassembly and reassembly,use gloves in order to protect yourhands and fingers properly.

DISASSEMBLY

x


x

Unscrew and remove the three screws(1), taking the relevant nuts.

x

Remove the chain casing (2).

x

Lock the rotation of the wheel pin (3) bymeans of the appropriate spanner.

x

Loosen the wheel nut (4) .

Wheel nut (4) driving torque:80 Nm (8 kgm).

Upon reassembly , beforetightening the wheel nut (4),check the chain tension, see p.

48 (DRIVE CHAIN).

x

Unscrew and remove the screw (5),together with the washer.

Screw (5) driving torque:5 Nm (0,5 kgm).

Due to the weight and dimen-sions of the vehicle, the follow-ing operation cannot be per-

formed by one person only.Proceed with care and make sure thatyou can support the weight of the vehi-cle.

Weight of the vehicle (ready forstarting): 129 kg.

x

Raise the rear part of the vehicle, have asuitable support (6) (the height of whichshould be 400 mm) placed under the en-gine, so that the rear wheel can rotatefreely and the vehicle cannot fall down.

a

a

a

c

x Move the wheel completely forward;release the drive chain from above, ro-tating the rear wheel anticlockwise.

Check the arrangement of thespacer rings (14) and (15), in

order to be able to reassemble them

c




The vehicle may fall down.Provide for balancing the vehi-cle, in order to prevent it from

falling down.Make sure that the vehicle is stable.

x

Place a support (7) under the tyre, in sucha way as to keep the wheel in the correctposition after releasing it.

x

Rotate the left chain adjuster cam (8)completely clockwise (end of stroke).

x

Rotate the right chain adjuster cam (9)completely anticlockwise (end of stroke).

Lower the drive chain (10) out-side the crown gear (11).

Do not introduce your fingersbetween the chain and the crowngear.

g

Upon reassembly, introduce thedrive chain from below, rotating

the rear wheel in the travelling direc-tion.

x

Unscrew and remove the wheel nut (4)and take the washer (12).

x

Remove the left chain adjuster cam (8).

To facilitate the extraction of thewheel pin, slightly raise the

wheel.

x

Hold the rear wheel and manually with-draw the wheel pin (3).

x

Take the spacer ring (13).

x

Take the right chain adjuster cam (9).

x

Withdraw the wheel from the rear forkfrom behind, carefully withdrawing thedisc from the brake caliper.

Never pull the rear brake leverafter removing the wheel, other-wise the caliper piston may go

out of its seat, thus causing the outflowof the brake fluid. In this case consultyour aprilia

Official Dealer, who willcarry out the proper maintenance oper-ation.

correctly.

x Take the left spacer ring (14).x Take the right spacer ring (15).

Upon reassembly:

x Moderately grease the outer seats of thewheel hub.

x Fit the spacer rings (13) (14) (15) with

the longer diameter towards the outsideof the vehicle.

x Make sure that the slot (16) in the brakecaliper support plate (17) is correctlylocated in the lug (18) on the inside ofthe rear fork left leg.

x Uniformly apply a moderate quantity ofgrease on the wheel pin (3).

After reassembly, pull the rearbrake lever repeatedly andcheck the correct functioning of

the braking system.

Check the wheel centering.

Have the driving torques, centering andbalancing of the wheel checked by youraprilia Official Dealer, in order to avoidaccidents that may be harmful for youand/or other people.

a

c

a

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a




DRIVE CHAIN


The vehicle is equipped with a chain withring link joint.

In case of disassembly and reassembly of

the chain, make sure that the clip (1) of thering link joint has its open side opposite thetravelling direction (see figure).

An excessive slackening of thechain can cause it to come off ofthe sprockets, which often re-

sults in accidents or serious damage to

the vehicle.Periodically check the slack and adjustit if necessary, see p. 49 (ADJUST-MENT).To change the chain, contact an OfficialDealer aprilia

, who will ensure youprompt and accurate servicing.

Incorrect maintenance maycause the untimely wear of thechain and/or damages to the pin-

ion and/or the crown.Carry out the maintenance operationsmore frequently if you use the vehicle indifficult conditions or on dusty and/ormuddy roads.

CHECKING THE SLACK

To check the slack, proceed as follows:

x

Stop the engine.

x


x

Position the shifting lever in neutral.

x

Make sure that the vertical oscillation, inan intermediate point between pinionand crown in the lower part of the chain,is about 30 ÷

35

mm.

x

Move the vehicle forwards, or turn thewheel, in order to be able to check thevertical oscillation of the chain evenwhen the wheel turns; the slack must beconstant in all the rotation phases of thewheel.

If in some positions the slack ishigher than in others, this meansthat there are crushed or seized

links; in this case, contact an Official De-aler aprilia

.To prevent the risk of seizures, lubricatethe chain frequently, see p. 49 (LUBRI-

CATION AND CLEANING).

