Aprilia CLASSIC 125 User Manual 1997

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use and maintenance

aprilia part# 8102785	Classic 125

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 partial adaptation, with any means, are reserved for all Countries.

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

aprilia s.p.a takes no responsibility as to the performance or the use of said products.

First edition: march 1997

Reprint:

Editing: aprilia s.p.a.

Via G. Galilei, 1 - 30033 Noale (VE) - Italy Ph. 041 - 58 29 111

Fax 041 - 44 10 54

Illustrated and printed by:

Studio Tecno Public

Viale del Progresso - 37038 Soave (VR) - Italy

Ph. 045 - 76 11 911

Fax 045 - 76 12 241

2 use and maintenance Classic 125

FOREWORD

Before starting the engine, carefully read this manual, paying particular attention to the chapter "RIDING SAFELY".

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 RIDING SAFELY. Therefore, get a thorough knowledge of the vehicle, in such a way as to be able to drive in the traffic safely.

For the controls and repairs not expressly described in this manual, for the purchase of aprilia Genuine Spare Parts, accessories and other products, as well as for specific technical advice, contact only aprilia Authorized Outlets and Official Dealers, who can 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 parts code indicated on the SPARE PARTS IDENTIFICATION LABEL.

Write down the identification code in the space here below, in order to remember it also in case of loss or deterioration of the label.

The label is positioned under the left side, on the frame tube.

aprilia CODICE RICAMBI spare parts code number

N˚			I.M.	A	B	C	D	E
			I.M.


I	UK	A	P	SF	B	D	F	E

GR	NL	CH	DK	J	SGP	PL	IL	ROK

MAL	RCH	BM

Carefully observe the instructions preceded by the following warning signs:

aSafety norms and regulations to protect the driver and other people from severe injuries or grave risks.

cIndicationsinformation.to make the operations easier. Technical

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

2 catalytic version
I Italy version
U United Kingdom version	C Switzerland version
A Austria version	£ Denmark version
P Portugal version	J Japan version
" Finland version	S Singapore version
B Belgium version	V Poland version
D Germany version	% Israel version
F France version	K South Korea version
E Spain version	M Malaysia version
G Greece version	R Chile version
O Holland version	Q Bermuda version

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TABLE OF CONTENTS
SAFE DRIVE .....................................................................................................	5
BASIC SAFETY RULES .............................................................................	6
CLOTHING .................................................................................................	9
ACCESSORIES........................................................................................	10
LOAD ........................................................................................................	10
ARRANGEMENT OF THE MAIN ELEMENTS ...............................................	12
ARRANGEMENT OF THE INSTRUMENTS ...................................................	14
INSTRUMENTS AND INDICATORS ..............................................................	14
INSTRUMENTS AND INDICATORS ........................................................	15
MAIN INDEPENDENT CONTROLS ...............................................................	16
CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR.......................	16
CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR ....................	17
IGNITION SWITCH...................................................................................	18
STEERING LOCK.....................................................................................	18
AUXILIARY EQUIPMENT...............................................................................	18
TOOL KIT .................................................................................................	18
CRASH HELMET/GLOVE COMPARTMENT ...........................................	19
MAIN COMPONENTS.....................................................................................	19
FUEL.........................................................................................................	19
TRANSMISSION OIL................................................................................	20
MIXER OIL TANK .....................................................................................	20
BRAKE FLUID (recommendations) ..........................................................	20
FRONT BRAKE ........................................................................................	21
REAR BRAKE...........................................................................................	22
REMOVING THE OIL PAN GUARD (LEFT SIDE) ...................................	22
ADJUSTING THE CLUTCH......................................................................	23
ADJUSTING THE SHIFTING LEVER.......................................................	24
COOLANT ................................................................................................	24
TYRES......................................................................................................	25
CATALYTIC SILENCER 2...................................................................	26
INSTRUCTIONS FOR USE.............................................................................	27
PRELIMINARY CHECKING OPERATIONS.............................................	27
STARTING................................................................................................	28
DEPARTURE AND DRIVE .......................................................................	29
STOPPING AND PARKING .....................................................................	31
SUGGESTIONS TO PREVENT THEFT..................................................	31
MAINTENANCE ..............................................................................................	32
REGULAR SERVICE INTERVALS CHART .............................................	32
IDENTIFICATION DATA...........................................................................	33

