APRILIA RS 125 - 2006 User manual

8104934

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First edition: December 2005

Reprint: June 2006

Produced and printed by:

VALLEY FORGE DECA

Ravenna, Modena, Torino

DECA S.r.l.

Registered & Admin. Offices

Via Vincenzo Giardini, 11

48022 Lugo (RA) - Italia -

Tel. 0545-216611

Fax 0545-216610

www.vftis.com

[email protected]

on behalf of:

Piaggio & C. S.p.A.

via G. Galilei, 1 - 30033 Noale (VE) - Italia

Tel. +39 - 041 58 29 111

Fax +39 - 041 44 10 54

www.aprilia.com

SAFETY WARNINGS

The following precautionary warnings are

used throughout this manual in order to

convey the following messages:

Safety warning. When you find

this symbol on the vehicle or in

the manual, be careful to the

potential risk of personal injury. Non-

compliance with the indications given

in the messages preceded by this

symbol may result in grave risks for

your and other people’s safety and for

the vehicle!

Indications to make the

operations easier. Technical

information.

TECHNICAL INFORMATION

The operations preceded by this

symbol must be repeated also on

the opposite side of the vehicle.

If not expressly indicated otherwise, for the

reassembly of the units repeat the

disassembly operations in reverse order.

The terms “right” and “left” are referred to

the rider seated on the vehicle in the

normal riding position.

WARNINGS - PRECAUTIONS -

GENERAL ADVICE

Before starting the engine, carefully read

this manual and in particular the section

“SAFE DRIVE”.

Your and other people’s safety depends

not only on your quickness of reflexes and

on your agility, but also on what you know

about the vehicle, on its efficiency and on

your knowledge of the basic information for

“SAFE DRIVE”.

Therefore, get a thorough knowledge of the

vehicle, in such a way as to be able to drive

in the traffic safely.





H

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This manual must be considered

as an integral part of the vehicle

and must always accompany it,

even in case of resale.

aprilia has carried out this manual with

the maximum attention, in order to supply

the user with correct and updated

information. However, since aprilia

constantly improves the design of its

products, there may be slight

discrepancies between the characteristics

of your vehicle and those described in this

manual.

For any clarification concerning the

information contained in this manual, do

not hesitate to contact your aprilia Official

Dealer.

For control and repair operations not

expressly described in this publication, for

the purchase of aprilia genuine spare

parts, accessories and other products, as

well as for specific advice, contact

exclusively aprilia Official Dealers and

Service Centers, which guarantee prompt

and accurate assistance.

Thank you for choosing aprilia. We wish

you a nice ride.

All rights as to electronic storage,

reproduction and total or partial adaptation,

with any means, are reserved for all

Countries.

In some countries the antipollution

and noise regulations in force

require periodical inspections.

The user of the vehicle in these countries

must:

– contact an aprilia Official Dealer to have

the non-homologated components

replaced with others homologated for use

in the country in question;

– carry out the required periodical

inspections.

Soon after purchasing the vehicle,

write down the identification data

indicated on the SPARE PARTS

IDENTIFICATION LABEL in the table here

below. The label is positioned under the

rider saddle, see page 56 (REMOVING

THE RIDER SADDLE).

These data indicate:

– YEAR = year of manufacture (Y, 1, 2, ...);

– I.M. = modification code (A, B, C, ...);

– COUNTRY CODES = homologation

country (I, UK, A, ...).

and are to be supplied to the aprilia

Official Dealer as reference data for the

purchase of spare parts or specific

accessories of the model you have

acquired.

In this manual the various versions are

indicated by the following symbols:



J

optional

k

Full Power version

L

catalytic version

VERSION:

+

Italy

2

Singapore

4

United Kingdom

P

Slovenia

>

Austria

F

Israel

M

Portugal

e

South Korea

(

Finland

-

Malaysia

$

Belgium

@

Chile

A

Germany

*

Croatia

C

France

#

Australia

'

Spain

R

United States

of America

)

Greece

g

Brazil

/

Holland

1

South Africa

6

Switzerland

K

New Zealand

&

Denmark

%

Canada

,

Japan

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TABLE OF CONTENTS

SAFETY WARNINGS .......................................... 2

TECHNICAL INFORMATION .............................. 2

WARNINGS - PRECAUTIONS - GENERAL

ADVICE ................................................................ 2

BASIC SAFETY RULES ................................ 6

CLOTHING .................................................... 8

ACCESSORIES............................................. 8

LOAD ............................................................. 9

ARRANGEMENT OF THE MAIN ELEMENTS .. 10

ARRANGEMENT OF THE

INSTRUMENTS/CONTROLS ............................ 12

INSTRUMENTS AND INDICATORS ................. 13

INSTRUMENTS AND INDICATORS TABLE....