If the slack is uniform, but higher or lowerthan 30 ÷

35

mm, adjust it, see p. 49 (AD-JUSTMENT).

a

a

a

x Check the wear of U-shaped chain guide(6)and of the chain tightening roller (7).

x Finally, check the wear of the rear fork




ADJUSTMENT

If after the check it is necessary to adjustthe chain tension, proceed as follows:

x


x

Loosen the wheel nut (3).

For the rear wheel centering,numbered reference marks are

provided on the chain adjuster cams (4)and (5) in correspondence with eachnotch.

x

Act on the right (4) and left (5) chain ad-

juster cams and adjust the chain slack,making sure that the reference markscoincide on both sides of the vehicle.

x


x

Tighten the wheel nut (3).

Wheel nut (3) driving torque:

80 Nm (8 kgm).

x

Check the chain slack, see p. 48(CHECKING THE SLACK).

CHECKING THE WEAR OF CHAIN,PINION AND CROWN

Further, check the chain and sprocketsand make sure that they do not present:

x

Damaged rollers.

x

Loose pins.

x

Dry, rusty, crushed or seized links.

x

Excessive wear.

x Lacking O rings.x Sprocket or teeth excessively worn or

damaged.

If the chain rollers are damaged,the pins are loose and/or the Orings are damaged or lacking, it

is necessary to change the whole chainunit (both sprockets and chain).

protection shoe.

Lubricate the chain frequently,

especially if there are dry orrusty parts. The crushed or

seized links must be lubricated andmade work again.If this is not possible, contact an OfficialDealer aprilia, who will provide forchanging the chain.

LUBRICATION AND CLEANING

Carry out the adjustment, lubri-cation, cleaning and change ofthe chain with great care.


Lubricate the chain every 500 km or when-ever necessary.

Lubricate the chain with spray grease forchains only, see p. 72 (LUBRICANT

CHART).Never wash the chain with water jets,steam jets, high-pressure water jets andhighly inflammable solvents.

c

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INSPECTING THE FRONTAND REAR SUSPENSIONS

Have the front fork oil changedby an Official Dealer aprilia

,who will ensure you prompt and

accurate servicing.



Change the fork oil every 16000 km.

Check the oil every 8000 km and change itif it is dirty.

Change the fork oil more frequently if thevehicle is used on dusty or wet roads or offroad.

Further, carry out the following checkingoperations:

x

With pulled front brake lever, press thehandlebar repeatedly, thrusting the forkdownwards.The stroke must be gentle and theremust be no trace of oil on the rods.

x

Check the fastening of all the compo-nents and the functionality of the frontand rear suspension joints.

If you notice irregularities in theoperation or if the help of a qual-ified technician is necessary,

contact your Official Dealer aprilia

.

a

c

a

x Slightly unscrew the locking ring nut (2) bymeans of the appropriate spanner (3)&.

x Act on the adjusting ring nut (1) (shockb b i l d dj t t)




REAR SUSPENSION

The rear suspension consists of a spring-shock absorber unit, fixed to the frame bymeans of silent-blocks and to the rear forkby means of lever systems.

For the setting of the vehicle attitude, the

shock absorber is provided with a ring nut(1) for the adjustment of the spring preloadand with a locking ring nut (2).

ADJUSTING THE REAR SHOCKABSORBER PRELOAD

The standard setting of the rear shockabsorber is such as to satisfy most drivingconditions at low and high speed, eitherwith reduced load and full load.

However, it is also possible to adjust thesetting according to the intended use of thevehicle.

The adjusting ring nut must not bescrewed for more than 25 mmfrom the beginning of the thread

(see f igure) . I f th is measure isexceeded, even the slightest uneven-ness on the road surface will causesudden jerks.Rotate the ring nut (1), giving it one turnat a time.Test the vehicle repeatedly on the road,until obtaining the optimal adjustment.

absorber spring preload adjustment)(see figure).

x

Once the optimal attitude has been ob-

tained, tighten the locking ring nut (2)completely.

a

Adjustingring nut

(1)

Byscrewing

it

Byunscrewing

it

Function Spring

preloadincrease

Spring

preloaddecrease

Attitude The vehicleis more rigid

The vehicleis less rigid

Recommended kind of road

Smooth ornormal roads

Roads withunevensurface

Notes Rider andpassenger

Solo rider




CHECKING THE BRAKE PAD WEAR

Carefully read p. 22 (BRAKE FLUID -recommendat ions) , p . 22 (D ISCBRAKES) and p. 39 (MAINTENANCE).

The following information refer to a sin-gle braking system, but are valid forboth.


Check the brake pad wear after the first

1000 km and successively every 4000 km.The wear of the brake pads depends onthe use, on the kind of drive and on theroad.