CHAIN .......................................................................................................	34
CHECKING THE TRANSMISSION OIL LEVEL........................................	36
CHANGING THE TRANSMISSION OIL ...................................................	37
FRONT WHEEL ........................................................................................	38
REAR WHEEL ..........................................................................................	39
REMOVING THE FUEL TANK..................................................................	40
AIR CLEANER ..........................................................................................	41
INSPECTING THE FRONT AND REAR SUSPENSIONS ........................	41
ADJUSTING THE REAR SUSPENSION ..................................................	42
CHECKING THE BRAKE PAD WEAR......................................................	43
CHECKING THE SHOE WEAR ...............................................................	43
CHECKING THE STEERING....................................................................	44
ADJUSTING THE ACCELERATOR CONTROL .....................................	44
IDLING ADJUSTMENT .............................................................................	45
BLEEDING THE MIXER OIL ....................................................................	45
SPARK PLUG ...........................................................................................	46
BATTERY..................................................................................................	46
CHECKING THE ELECTROLYTE LEVEL................................................	47
LONG INACTIVITY OF THE BATTERY ..................................................	47
CHANGING THE FUSES..........................................................................	48
ADJUSTING THE HEADLIGHT BEAM.....................................................	49
BULBS ......................................................................................................	49
CHANGING THE HEADLIGHT BULBS ....................................................	49
CHANGING THE DASHBOARD BULBS ..................................................	50
CHANGING THE REAR LIGHT BULB......................................................	50
CHANGING THE NUMBER PLATE BULB ...............................................	51
CHANGING THE FRONT AND REAR
DIRECTION INDICATOR BULBS.............................................................	51
TRANSPORT...................................................................................................	52
DRAINING THE FUEL TANK....................................................................	52
CLEANING ......................................................................................................	52
LONG PERIODS OF INACTIVITY ............................................................	53
AFTER A PERIOD OF INACTIVITY .........................................................	53
TECHNICAL DATA .........................................................................................	54
LUBRICANT CHART ................................................................................	58
Importers ...................................................................................................	59
WIRING DIAGRAM - Classic 125 .............................................................	60
WIRING DIAGRAM KEY - Classic 125 .....................................................	61
WIRING DIAGRAM - Classic 125 - 11 kW version ...................................	62
WIRING DIAGRAM KEY - Classic 125 - 11 kW version ...........................	63

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safe drive

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.

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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.

COOLER

OIL

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.

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A12

345

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

ONLY ORIGINALS

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.

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.

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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.

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.

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KG!

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


	Fig. 1
KEY Fig. 1
1)	Mixer oil tank plug	6)	Fuses
2)	Air cleaner	7)	Battery
3)	Saddle lock	8)	Side stand
4) Rear suspension spring preload adjusting ring		9)	Footrest
5)	Passenger's footrest	10)	Shifting lever

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		Fig. 2
KEY Fig. 2
1)	Fuel cock	7)	Footrest
2)	Fillercap	8)	Took kit/glove compartment
3)	Front brake fluid tank	9)	Passenger's footrest
4)	Ignition switch/steering lock	10)	Rear suspension spring preload adjust-
5)	Mixer oil tank		ing ring
6)	Rear brake control lever

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ARRANGEMENT OF THE INSTRUMENTS

INSTRUMENTS AND INDICATORS

Fig. 3

KEY Fig. 3

1)Left rear-view mirror

2)Clutch lever

3)High beam signalling push button (a)

4)Cold start lever (e)

5)Ignition switch/steering lock (n - m - s)

6)Throttle grip

7)Front brake lever

8)Right rear-view mirror

9)Engine stop switch (n - m)

10)Light switch (o - p - •)

11)Start push button (r)

12)Instruments and indicators

13)Horn push button (f)

14)Direction indicator switch (c)

15)Dimmer switch (b - a)

Fig. 4

KEY Fig. 4

1)Speedometer

2)Total kilometres odometer

3)Coolant overheating warning light (h)

4)Red mixer oil reserve warning light (j)

5)Green neutral indicator warning light (q)

6)Blue high beam warning light (a)

7)Green direction indicator warning light (c)

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INSTRUMENTS AND INDICATORS

Description		Function

Speedometer		It indicates the driving speed.