14

MULTIFUNCTION COMPUTER.................. 16

MAIN INDEPENDENT CONTROLS .................. 21

CONTROLS ON THE LEFT PART

OF THE HANDLEBAR................................. 21

CONTROLS ON THE RIGHT PART

OF THE HANDLEBAR................................. 21

IGNITION SWITCH...................................... 22

STEERING LOCK........................................ 22

AUXILIARY EQUIPMENT.................................. 23

GLOVE/TOOL KIT COMPARTMENT.......... 23

SPECIAL TOOLS J ................................. 24

MAIN COMPONENTS........................................ 25

FUEL............................................................ 25

TRANSMISSION OIL................................... 25

BRAKE FLUID-recommendations ............... 26

DISC BRAKES............................................. 26

FRONT BRAKE ........................................... 27

REAR BRAKE.............................................. 28

2 STROKE OIL TANK.................................. 29

ADJUSTING THE SHIFTING LEVER.......... 29

ADJUSTING THE REAR BRAKE ................ 30

ADJUSTING THE CLUTCH......................... 30

COOLANT ................................................... 32

TYRES ......................................................... 33

CATALYTIC SILENCER............................... 34

INSTRUCTIONS FOR USE ................................ 34

PRELIMINARY CHECKING OPERATIONS 35

STARTING ................................................... 36

DEPARTURE AND DRIVE........................... 38

RUNNING-IN................................................ 41

STOPPING................................................... 41

PARKING ..................................................... 42

SUGGESTIONS

TO PREVENT THEFT.................................. 42

MAINTENANCE.................................................. 43

REGULAR SERVICE INTERVALS CHART. 44

IDENTIFICATION DATA .............................. 46

POSITIONING THE VEHICLE ON THE REAR

SUPPORT STAND J ............................... 47

POSITIONING THE VEHICLE ON THE

FRONT SUPPORT STAND J.................. 47

CHECKING THE TRANSMISSION OIL LEVEL

AND TOPPING UP....................................... 48

CHANGING THE TRANSMISSION OIL....... 49

FRONT WHEEL ........................................... 50

REAR WHEEL.............................................. 52

DRIVE CHAIN .............................................. 54

REMOVING THE RIDER SADDLE.............. 56

REMOVING THE SIDE FAIRINGS .............. 56

REMOVING THE LOWER FAIRING............ 57

LIFTING THE FUEL TANK........................... 57

AIR CLEANER ............................................. 58

REAR SUSPENSION................................... 59

CHECKING THE BRAKE PAD WEAR......... 60

IDLING ADJUSTMENT ................................ 61

ADJUSTING

THE ACCELERATOR CONTROL................ 62

ADJUSTING

THE COLD START CONTROL ()............. 62

SPARK PLUGS ............................................ 63

BATTERY..................................................... 64

LONG INACTIVITY

OF THE BATTERY ...................................... 64

CHECKING AND CLEANING

THE TERMINALS ........................................ 65

REMOVING THE BATTERY........................ 65

CHECKING

THE ELECTROLYTE LEVEL....................... 66

RECHARGING THE BATTERY................... 66

INSTALLING THE BATTERY ...................... 66

CHANGING THE FUSES ............................ 67

CHECKING THE SWITCHES...................... 68

VERTICAL ADJUSTMENT OF THE

HEADLIGHT BEAM ..................................... 69

BULBS ......................................................... 69

CHANGING

THE HEADLIGHT BULBS ........................... 70

CHANGING

THE REAR LIGHT BULB............................. 71

TRANSPORT ..................................................... 72

CLEANING......................................................... 73

LONG PERIODS OF INACTIVITY............... 74

TECHNICAL DATA............................................ 75

LUBRICANT CHART ................................... 78

Official Dealers and Service Centres........... 80

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BASIC SAFETY RULES

To drive the vehicle it is necessary to be in

possession of all the requirements

prescribed by law (driving licence,

minimum age, psychophysical ability,

insurance, state taxes, vehicle registration,

number plate, etc.).

Gradually get to know the vehicle by

driving it first in areas with low traffic and/or

private areas.

The use of medicins, alcohol and drugs or

psychotropic substances notably increases

the risk of accidents.

Be sure that you are in good

psychophysical conditions and fit for

driving and pay particular attention to

physical weariness and drowsiness.

Most road accidents are caused by the

driver’s lack of experience.