The wear is greater when the vehicle isused on dusty or wet roads and off road

Check the brake pads beforeevery trip.

To carry out a rapid checking of the wear ofthe pads, proceed as follows:

x


x

Carry out a visual checking between thebrake caliper and the pads.Proceed: – from the front upper part for the front

brake caliper (1); – from the rear upper part for the rear

brake caliper (2).

x

If the thickness of the friction material(even of one pad only) has reduced toabout 1 mm, replace both pads.

Have the pads changed by yourOfficial Dealer aprilia

.

ADJUSTINGTHE COLD START CONTROL (

e

)

Leggere attentamente Carefully readp. 39 (MAINTENANCE).

The ideal slack of the cold start controlshould be about 2 ÷ 3 mm.

To adjust the slack, proceed as follows:

x


x

Move to the left side of the vehicle.

DO NOT withdraw the accelera-tor cable protection element (3).

x


x

Loosen the nut (5)(by screwing it).

x

Act on the adjuster (6) positioned on thecarburettor.

After the adjustment:

x

Tighten the nut (5) (by turning it anti-clockwise), thus locking the adjuster (6)

and put back the protection element (4).

c

a

a

c

The minimum speed of the engine (idling)must be about 1500 ± 100 rpm.

If necessary:




IDLING ADJUSTMENT



Adjust the idling after the first 1000 km andevery time it is irregular.

To carry out this operation, proceed as fol-lows:

x

Drive for a few miles until the enginereaches the normal running temperature,then stop the engine.

x


Work on the right side of thevehicle.

x

Connect an electronic revolution counterto the spark plug cable.

x

Start the engine.

y

x

Act on the adjusting screw (1) positionedon the carburettor.

By SCREWING IT (clockwise), you in-crease the engine rpm.

By UNSCREWING IT (anticlockwise), youdecrease the engine rpm.

x

Twist the throttle grip, accelerating anddecelerating a few times to make sure

that it functions correctly and to check ifthe idling speed is constant.

Do not act on the air adjustingscrew, to avoid variations of the

carburation setting.

If necessary, contact your aprilia

Official Dealer.

ADJUSTINGTHE ACCELERATOR CONTROL


The ideal slack of the accelerator controlshould be about 2-3 mm.

To adjust the slack, proceed as follows:

x

Position the vehicle on the stand.x Remove the protection element (2).x Loosen the nut (3) (by turning it clock-

wise).x Act on the adjuster (4), positioned at the

beginning of the accelerator control ca-ble.

After the adjustment:x Tighten the nut (3) (by turning it anti-

clockwise), thus locking the adjuster (4)and put back the protection element (2).

c

c

c

a

x Check the spark plug gap with a thick-ness gauge.The gap must be 0.5÷0.6 mm, if neces-sary adjust it carefully bending the earth




SPARK PLUG



Check the spark plug after the first 1000km and successively every 4000 km;change it every 8000 km.

Periodically remove the spark plug andclean it carefully, removing carbon depos-its; change it if necessary.

To reach the spark plug:

x


Work on the right side of thevehicle.

To remove and clean the spark plug:

x

Take off the spark plug cap (1).

x

Remove all the dirt from the base of thespark plug, then unscrew it with thespanner you will find in the tool kit andextract it from its seat, taking care thatneither dust nor other substances enterthe cylinder.

x

Make sure that there are neither carbondeposits, nor corrosion marks on theelectrode and on the central porcelainpart; if necessary, clean them with thespecial cleaners for spark plugs, with aniron wire and/ or a metal brush.

x

Energetically blow some air, in order toprevent the removed residues from get-ting into the engine.If the spark plug has crackings on the in-sulating material, corroded electrodes orexcessive deposits, it must be changed.

sary adjust it, carefully bending the earthelectrode.

x

Make sure that the washer is in good

conditions. With the washer on, screwthe spark plug by hand in order not todamage the thread.

x

Tighten the spark plug by means of thespanner you will find in the tool kit, givingit half a turn to compress the washer.

Spark plug driving torque:20 Nm (2 kgm).

The spark plug must be welltightened, otherwise the enginemay overheat and be seriously

damaged.Use the recommended type of sparkplug only, see p. 68 (TECHNICAL DA-TA), in order not to compromise the lifeand performance of the engine.

x

Position the spark plug cap (1) correctly,so that it does not come off due to theengine vibrations.

c

c

a

BATTERY


If the electrolyte is accidentally swal-lowed, drink a lot of water or milk, thencontinue drinking milk of magnesia orvegetable oil and consult a doctor with-





Check the electrolyte level and the tighten-ing of the terminals after the first 1000 kmand successively every 4000 km or 8months.

The electrolyte in the battery istoxic and caustic and if it gets in

contact with the skin it cancause burns, since it contains sulphuricacid.Wear protection clothes, a face maskand/or goggles during maintenance op-erations.