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

		It comes on when the coolant reaches or exceeds the limit temperature.
Coolant overheating		In this case, stop the engine and check the coolant level, see p. 24 (COOLANT).
Coolant overheating	h
warning light	h	If the maximum allowed temperature is exceeded (the warning light comes on),

		athe engine may be seriously damaged.
		It comes on when the ignition switch is in position "n" and the start push button “r“ is pres-
		sed, thus checking the proper functioning of the bulb.
Mixer oil reserve		If the light does not come on during the starting, provide for replacing the bulb.
Mixer oil reserve	j	If the warning light comes on and does not go out after the start push button
warning light	j
		"r" has been released, or if it comes on during normal functioning, this means
		athat the mixer oil reserve is being used; in this case, top up the mixer oil tank,
		see p. 20 (MIXER OIL TANK).

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

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

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

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MAIN INDEPENDENT CONTROLS

Fig. 5

CONTROLS ON THE LEFT SIDE

OF THE HANDLEBAR (Fig. 5)

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

1)DIMMER SWITCH (b - a)

When the light switch (right side of the handlebar) is in position "o", if the dimmer switch is in position "a", the high beam comes on, while if it is in position "b", the low beam comes on.

2)DIRECTION INDICATOR SWITCH (c)

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

3)HORN PUSH BUTTON (f)

The horn is activated when the push button is pressed.

4)COLD START LEVER (e)

The starter for the cold start of the engine is operated by rotating the lever "e" downwards.

To disconnect the starter, move the lever "e" to its initial position.

5)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 peril and/or emergency.

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CONTROLS ON THE RIGHT SIDE

OF THE HANDLEBAR (Fig. 6)

The electrical parts work only when the ignition
cswitch is in position "n".
1) HEADLIGHT SWITCH (o - p - •)
When the light switch is in position "•", the lights are off; when
the switch is in position "p", the parking lights are on; when
the switch is in position "o", the low beam or the high beam is
on. The high/low beam can be operated by means of the dim-
mer switch, see p. 16 (CONTROLS ON THE LEFT SIDE OF
THE HANDLEBAR).
2) START PUSH BUTTON (r)
When the start push button "r" is pressed, the starter makes
the engine run. For the starting, see p. 28 (STARTING).
3) ENGINE STOP SWITCH (n - m)	Fig. 6
Do not operate the engine stop switch “n - m” in
arunning conditions.
This is a safety or emergency switch.
With the switch in position "n", it is possible to start the en-
gine; the engine can be stopped by moving the switch to posi-
tion "m".
With stopped engine and ignition switch in posi-
tion "n", the battery may discharge.
aWhen the vehicle has come to rest, after stopping
the engine, move the ignition switch to position "m".

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Fig. 7

IGNITION SWITCH (Fig. 7)

The ignition switch is positioned on the right side of the vehicle, between the fuel tank and the steering tube (Fig. 7).

cThe key (1) operates the ignition switch/steering lock, the saddle

lock and the fuel tank lock.

Two keys are supplied together with the vehicle (one spare key).

STEERING LOCK (Fig. 7)

aNever turn the key to position "s" in running conditions, in order to avoid losing control of the

vehicle.

OPERATION

To lock the steering:

Turn the handlebar completely leftwards.

Turn the key to position "m" and press it.

Release the key and turn it to position "s".

Extract the key.

Position	Function	Key
Position	Function	removal
		removal

	The steering is	It is possible
s	locked.	to remove
	It is neither	the key.
	possible to
Steering	start the
Steering	engine, nor to
lock	engine, nor to
lock	switch on the
	switch on the
	lights.

m	Neither the	It is possible
	engine, nor the	to remove
	lights can be	the key.
	switched on.

n	The engine	It is not pos-
	and the lights	sible to
	can be	remove the
	switched on.	key.

Fig. 8

AUXILIARY EQUIPMENT

TOOL KIT (Fig. 8)

To reach the tool kit (right side of the vehicle), unscrew and remove the knob (1) and remove the cover (2).