NEVER lend the vehicle to beginners and,

in any case, make sure that the driver has

all the requirements for driving.

Rigorously observe all road signs and

national and local road regulations.

Avoid abrupt movements that can be

dangerous for yourself and other people

(for example: rearing up on the back

wheel, speeding, etc.), and give due

consideration to the road surface, visibility

and other driving conditions.

Avoid obstacles that could damage the

vehicle or make you lose control.

Avoid riding in the slipstream

created by preceding vehicles in

order to increase your speed.

Always drive with both hands on the

handlebars and both feet on the

footrests (or on the rider’s footboards),

in the correct driving posture.

Avoid standing up or stretching your limbs

while driving.



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The driver should pay attention and avoid

distractions caused by people, things and

movements (never smoke, eat, drink, read,

etc.) while driving.

Use only the vehicle’s specific fuels and

lubricants indicated in the "LUBRICANT

CHART"; check the oil, fuel and coolant

levels regularly.

If the vehicle has been involved in an

accident, make sure that no damage has

occurred to the control levers, pipes, wires,

braking system and vital parts.

If necessary, have the vehicle inspected by

an aprilia Official Dealer, who should

carefully check the frame, handlebars,

suspensions, safety parts and all the

devices that you cannot check by yourself.

Always remember to report any

malfunction to the technicians to help them

in their work.

Never use the vehicle when the amount of

damage it has suffered endangers your

safety.

Never change the position, inclination or

colour of: number plate, direction

indicators, lights and horns.

Any modification of the vehicle will result

in the invalidity of the guarantee.

Any modification of the vehicle and/or the

removal of original components can

compromise vehicle performance levels

and safety or even make it illegal.

We recommend respecting all regulations

and national and local provisions regarding

the equipment of the vehicle.

In particular, avoid all modifications that

increase the vehicle’s performance levels

or alter its original characteristics.

Never race with other vehicles.

Avoid off-road driving.

ONLY ORIGINALS

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CLOTHING

Before starting, always wear a correctly

fastened crash helmet. Make sure that it is

homologated, in good shape, of the right

size and that the visor is clean.

Wear protective clothing, preferably in light

and/or reflecting colours. In this way you

will make yourself more visible to the other

drivers, thus notably reducing the risk of

being knocked down, and you will be more

protected in case of fall.

This clothing should be very tight-fitting

and fastened at the wrists and ankles.

Strings, belts and ties should not be

hanging loose; prevent these and other

objects from interfering with driving by

getting entangled with moving parts or

driving mechanisms.

Do not keep objects that can be dangerous

in case of fall, for example pointed objects

like keys, pens, glass vials etc. in your

pockets (the same recommendations also

apply to passengers).

ACCESSORIES

The owner of the vehicle is responsible for

the choice, installation and use of any

accessory.

Avoid installing accessories that cover

horns or lights or that could impair their

functions, limit the suspension stroke and

the steering angle, hamper the operation of

the controls and reduce the distance from

the ground and the angle of inclination in

turns.

Avoid using accessories that hamper

access to the controls, since this can

prolong reaction times during an

emergency.

Large fairings and windscreens assembled

on the vehicle can produce aerodynamic

forces capable of compromising the

stability of the vehicle while driving.

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Make sure that the equipment is well

fastened to the vehicle and not dangerous

during driving. Do not install electrical

devices and do not modify those already

existing to avoid electrical overloads,

because the vehicle could suddenly stop or

there could be a dangerous current

shortage in the horn and in the lights.

aprilia recommends the use of genuine

accessories (aprilia genuine

accessories).

LOAD

Be careful and moderate when loading

your luggage. Keep any luggage loaded as

close as possible to the centre of the

vehicle and distribute the load uniformly on

both sides, in order to reduce imbalance to

the minimum. Furthermore, make sure that

the load is firmly secured to the vehicle,

especially during long trips.

Avoid hanging bulky, heavy and/or

dangerous objects on the handlebars,

mudguards and forks, because the vehicle

might respond more slowly in turns and its

manoeuvrability could be unavoidably

impaired.

Do not place bags that are too bulky on the

vehicle sides and do not ride with the crash

helmet hanging from its string, because it

could hit people or obstacles making you

lose control of the vehicle.

Do not carry any bag if it is not tightly

secured to the vehicle.

Do not carry bags which protrude too much

from the luggage rack or which cover the

lights, horn or indicators.

Do not carry animals or children on the

glove compartment or on the luggage rack.

Do not exceed the maximum load allowed

for each side-bag.