In case of contact with the skin, rinsewith plenty of water.

In case of contact with the eyes, rinsewith plenty of water for 15 minutes, thenconsult an oculist without delay.

vegetable oil and consult a doctor without delay.

The battery gives off explosive gases;keep it away from flames, sparks, ciga-rettes and any other source of heat.During the recharging or the use, makesure that the room is properly ventilatedand avoid inhaling the gases releasedduring the recharging.


Never invert the connection ofthe battery cables.

Do not incline the vehicle too much, inorder to avoid dangerous leaks of thebattery fluid.

Connect and disconnect the batterywith the ignition switch in position “

m

”.Connect first the positive cable (+) andthen the negative cable (–).

Disconnect following the reverse order.

The electrolyte is corrosive.

Do not pour or spill it, especially on theplastic parts.

LONG INACTIVITYOF THE BATTERY

If the vehicle remains unused for a long pe-riod:

x

Remove the battery, see p. 56 (REMOV-ING THE BATTERY) and put it in a cool

and dry place.x

Recharge it completely, by using a tricklecharge, see p. 57 (RECHARGING THEBATTERY).

If the battery remains on the vehicle, dis-connect the cables from the terminals.

It is important to check the charge periodi-

cally (about once a month), during the win-ter or when the vehicle remains unused, inorder to prevent the deterioration of thebattery.

c

aa




CHECKING AND CLEANINGTHE TERMINALS

Carefully read p. 55 (BATTERY).

x


x

Make sure that the cable terminals (1)and the battery terminals (2) are: – in good conditions (and not corroded

or covered with deposits); – covered with special grease or Vase-

line.

If necessary:

x

Remove the battery, see beside(REMOVING THE BATTERY).

x

Eliminate any sign of corrosion with awire brush.

x

Reconnect first the positive (+) and thenthe negative cable (–).

x

Cover the terminals with special greaseor Vaseline.

x

Reinstall the battery, see p. 57(INSTALLING THE BATTERY).

REMOVING THE BATTERY


x

Make sure that the ignition switch is inposition “

m

”.

x


x

Unscrew and remove the screw (3) fromthe negative terminal (–).

x

Move the negative cable (–) (4) sidewards.

x

Unscrew and remove the screw (5).

x

Remove the cover (6).

x

Partially remove the battery from itscompartment.

x

Unscrew and remove the screw (7) fromthe positive terminal (+).

x

Move the positive cable (+) (8) sidewards.

x

Withdraw the breather pipe(9).

Once it has been removed, thebattery must be stored in a safeplace and kept away f rom

children.

x

Remove the battery from its compartment

and put it on a flat surface, in a cool anddry place.

a

Otherwise:

x Remove the battery from its compart-ment, see p. 56 (REMOVING THE BAT-TERY)

x Replace the element plugs.

Reinstall the battery only 5-10minutes after disconnecting thea




CHECKINGTHE ELECTROLYTE LEVEL



x


x


Fa i lure to per form the

operations described above maylead to the wrong measurement of thelevel.

x

Make sure that the fluid level is includedbetween the two “

MIN

” and “

MAX

”notches stamped on the battery side.

TERY).

x

Unscrew and remove the element plugs.

Top up with distilled water only.Do not exceed the “MAX” mark,since the electrolyte level in-

creases during the recharge.

x

Top up by adding distilled water.

RECHARGING THE BATTERY


x

Remove the battery from its compart-ment, see p. 56 (REMOVING THE BAT-

TERY).

x

Unscrew and remove the element plugs.x Check the electrolyte level, vedi sopra

(CHECKING THE ELECTROLYTELEVEL).

x Connect the battery with a battery charg-er.

x A recharge with an amperage equal to

1/10th of the battery capacity is recom-mended.

x After the recharging operation, check theelectrolyte level again and if necessarytop up with distilled water.

grecharge equipment, since the

battery keeps sending out extremely in-

flammable hydrogen gas for a shortlapse of time.

INSTALLING THE BATTERY


x Connect the breather pipe (1).

Always connect the batterybreather pipe, to prevent the sul-phuric acid vapours from cor-

roding the electric system, paintedparts, rubber elements or gasketswhen they exit the breather pipe itself.

x Connect, in order, the positive (+) andnegative (–) cable.

x Cover the terminals with special greaseor Vaseline.

x Put the battery in its container.

x Put back the cover (2).x Screw and tighten the screw (3).x Put back the left side cover, see p. 40

(REMOVING THE SIDE COVERS).

c

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a

a

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CHECKING THE SIDE STANDAND THE SAFETY SWITCH

Carefully read p. 39 (MAINTENANCE)and p. 60 (CHECKING THE SWITCHES).

The side stand (1) must rotate without hin-

drances.