The tool kit includes:

n. 1 25 mm spark plug spanner n. 1 3 mm hexagon spanner

n. 1 cross-/cut-headed screwdriver + 4 mm hexagon spanner

n. 1 3 mm hexagon spanner n. 1 screwdriver handle

n. 1 tool case

18 use and maintenance Classic 125

Fig. 9

CRASH HELMET/GLOVE

COMPARTMENT (Fig. 9)

The crash helmet/glove compartment (1) is positioned under the rider's saddle (2) and can contain a JET crash helmet (3).

To reach it, introduce the ignition key in the lock (4), rotate it clockwise and raise the saddle (2). Before positioning the crash helmet, empty the compartment completely; remove the visor - if provided - from the helmet and position the latter with the chin protector facing the right side of the vehicle (see Fig. 9). Put back any object that was previously removed.

aBefore leaving, make sure that you have not left the key in the crash helmet/glove compartment and that the saddle is properly

locked.

To lock the saddle, it is sufficient to lower it and to press it until it locks.

MAIN COMPONENTS

FUEL

aThe fuel used for internal combustion engines is extremely inflammable and in particular con-

ditions it can become explosive.

It is important to carry out the refuelling and the maintenance operations in a well-ventilated area, with the engine off. Do not smoke while refuelling or near fuel vapours, in any case avoid any contact with naked flames, sparks and any other heat source to prevent the fuel from catching fire or from exploding.

Further, prevent fuel from flowing out of the fuel filler, as it could catch fire when getting in contact with the red-hot surfaces of the engine.

In case some fuel has accidentally been spilt, make sure that the area has completely dried and before starting the vehicle verify that there is no fuel inside the fuel filler neck.

Since petrol expands under the heat of the sun and due to the effects of sun radiation, never fill the tank to the brim. Screw the plug (Fig. 10) up carefully after refuelling.

Avoid any contact of the fuel with the skin and the inhalation of vapours; do not swallow fuel or pour it from a receptacle into another by means of a tube.

Fig. 10

KEEP AWAY FROM CHILDREN

U s e o n l y p r e m i u m g r a d e p e t r o l (4 Stars U), in conformity with the DIN 51600 standard, min. O.N. 98 (N.O.R.M.) and 88 (N.O.M.M.).

FUEL TANK CAPACITY (reserve included): 10 l

TANK RESERVE: 2 l

To unlock the tank plug, insert the ignition key in the lock and turn it clockwise.

ONLY FOR THE CATALYTIC VERSION Use only unleaded petrol, in conformity with the DIN 51607 standard, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.).

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TRANSMISSION OIL

cRemember:1 miles = 1.6 km

1 km = 0.625 miles

The transmission oil must be changed after the first 1000 km and successively every 12000 km; see p. 36 (CHECKING THE TRANSMISSION OIL LEVEL AND TOPPING UP), p . 37 (CHANGING THE TRANSMISSION OIL) and p. 58 (LUBRICANT CHART).

aUsed transmission oil can seriously damage the skin if handled every day and for long periods.

aIf the vehicle is used on dusty roads, change the oil more frequently.

aDo not dispose of the oil in the environment. Put it in a sealed container and take it to the filling

station where you usually buy it.

MIXER OIL TANK (Fig. 11)

The vehicle is provided with a separate mixer that ensures the mixing of petrol and oil for the correct lubrication of the engine, see p. 58 (LUBRICANT CHART).

The reserve is indicated by the coming on of the mixer oil reserve warning light “j“ positioned on the dashboard, see p. 14 and 15 (INSTRUMENTS AND INDICATORS).

aIf you run out of oil in the mixer oil tank, or if the mixer oil pipe has been removed, it is neces-

sary to bleed the mixer oil, see p. 45 (BLEEDING THE MIXER OIL).

To introduce the oil in the tank, remove the plug (1) on the left side of the vehicle, between the tank and the steering tube.

MIXER OIL TANK CAPACITY: 2 l

TANK RESERVE: 0.5 l

aWash your hands carefully after using the oil. Do not dispose of the oil in the environment.

KEEP AWAY FROM CHILDREN.

Fig. 11

BRAKE FLUID (recommendations)

aSudden resistance or clearance problems on the brake lever may be due to troubles in the hydrau-

lic system.

For any doubt regarding the perfect functioning of the braking system and in case you are not able to carry out the usual checking operations, contact your aprilia Official Dealer.

Make sure that the brake disc is neither oily nor greasy, especially after maintenance or checking operations.

20 use and maintenance Classic 125

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