When the vehicle is overloaded, its stability

and its manoeuvrability can be

compromised.

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ARRANGEMENT OF THE MAIN ELEMENTS

KEY

1) Dashboard

2) Left rear-view mirror

3) Ignition switch/steering lock

4) Battery

5) Fuse carrier

6) Saddle lock

7) 2 stroke oil tank

8) 2 stroke oil tank plug

9) Glove/tool kit compartment

10) Passenger left footrest

(snapping, closed/open)

11) Rider left footrest

(with spring, always open)

12) Shifting lever

13) Side stand

14) Lower fairing

15) Horn

16) Left side fairing

1

1416

2

94

15

75

83 6

10

111213

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KEY

1) Passenger right footrest

(snapping, closed/open)

2) Passenger grab strap

3) Rider saddle

4) Air cleaner

5) Rear brake fluid tank

6) Fuel tank plug

7) Coolant expansion tank plug

8) Expansion tank

9) Right rear-view mirror

10) Front brake fluid tank

11) Rear brake pump

12) Rear brake control lever

13) Rider right footrest

(with spring, always open)

14) Drive chain

3

14 13 12 11

9

10

5 61 4 7 8

2

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ARRANGEMENT OF THE INSTRUMENTS/CONTROLS

KEY

1) Ignition switch/steering lock (

 -  - + )

2) Cold start lever (

)

3) Direction indicator switch (

( )

4) Horn push button (

 )

5) MODEpush button

6) Dimmer switch (  -  )

7) High beam signalling push button (

 )

8) Clutch lever

9) Instruments and indicators

10) Front brake lever

11) Throttle grip

12) Start push button (

)

13) Engine stop switch (

 - )

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KEY

1) Revolution counter

2) Green turn indicator warning light ( )

3) lue high beam warning light ( )

4) Multifunction digital display (coolant temperature - clock -

battery voltage - lap timer - mixer oil level diagnostics ( )

5) Amber low fuel warning light ( )

6) Green neutral light ( )

7) Red general warning light ( )

INSTRUMENTS AND INDICATORS

7 6

5 4

1 2 3

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INSTRUMENTS AND INDICATORS TABLE

When the ignition key is turned to " " with the engine stopped, all warning lights come on for a LED check-up and go out after two

seconds. If one or more warning lights do not come on at this stage, contact an aprilia Official Dealer

Description Function

Revolution counter rpm

Indicates the number of revolutions of the engine per minute.

Never exceed the engine max. speed rate, see page 41 (RUNNING-IN).

Direction indicator warning light Blinks when the direction indicators are on.

High beam warning light Comes on when the high beam bulbs are on or when the headlight signaller is operated.

Low fuel warning light

It comes on when the quantity of fuel left in the tank is approx. 3.5

b.

In this case, top up as soon as possible, see page 25 (FUEL).

Neutral indicator warning light Comes on when the gear is in neutral.

Error warning light

Comes on when the ignition switch is set to " " with the engine stopped as a lamp test.

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

aprilia Official Dealer.

If the light

remains on after the engine starts or comes on during

the normal operation of the engine, this means that low fluid level in

tank and mixer or high coolant temperature was detected.

In this case, check and/or top up to recommended fluid level and contact an aprilia Authorised

dealer, if necessary.

CAUTION

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Multifunction

digital display

Speedometer (km/h - MPH)

Displays current, average or maximum riding speed (in kilometres or miles)

depending on pre-setting, see page 16 (MULTIFUNCTION COMPUTER).

To toggle be-

tween readouts,

see page 16

(MULTIFUNC-

TION COMPU-

TER)

Odometer (KM - Mi)

Gives total distance covered or distance covered since the trip meter was last reset

(in km or miles).

Coolant temperature

(°C/°F)

It reproduces engine coolant temperature on a scale, see page 16

(MULTIFUNCTION COMPUTER).

If you enter the dangerous range, the display shows all six scale segments, the

alarm light comes on, and logo flashes; allow the cooling fans to switch off.

Do not leave the ignition switch on “ ”, since the

cooling fans would stop regardless of the coolant

temperature and in this case the temperature would increase even further.

Now turn the key to “” and check coolant level, see page 32 (COOLANT).

Contact an

aprilia Official Dealer.

If the maximum allowed temperature is exceeded

(114 °C - 237 °F), the engine may be seriously

damaged.

Mixer oil reserve

indicator on

multifunction display

It comes on when the quantity of mixer oil left in the tank is 0.60

b.

If oil reserve indicator comes on, this means that

mixer oil level is low (reserve); top up mixer oil, see

page 29 (2 STROKE OIL TANK).