Carry out the following checks:

x

The springs (2) must not be damaged,worn, rusty or weakened.

x

The side stand must rotate freely, if nec-essary grease the joint, see p. 72 (LU-

BRICANT CHART).

The side stand (1) is provided with a safetyswitch (3) that has the function to preventor interrupt the operation of the engine withthe gears on and the side stand (1) down.

To check the proper functioning of thesafety switch (3), proceed as follows:

x

Seat on the vehicle in driving position.

x

Fold the side stand (1).

x

Start the engine, see p. 32 (STARTING).

x

With released throttle grip (4) (

Pos. A

)and engine idling, pull the clutch lever (5)completely.

x

Engage the first gear, pushing the shift-ing lever (6) downwards.

x

Lower the side stand (1), thus operatingthe safety switch (3).At this point the engine must stop.

If the engine does not stop, con-tact an Official Dealer aprilia

.a




CHECKING THE SWITCHES


The vehicle is provided with three switch-es:

x

Stoplight switch (1) on the rear brakecontrol lever.

x

Stoplight switch (2) on the front brakecontrol lever.

x

Safety switch (3) on the side stand.

Checking:

x

Switches (1) and (2): withdraw theprotection element.

x

Make sure that there are neither dirt, normud deposits on the switch.

x

Make sure that the cables are connected

correctly.




CHANGINGTHE HEADLIGHT BULBS

Carefully read p. 61 (BULBS).

Before changing a bulb, checkthe fuses, see p. 58 (CHANGING

THE FUSES).

The headlight contains:

x

A parking light bulb (1)

.

x

A low beam/high beam bulb (haloge-nous) (2).

To change the bulbs, proceed as

follows:

The front part of the fairing (4),complete with the headlight,remains connected to the elec-

tric wires; do not pull them.

x

Unscrew and remove the two screws (3).

Handle the plastic componentswith care and avoid scraping or

damaging them.

x

Withdraw the front part of the fairing (4),complete with the headlight, downwardsand disconnect i t from the pin (5)

provided on the dashboard.

LOW / HIGH BEAM BULB (HALOG-ENOUS)

To extract the bulb electricconnector, do not pull its electricwires.

x

Grasp the bulb electric connector (6),pull it and disconnect it from the bulb (2).

x

Withdraw the protection element (7) fromthe reflector and from the bulb terminals.

x

Rotate the bulb socket (8) anticlockwiseand extract it from the reflector.

x

Extract the bulb (2).

For the installation:

Insert the bulb (2) in the reflector,making the two teeth (9) provided

on the bulb coincide with the relevantguide (10) on the reflector.

x

Position the bulb socket (8) in the

reflector and rotate it clockwise.

x

Correctly insert the protection element(7) in the bulb terminals and in thereflector.

x

Connect the bulb electric connector (6).

PARKING LIGHT BULB

To extract the bulb socket, donot pull its electric wires.

x

Grasp the bulb socket (11), pull anddisconnect it from its seat.

x

Withdraw the parking light bulb (1) and

replace it with one of the same type.

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WARNING LIGHT BULBS

Extract the bulb sockets one byone, in order not to position themincorrectly upon reassembly.a




CHANGING THE DASHBOARDBULBS



THE FUSES).

The dashboard contains:

x

The warning light bulbs.

x

The dashboard lighting bulb.

To change the bulbs, proceed asfollows:

The front part of the fairing (2),complete wi th headl ight ,remains connected to the elec-

tric wires; do not pull them.

x


Handle the plastic componentswith care and avoid scraping or

damaging them.

x

Withdraw the front part of the fairing (2),

complete with headlight, downwards anddisconnect it from the pin (3) provided onthe dashboard.

x

Extract the corresponding bulb

socket:

x

Withdraw the bulb and replace it with anew one of the same type.

DASHBOARD LIGHTING BULB

x

Extract the bulb socket (9).

x

Withdraw the bulb and replace it with anew one of the same type.

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Pos. Warning light Colour

4 High beam (a) blue

5Directionindicators (c)

green

6 Neutral indicator (q) green

7Coolantoverheating (h)

red

8 2 stroke oil reserve (j) red




CHANGING THE FRONT AND REARDIRECTION INDICATORS



THE FUSES).

x

Unscrew and remove the screw (1).

Upon reassembly, tighten thescrew (1 ) care fu l ly andmoderately, in order not to

damage the protection screen.

x

Remove the protection screen (2).

x

Press the bulb (3) slightly and rotate itanticlockwise.

x

Extract the bulb from its seat.

Insert the bulb in the bulbsocket, making the two pins co-

incide with the relevant guides on thebulb socket.

x

Correctly install a new bulb of the sametype.

CHANGING THE REAR LIGHTBULB

Before changing a bulb, check

the fuses, see p. 58 (CHANGINGTHE FUSES) and the efficiency of thestoplight switches, see p. 60 (CHECK-ING THE SWITCHES).


x


Upon reassembly, tighten thetwo screws (4) carefully andmoderately, in order not to

damage the protection screen.

x

Remove the protection screen (5).

x

Press the bulb (6) slightly and rotate itanticlockwise.

x

Extract the bulb from its seat.

Insert the bulb in the bulbsocket, making the two pins

coincide with the relevant guides onthe bulb socket.

x

Correctly install a new bulb of the sametype.

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TRANSPORT

Before transporting the vehicle,it is necessary to empty the fuel

tank and the carburettor carefully see

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tank and the carburettor carefully, seebelow (DRAINING THE FUEL TANK),

making sure that they are completelydry.During transport the vehicle must bekept in vertical position, in order toavoid any oil, coolant and battery fluidleakage.The vehicle must be firmly anchored

with the 1st gear on.

In case of failure, do not tow thevehicle, but have it moved by amaintenance vehicle.

DRAINING THE FUEL TANK

Carefully read p. 20 (FUEL).

Risk of fire.Wait until the engine and the

exhaust silencers have comple-tely cooled down.

Fuel vapours are noxious foryour health.Before proceeding, make sure

that the room in which you are workingis properly ventilated.Do not inhale fuel vapours.Do not smoke, nor use free flames.Do not dispose of fuel in the environ-ment.

x


x

Stop the engine and wait until it has

cooled down.

x

Prepare a container with capacity ex-ceeding the fuel quantity present in thetank and put it on the ground on the leftside of the vehicle.

x

Remove the fillercap.

x

Empty the fuel tank by means of a ma-nual pump or a similar system.

After draining the tank, tighten

the fillercap.

To drain the carburettor completely,proceed as follows:

x

Position the fuel tap (1) on “

RES

”.

x

Start the vehicle, see p. 32 (STARTING).

x

Accelerate a few times, until the engine

stops due to lack of fuel.

If necessary, contact an Official Dealer

aprilia.

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CLEANING

After the vehic le has beenwashed, its braking functionscould be temporarily impaired

Do not wash the vehicle underthe sun, especially during the

summer when the body is still warmac




Clean the vehicle frequently if it used inparticular areas or conditions, such as:

x

Polluted areas (cities and industrial are-as).

x

Areas characterized by an high percent-age of salinity and humidity (sea areas,

hot and humid climates).

x

Particular conditions (use of salt andanti-ice chemical products on the roadsduring the winter).

x

Avoid leaving deposits of industrial andpolluting powders, tar spots, dead in-sects, bird droppings, etc. on the body.

x

Avoid parking the vehicle under trees,since in some seasons residues, resins,fruits or leaves fall down, which containsubstances that may damage the paint.

could be temporarily impairedbecause of the presence of water on the

grip surfaces. Calculate long brakingdistances to avoid accidents. Brake re-peatedly to restore normal conditions.

To remove dirt and mud from the paintedsurfaces use a low- pressure water jet,carefully wet the dirty parts, remove mud

and filth with a soft car sponge impregnat-ed with a lot of water and shampoo (2 ÷ 4%parts of shampoo in water).

Then rinse with plenty of water and dry withchamois leather.

To clean the outer parts of the engine usea degreaser, brushes and wipers.

Polish with silicone wax only af-ter having carefully washed the

vehicle.

summer, when the body is still warm,since if the shampoo dries before being

rinsed away, it can damage the paint

Use neither high pressure water/air jets,nor vapour jets on the following parts:wheel hubs, controls on the right andon the left side of the handlebar, brakepumps, instruments and indicators, si-

lencer exhaust, glove/tool kit compart-ment, ignition switch/steering lock.

Do not use alcohol or solvents to cleanthe rubber and plastic parts and thesaddle: use water and mild soap.Do not apply protection waxes onto thesaddle, in order not to make it too slip-pery.

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LONG PERIODS OF INACTIVITY

After a long period of inactivity of the vehi-cle some precautions are necessary toavoid any problem.

Further, it is important to carry out the nec-essary repairs and a general check up be-

fore the period of inactivity, since you couldforget to carry them out later.

Proceed as follows:

x

Drain the fuel tank and the carburettorcompletely, see p. 65 (DRAINING THEFUEL TANK).

x

Remove the spark plug, see p. 54

(SPARK PLUG).

x

Pour a teaspoon (5 ÷ 10 cm

C

) of engineoil into the cylinder.

x

Rotate the ignition switch (1) to position“

m

”.

x

Press the start lever (2) a few times, todistribute the oil evenly on the cylinder

surfaces.

x

Reinstall the spark plug, see p. 54(SPARK PLUG).

x

Remove the battery, see p. 56 (REMOV-ING THE BATTERY).

x

Wash and dry the vehicle, see p. 66(CLEANING).

x

Polish the painted surfaces with wax.

x Inflate the tyres, see p. 27 (TYRES).

x By means of a suitable support, positionthe vehicle so that both tyres are raisedfrom the ground.

x Place the vehicle in an unheated, not-hu-

mid room, away from sunlight, with mini-mum temperature variations.

x Cover the vehicle avoiding the use ofplastic or waterproof materials.