Clock

Displays time (hour and minutes) as preset, see page 16 (MULTIFUNCTION

COMPUTER).

Battery voltage

Displays the battery voltage in Volts, see page 16 (MULTIFUNCTION

COMPUTER).

Lap timer

Displays the different lap times, as preset, see page 16 (MULTIFUNCTION

COMPUTER).

Description Function

CAUTION

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MULTIFUNCTION COMPUTER

Controls

1) MODE Button:

press briefly to switch across functions;

press for several seconds (more than

three seconds) to change settings.

When you turn the ignition key to " ", the

following instrument panel lights will turn

on for two seconds:

– all warning lights;

– backlighting;

– All segments on the display come on.

The rev counter index (2) gets to scale

end and goes back to starting position.

During the initial check-up, all instruments

will briefly show the current values of the

corresponding parameters. The following

standard settings are displayed:

– Alarm icons, (zone A);

– Current speed (zone B)

– Odometer / trip meter / time / battery

voltage / lap timer (zone C) (*);

– Coolant temperature (zone D).

(*) The function displayed the last time the

key was turned off is the one displayed

first.

1

2

A D

C

B

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Description of the functions

Press the MODE button a few times and

the following functions are alternatively

displayed in area C of the display:

– ODOMETER (ODO)

– TRIP METER (TRIP)

–CLOCK

– BATTERY VOLTAGE

– LAP TIMER

ODOMETER (ODO)

Displayed value indicates total distance

covered by the vehicle.

It can not be reset.

TRIP METER (TRIP)

With the ODO function displayed briefly

press the MODE button to display trip

meter value.

With the TRIP value displayed, press and

hold the MODE button to reset it.

CLOCK

With the TRIP value displayed, briefly

press the MODE button to display the

time.

Setting the time

With vehicle stopped and time displayed,

press the MODE button for several

seconds to activate time setting mode.

The display will show the two digits

indicating hour; every time you press the

MODE button, the value increases by one;

if you press the MODE button when hour

value is 12, the indication will go back to 1.

Press the MODE button for several

seconds to save the value and start

setting minutes, the display will only show

minute digits; every time you press the

MODE button, the value increases by one,

if you press the MODE button when value

is 59, the indication will go back to 0.

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Do not disturb any button for three

seconds to complete the procedure and

the display will show set time.

LAP TIMER

With the Clock function displayed, briefly

press the MODE button to display Lap

timer function. Press the MODE button for

several seconds with the vehicle running

to enter the time acquisition mode, or

press it with the vehicle stopped to enter

the lap time display mode.

Timing

With the vehicle running, briefly press the

MODE button to start the lap timer. Press

it once to start the timer, press it further

within the first ten seconds to reset the lap

timer. If you press it again after 10

seconds have elapsed since timer start,

value is stored and timer for next lap

starts. The value stored is displayed for

the first 10 seconds, then the current

value is shown.

Press the MODE button for several

seconds to abort timing, the display will

show the last value stored; timing session

restarts as previously indicated.

As soon as 16 lap times have been stored,

the display reads FULL, any new lap times

will not be stored.

Detaching the battery will result in loss of

any data stored.

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View times

Entering the Lap timer function with

vehicle stopped lets you view the times

stored.

The central area of the display, usually

dedicated to current speed, shows LAP

session number and the lap time just

below.

Restart the vehicle or hold the MODE

button for several seconds to quit view

time mode.

Delete times

With the ODO function displayed, press

the MODE button for several seconds to

delete all lap times stored.

BATTERY VOLTAGE

With the Clock function displayed, briefly

press the MODE button to display the

battery icon and battery charge.

If the system detects a faulty voltage (not

between 10 and 16 Volt) the symbol " "

is displayed and flashes.

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Service interval

As the scheduled service interval is

getting closer the display will show the

wrench icon flashing for five seconds.

When scheduled service mileage is

reached, the icon will stay on

permanently.

First switch-on at 1,000 km (625 mi)

Then: every 4000 km (1,700 mi)

Have the scheduled service operations

performed by aprilia Authorised Dealers

and Service Centres, so that they will also

delete the service warning.

Km/miles

When battery is connected, with key to

" ", hold the MODE button for more than

ten seconds to switch both the odometer

(ODO) and the tachometer from

kilometres (km) to miles (mi).

During the first five seconds the

instrument panel will not react with any

signal, but then current unit of

measurement will start flashing. If MODE

button is released before ten seconds

have elapsed, the unit of measurement

will still be the one previously in use.

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