AFTER A PERIOD OF INACTIVITY

x Uncover and clean the vehicle, see p. 66(CLEANING).

x Check the electrolyte level in the batteryand install it, see p. 57 (CHECKING THEELECTROLYTE LEVEL) and p. 57 (IN-

STALLING THE BATTERY).x Refill the fuel tank, see p. 20 (FUEL).

x Carry out the preliminary checking oper-at ions, see p. 31 (PRELIMINARYCHECKING OPERATIONS).

Have a test ride at moderatespeed in a low-traffic area.a

TECHNICAL DATA

DIMENSIONS Max. length(with rear mudguard extension) ................... 2295 mm

Max. width.................................................... 850 mm




Max. width.................................................... 850 mm

Max. height (front part of the fairing included) 1205 mm

Seat height .................................................. 915 mm

Distance between centres ........................... 1475 mm

Min. ground clearance ................................. 360 mm

Weight ready for starting ............................. 129 kg

ENGINE Type ............................................................. One-cylinder, 2-stroke with laminar suction. Separate lubrication

with variable strength automatic mixer (1.0 - 3.0 %).Number of cylinders..................................... 1

Total displacement....................................... 124.82 cm

C

Bore / stroke ................................................ 54 mm / 54.5 mm

Compression ratio ....................................... 12.5 ±

0.5 : 1

Starting........................................................ with pedal

Engine idling rpm......................................... 1500 ±

100 rpm

Clutch .......................................................... multidisc in oil bath, with manual control on the left side of the hand-lebar.

Cooling ........................................................ liquid-cooled

CAPACITY Fuel (reserve included)................................ 11 l

Fuel reserve................................................. 4 l

(mechanical reserve)

Transmission oil........................................... 600 cm

C

Coolant ........................................................ 0.75 l

(50% water + 50% antifreeze with ethylene glycol)

2 stroke oil (reserve included) ..................... 1.4 l

2 stroke oil reserve ...................................... 0.5 l

Seats ........................................................... 2

Vehicle max. load

(driver + passenger + luggage) ................... 180 kg

TRANSMISSION Type ............................................................. mechanical, 6 gears with foot control on the left side of the engine

GEAR RATIOS Ratio Primary Secondary1st 19/63 = 1 : 3.315 10 / 30 = 1: 3.0002nd 14 / 29 = 1: 2.071

Final ratio Total ratio16 / 45 = 1 : 2.81 R1 x R2 x R3 = 1 : 27.35

R1 x R2 x R3 = 1 : 18.88




3

rd

17 / 27 = 1: 1.588

4

th

19 / 25 = 1: 1.3165

th

21 / 23 = 1: 1.0956

th

22 / 21 = 1: 0.954

R1 x R2 x R3 = 1 : 14.48

R1 x R2 x R3 = 1 : 11.99R1 x R2 x R3 = 1 : 9.98R1 x R2 x R3 = 1 : 8.70

CARBURETTORS Number ........................................................ 1

Model ........................................................... DELL’ORTO PHBH 28

FUEL SUPPLY Fuel ............................................................. premium grade petrol (4 StarsU

) according to the DIN 51600standard, min. O.N. 98 (N.O.R.M.) and 88 (N.O.M.M.)

Fuel2

....................................................... unleaded petrol according to the DIN 51607 standard, min. O.N. 95(N.O.R.M.) and 85 (N.O.M.M.)

FRAME Type ............................................................. One-beam with two cradles in high-resistance steel tubes

Steering inclination angle............................. 28˚

Fore stroke................................................... 127 mm

SUSPENSIONS Front............................................................. Hydraulically operated telescopic fork

Stroke........................................................... 232 mm

Rear ............................................................. Hydraulic adjustable mono-shock absorber

Stroke........................................................... 101.5 mm

BRAKES Front............................................................. Disc brake - Ø 250 mm - with hydraulic transmissionRear ............................................................. Disc brake - Ø 220 mm - with hydraulic transmission

WHEEL RIMS Type.............................................................. in stainless steel with tangential spokes

Front ............................................................. E - 21” x 1.60 DOT

Rear.............................................................. E - 18” x 2.15 DOT

TYRES FRONT 3 00 - 21” 51 P




TYRES FRONT ......................................................... 3.00 - 21 51 P

alternative:- 90/90 - 21” 54R- 90/90 - 21” 54S- 80/100 - 21” 51R

Inflation pressure for solo rider:- asphalted road ...........................................- off-road ......................................................Inflation pressure for rider and passenger:- asphalted road ...........................................- off-road ......................................................

150 kPa (1.5 bar)130 kPa (1.3 bar)

160 kPa (1.6 bar)140 kPa (1.4 bar)

REAR ........................................................... 4.60 - 18” 63 Palternative:- 120/80 - 18” 62S- 120/90 - 18” 65R

- 120/90 - 18” 65PInflation pressure for solo rider:- asphalted road ...........................................- off-road ......................................................Inflation pressure for rider and passenger:- asphalted road ...........................................- off-road ......................................................

170 kPa (1.7 bar)150 kPa (1.5 bar)

180 kPa (1.8 bar)160 kPa (1.6 bar)

IGNITION Type.............................................................. CDI

Spark advance ............................................. 12˚ ± 2˚ prima del P.M.S.

SPARK PLUG Standard....................................................... NGK R BR8 ES

Spark plug gap ............................................. 0.5÷0.6 mm

ELECTRIC Battery ......................................................... 12 V - 4 Ah

SYSTEM Fuses ........................................................... 20 - 15 - 7.5 A

Generator .................................................... 12 V - 180 W

BULBS Low/high beam (halogenous) 12 V - 55/60 W




BULBS Low/high beam (halogenous)....................... 12 V 55/60 W

Front parking light ........................................ 12 V - 5 WDirection indicators ...................................... 12 V - 10 W

Rear parking light/number platelight/ stoplight............................................... 12 V - 5 / 21 W

Dashboard ................................................... 12 V - 2 W

WARNING LIGHTS Neutral ......................................................... 12 V - 2 W

Direction indicators ...................................... 12 V - 2 WHigh beam ................................................... 12 V - 2 W

2 stroke oil reserve....................................... 12 V - 2 W

Coolant overheating..................................... 12 V - 2 W

LUBRICANT CHART

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

2 t k il ( d d) 0 MAX 2T COMPETITION




2 stroke oil (recommended):

0

MAX 2T COMPETITION

As an alternative to the recommended oil, use high-quality oils with characteristics in compliance with or superior to the ISO-L-ETC++,A.P.I. TC++ specifications.

Fork oil (recommended):

0

F.A. 5W or0

F.A. 20W fork oil.If you need an oil with intermediate characteristics in comparison with the two recommended products, these can be mixed as indicatedbelow:

SAE 10W0

F.A. 5W 67% of the volume, +0

F.A. 20W 33% of the volume.

SAE 15W0

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 temperature range -30°C.... +140°C,

dripping point 150°C... 230°C, high protection against corrosion, good resistance to water and 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 (DOT 4 compatible).

Use new brake fluid only.

Engine coolant (recommended) 1

:

0

ECOBLU - 40°C.

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

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Importers

APRILIA MOTO U.K. LTD.




DUNRAGITSTRANRAERWIGTOWNSHIRE DG9 8PNSCOTLAND (UK)TEL. (01581) 400660FAX (01581) 400661

IDEAL MOTOR SPORT PTE LTD.

18, HOWARD ROAD1336 SINGAPORE (SGP)TEL. 2820082FAX 2821012

AVIRAM & GOLDMAN IMPORT & MARKETING CO. LTD.

21, TUSHIA STREET

61572 TEL-AVIVP.O. BOX 57266ISRAEL (IL)TEL. (3) 5623951FAX (3) 5623950

ASK FOR GENUINE SPARE PARTS ONLY

WIRING DIAGRAM - ETX 125




WIRING DIAGRAM KEY - ETX 125

1) Generator

2) Coil4) Voltage regulator5) Fuses

31) Front right direction indicator

32) Low/high beam bulb

33) Front parking light bulb

34) Front left direction indicator




)

6) Battery8) Front stoplight switch9) Rear stoplight switch

11) 2 stroke oil reserve sensor

14) Rear left direction indicator

15) Rear light

16) Rear right direction indicator

17) Blinking

18) Ignition switch/steering lock

19) Neutral warning light

20) Left dimmer switch

21) Dashboard

22) Coolant overheating warning light

23) Dashboard lighting bulb24) High beam warning light

25) Side stand switch

26) Direction indicator warning light

27) 2 stroke oil reserve warning light

28) Neutral switch

29) Coolant temperature thermistor30) Horn

34) Front left direction indicator

35) Diode36) Multiple connectors

37) Spark plug

39) Headlight

42) CDI

44) Pick up

CABLE COLOURS

Ar

orange

Az

light blue

B

blue

Bi

white

G

yellow

Gr

grey

M

brown

N

black

R

red

V

green

Vi

violet

NOTE




NOTE




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 envi-ronment.

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

– Avoid disturbing noises.

– Respect nature.

aprilia instrukcja english - 1998

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